Nussbaum 4.45 H User manual

4.45 H
Automotive-Lift date 12/2002
Manual date: 17.12.2002
Operating Instruction and Documentation
Serial-number:............................................
Nußbaum Hebetechnik GmbH & Co.KG//Korker Straße 24//D-77694 Kehl-Bodersweier//Tel: [phone]
Fax: [phone]//E-mail: [e-mail]//http://www.nussbaum-lifts.de
Retailer address / phone

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Inhalt
Foreword.................................................................................................................................3
Record of installation..............................................................................................................5
Record of handing over...........................................................................................................6
1.General Information................................................................................................................7
1.1 Installation and service checks of the automotive lift.......................................................7
1.2 Warning Symbols..............................................................................................................7
2.Master document of the automotive lift..................................................................................8
2.1 Lift–manufacturer .............................................................................................................8
2.2 Application........................................................................................................................8
2.3 Changes at the construction ..............................................................................................8
2.4 Displacement of the automotive-lift .................................................................................8
3. Technical Information..........................................................................................................10
3.1 Technical ratings.............................................................................................................10
3.2 Safety device...................................................................................................................10
3.3 Data sheet........................................................................................................................11
3.4 Foundation diagram drawing..........................................................................................12
4.Safety regulations.................................................................................................................. 14
5. Operating Instructions..........................................................................................................14
5.1 Lifting the vehicle...........................................................................................................14
5.2 Lowering the vehicle.......................................................................................................15
CE-STOP ..............................................................................................................................16
5.3 Lower the lift into the safety ratchets .............................................................................16
5.4 Adjusting the platform....................................................................................................16
6.Troubleshooting ....................................................................................................................17
6.1 Lowering onto an obstacle..............................................................................................18
6.2 Emergency lowering....................................................................................................... 18
7. Inspection and Maintenance.................................................................................................19
7.1 Maintenance plan of the lift............................................................................................20
7.3 How often must the lift be cleaned? ...............................................................................21
8. Security check...................................................................................................................... 22
9. Handing over and Initiation..................................................................................................23
9.1 Regulations .....................................................................................................................23
9.2 Erection and bolting down the lift...................................................................................23
9.3 Change of lift location ....................................................................................................26
9.4 Initiation..........................................................................................................................26
First security check before installation ................................................................................30
Regular security check and Maintenance.............................................................................31
Extraordinary security check ................................................................................................38
Hydraulic diagram drawing ..................................................................................................39
Electrical diagram drawing...................................................................................................40

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Foreword
Nußbaum lifting systems are the result of over 25 years experience in the automotive lifting
industry.
The high quality and the superior concept ensure reliability, a long lift lifetime and above all
and economic business solution.
To avoid unnecessary damage, injury or even death, read the operating instructions with care
and observe the contents.
Nußbaum lifts is not responsible for incidents involving the use of Nußbaum lifting systems
for applications other than those for which they were designed.
Nußbaum Hebetechnik GmbH & Co. KG is not liable for any resulting damages. The user
carries the risk alone.
Obligations of the user:
- To observe and adhere to the operating instructions.
- To follow the recommended inspection and maintenance procedures and carry out the
prescribed tests.
- The operating instructions must be observed by all persons working with or around the lift.
- Above all chapter 4 “Safety Regulations“ is very important and must be closely adhered to.
- In addition to the safety regulations stated in the operating instructions manual, the
appropriate safety regulations and the operating procedures of the place of operation
must also be considered.
Obligations of the operator:
The operator is obliged to allow only those persons complying to the following requirements
to work with or around the unit.
- Persons being familiar with the basic regulations concerning labour safety and accident
prevention and being trained to operate the particular unit.
- Persons having read and understood the chapter concerning safety and warning
symbols.
- Persons using the lift are required to confirm that they have read and understood the
chapter on safety and warning symbols by signing the appropriate form.
Dangers when operating the lift:
Nußbaum-Lifts are designed and built according to technical standards and the approved
regulations for technical safety. The use of Nußbaum lifts for purposes other than those for
which they were designed, may result in injury or even death.

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The lift must only be operated :
- For its appropriate use
- In faultless condition concerning technical security.
Organisational Requirements
- The instructions for use are to be kept at the place of operation being easily accessible
at any time.
- In addition to the instructions for use, rules pertaining to other regulations i.e. accident
prevention and environmental rules are to be observed and adhered to.
- The owner of the Nußbaum lifting system must ensure that operators and persons
working with or around the lift occasionally conduct “refresher” courses to ensure that
the appropriate operating procedures and safety precautions are known.
- Personal Protective Equipment (PPE) must be used according to the appropriate
regulations.
- All safety- and danger signs on and around the lift are to be observed and followed!
- Spare parts must comply with the technical requirements specified by the manufacturer.
This is only warranted with original parts.
- Observe and adhere to the specified time intervals between tests and inspections.
Maintenance works, repairing faults
- Adjustments, maintenance, and inspections, are to be followed according to the time
intervals specified. Details regarding the exchange of parts and components as
mentioned in the operating instructions are to be adhered to.
These works must only be carried out by expert personal.
- After maintenance- and repair works loose screws, nuts and bolts must always be firmly
tightened!
Guarantee and liability
- Our “General conditions of selling and delivering” are in force.
There will be no guarantee or liability for incidents involving injuries or death or damage
to equipment if these incidents are the result of one or more of the following reasons.
- Inappropriate use of the lift
- Inappropriate installation, initiation, operation and maintenance of the lift.
- Use of the lift while one or several security devices do not work, do not work correctly or
are not installed correctly.
- Failure to follow the regulations of the operating instructions regarding transport, storage,
installation, initiation, operation and maintenance of the lift.
- Unauthorized changes to the structure of the lift without first asking the producer.
- Unauthorized changes of adjustments of important components of the lift (e.g. driving
elements, power rating, motor speed, etc)
- Wrong or incorrect maintenance practice.
- Catastrophes, acts of God or external reasons.

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After completely filling out this sheet including signatures, copy and return the
original to the manufacturer. The copy must remain in the manual..
Otto Nußbaum Hebetechnik GmbH & Co. KG
Korker Straße 24
D-77694 Kehl-Bodersweier
Record of installation
The automotive lift 4.45 H with the
serial number:............................................ was installed on:...............................................
at the firm:................................................. at:.....................................................................
The initial safety check was carried out and the lift was started.
The installation was carried out by the operating authority/competent (please delete as applicable).
The initial safety check was carried out by a competent person before the initial operation.
The operating authority confirms the correct installation of the automotive lift, the competent
person confirms the correct initial operation.
............................................ ..................................................... ............................................
date name of the operating authority signature of the operating authority
............................................ ..................................................... ............................................
date name of the competent person signature of the competent person
Your customer service:.....................................................................................................(stamp)
Automotive Lift date: 06/2003 / Manual date: 21.05.2003

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Record of handing over
The automotive lift 4.45 H with the
serial number:............................................ was installed on:...............................................
at the firm:................................................. at:.....................................................................
the safety was checked and the lift was started.
The persons below were introduced after the installation of the automotive lift. The
introduction was carried out by either the erector from the lift-manufacturer or from a
franchised dealer (competent person).
............................................ ..................................................... ............................................
date name signature
............................................ ..................................................... ............................................
date name signature
............................................ ..................................................... ............................................
date name signature
............................................ ..................................................... ............................................
date name signature
............................................ ..................................................... ............................................
date name signature
............................................ ..................................................... ............................................
date name signature
............................................ ..................................................... ............................................
date name of competent signature of the competent
Your customer service:.................................................................................................(stamp)

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1.General Information
The document “Operating Instructions and Documentation” contains important
information about installation, operation and maintenance of the automotive lift.
• Conformation of installation of the automotive lift is recorded on the ”Record of
Installation” form and must be signed and returned to the manufacturer.
• Conformation of once of, regular and out of the ordinary service checks is recorded
in the respective check forms. The forms are used to document the checks. They
should not be removed from the manual.
All Changes to the structure and any change of location of the automotive lift must be
registered in the ”Master document” of the lift
1.1 Installation and service checks of the automotive lift
Only specialised staff are allowed to repair and maintain the lift and only these specialised
staff are allowed to conduct safety checks on the lift. For the purposes of this document
these specialised staff will be called Experts and Competent persons.
Experts are persons (for example self-employed engineers, experts) which have
received instructions and have the appropriate experience to check and to test
the automotive lifts. They are aware of the work involved and know the
accident prevention regulations.
Competent persons are persons who have acquired adequate knowledge and experience
with automotive lifts. They have completed the appropriate training provided
by the lift-manufacturer (the servicing technicians of the manufacturer or
dealer, are regarded as competent)
1.2 Warning Symbols
The three symbols below are used to indicate danger and other important information. Pay
attention to areas on and around the lift that are marked with these symbols.
Danger! This sign indicates danger. Ignoring this warning may result in injury
or even death.
Caution! This sign cautions against possible damage to the automotive lift or other
material objects in the case of improper use .
Attention! This sign indicates an important function or other important
information regarding the operation of the lift.

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2.Master document of the automotive lift
2.1 Lift–manufacturer
Otto Nußbaum Hebetechnik GmbH & Co. KG
KorkerStraße24
D-77694 Kehl-Bodersweier
2.2 Application
The automotive lift 4.45 H is a lifting mechanism for lifting motor vehicles
with a laden weight of up to 4500 kg . The max. load distribution is 2:1 either in or against
the drive-on direction.
The automotive lift has been designed for servicing vehicles only. It has not been designed
to carry people. Carrying people either directly on the lift or in vehicles that are on the lift
is therefore not allowed.
The installation of the standard lift in hazardous or dangerous locations such as wash bays
is dangerous and is therefore not allowed.
Changes of construction, repairing and changes of place must be registered in this
master document.
2.3 Changes at the construction
Changes at the construction, expert checking, resumption of work (date, kind of
change, signature of the expert)
..................................................................................................................................................
..................................................................................................................................................
..................................................................................................................................................
..................................................................................................................................................
name, address of the expert
........................................................... ............................................................
place, date signature of the expert
2.4 Displacement of the automotive-lift
Displacement of the automotive-lift, expert checking, resumption of work (date, kind
of change, signature of the competent)
..................................................................................................................................................
..................................................................................................................................................
name, address of the competent
........................................................... ............................................................
place, date signature of the competent

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Page for notice

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3. Technical Information
3.1 Technical ratings
Capacity : 4500 kg
Load distribution max. 2:1 in or against the drive on direction
Lifting time: approx. 45 sec. with load
Lowering time approx. 12 sec. with load
Lifting height: max. 1800 mm
Line voltage 3 x 400 Volt , 50Hz
Power rating 3 kW (Nr. 990303)
Motor speed: 2800 rotation/min
Pump capacity 4,3 cm3/rotation
Hydraulic pressure approx. 240 bar
Pressure control valve approx. 260 bar
Oil Tank approx. 14 Litre
Sound level ≤75 dB(A)
Connection by customer 3~/N+PE, 400V, 50 Hz
fuse T16A (time-lag fuse)
observe your state regulations
3.2 Safety device
1. Safety ratchet
Safety device against unintentional lowering.
2. Holding valve
Safety device against unintentional lowering.
3. Pressure relief valve
Overpressure safety of the hydraulic system
3. Lockable main switch
Safety device against unauthorised operation
4. Safety device at the platform against rolling.
Safety device against falling down, in case the hand brake is not fasten.
5. CE-Stop
Safety device against squeeze.

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3.3 Data sheet

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3.4 Foundation diagram drawing

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5050/5750*
3300
5750/6450*
4000
* (Version with rail 5500)

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4.Safety regulations
When using automotive lifts the safety regulation EN1493/Aug.98 (CEN/TC98
„ Automotive lifts”) must be observe adhered to.
Especially the following regulations are very important:
• The laden weight of the lifted vehicle must not exceed 8000 kg for the automotive lift.
Load distribution max. 2:1 in or against the drive on direction.
• The automotive lift must be in its lowest position (fully collapsed), before the
vehicle can be driving on to the lift. Only then can the vehicle be lifted.
• While working with the lift the operating instructions must be followed.
• Vehicles with low clearance or vehicles that are specially equipped should be pre
tested to ensure that they clear the lift ramp to avoid damage.
• Only trained personnel over the age of 18 years old are to operate this lift.
• No one is to stand within the working area (danger area) during lifting and
lowering
• No one is to be raised or lowed either directly or in a vehicle by the automotive
lift.
• No one is to climb onto the automotive lift or onto an already raised vehicle.
• The automotive column lift must be checked by an expert after changes in the
construction have been made.
• The main switch must be switched off and locked before work on the vehicle can
commence. This is a safety precaution to ensure that the lift does not move during
work.
• The main switch must be switched off and locked before any maintenance or
repair work on the automotive lift itself can be carried out.
• During lifting or lowering the operator must observe the vehicle to ensure that the
vehicle and the lift are functioning correctly.
• Installation of the standard-mobile column lift in hazardous or dangerous
locations such as washing bays is dangerous and is not allowed.
5. Operating Instructions
The Safety Regulations must be observed and adhered to while working with the
automotive lift. Read the safety regulations in chapter 4 carefully before working
with the lift!
5.1 Lifting the vehicle
• Drive the vehicle onto the middle of the lift.
The complete wheels must be standing on the platform, otherwise the vehicle can
fall down.
• Secure the vehicle from rolling, put into gear, apply the hand brake.

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• Check all the danger points of the lift and ensure that there are no objects or
people in the working area around the lift or on the lift.
• Switch on the main switch.
• Raise the vehicle Press the button „Lifting“.
• Raise the vehicle to the required working height. Press the button “lifting“ .
• Observe the complete process.
5.2 Lowering the vehicle
• Check all danger points of the lift and be sure that there are no objects or people
in the working area (danger area) around the lift or on the lift..
• Press the button at the lever. (unlocking the safety ratchets). After it, pull the lever
slowly downward.
The ratchets equipped with a safety switch. It means, only when all four ratchets
are free, the lift will lower.
• The lowering process begins directly.
• In case the lift is in the safety ratchets, raise the lift a few millimetres. Press the
button “lifting” and repeat the lowering process.
• Lower the lift to the required working height or to its lowest (or fully collapsed)
position. Observe the complete lowering process.
• Before the lift reaches its lowest position, the lift stops automatically (CE-Stop).
After the lift has stopped, check the danger areas around the lift. Press the button
“lowering” again. A warning signal will sound as the lift is further lowered. This
is to warn against the risk of crushing as the lift is lowered to its lowest (fully
collapsed) position.
• Drive the vehicle off the lift if it is in the lowest position.

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CE-STOP
5.3 Lower the lift into the safety ratchets
• Press the button „lowering“ and the pull the lever slowly. The lowering process
begins directly.
• Press the button „lifting“ to raise the lift out of the ratchets.
5.4 Adjusting the platform
• It is possible to adjust the rail of the different wheelbase. That is necessary to
reach the different wheelbases of the vehicles. One platform is only movable
without load. The measure 850-1150 mm between the platform can reached.
• Remove the load and raise the lift on approx.1000 mm height. The platform is
movable on the chosen position without high force.
adjustable platform

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6.Troubleshooting
If the lift does not work properly, the reason might be quite simple. Please check
the lift for the potential reasons mentioned on the following pages. If the cause of
trouble still cannot be found, please call technical service.
Self-employer repair-working is prohibited.
Problem: the lift does not lower!
Potential causes:
An obstacle is restricting the lift from being lowered
The ball is defective
Fuse is defective
The ratchets are locked of defective
Button “unlocking the ratchets” is defective
Wrong sequence when operation
No feedback from the ratchet switch
solution:
(see chapter 6.1)
Call technical service
Check the fuse
Call technical service
Call technical service
See chapter 5.2
Call technical service
Problem: Motor does not start!
Potential causes:
No power supply
Main switch is not engaged
The main switch is defective
The main fuse defective
The feed line is cut
Thermal switch in the motor is active
Motor is defective
solution:
Check the power supply
Check the main switch
Check the main switch
Check Fuse
Check the complete cable
Let motor cool down
Call technical service
Problem: Motor starts, lift does not lift!
Potential causes:
The vehicle is too heavy
Level of the oil is too low
The ball valve is defective
Hydraulic valve is defective
Gear pump is defective
solution:
unload the vehicle
check the oil level, fill with
hydraulic oil as required
Call technical service
Call technical service
Call technical service

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6.1 Lowering onto an obstacle
• In case the lift is lowering onto an obstacle, only the ropes are slack which are in
the near area of the obstacle.
The ratchet is pressed by the mechanical spring-pressure to the front and
interrupts the contact to the Micro switch.
• The automotive-lift turns-off, and the lowering process stops.
• In case the ropes are slack, press only the button “lifting” and raise the lift until
the obstacle can be removed.
6.2 Emergency lowering
It is possible to open the hydraulic valve manually to lower the lift into the lowest position.
A emergency lowering is an intervention into the controls of the lift and can be
done only by experienced expert.
The emergency lowering must be carried in this order. Otherwise a malfunction
may lead to damage to equipment, injury or even death.
Every kind of external leakage must be removed. This is particularly necessary
before an emergency lowering.
The emergency lowering may only be done by persons who are trained in using the
lift.
• Loosen and remove the cover of the safety ratchet at the crossbeam.
• In case the lift is locked in the safety ratchets, every ratchet must pull back
manually.
First, raise the crossbeam with a help of a jack until the tooth of the ratchet is
movable.
Fasten the ratchet with suitable support (wire), so the ratchet tooth of the ratchet
can not engage in ratchet-strip any more.
Repeat this process at all four ratchets.
• Check all danger points of the lift and be sure that there are no objects or people
in the working area (danger area) around the lift or on the lift..
• Loosen security nut of emergency lowering screw at operating unit (marked with
red colour, see picture).

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• Loosen emergency lowering screw (thread pin) for about one turn (unscrew it).
• Pull the lever slowly downwards. The emergency-lowering starts directly.
• Observe the complete lowering process. In case of danger, let go off the lever.
• Lower the lift into the lowest position.
• Remove the vehicle if the lift is in the lowest position.
• Fasten set screw and secure it by fastening the security screw of the hydraulic
unit.
• Switch off the main switch and secure it against unauthorised operation until the
defective pieces or valves have been replaced.
Call your service partner.
• If the lift has been deemed safe to operate, carry out a reset as described in the
operating instructions.
Do not work with the lift until the defective parts are changed.
After the emergency-lowering process, remove the wire at the ratchets; otherwise
the safety device is out of function.
7. Inspection and Maintenance
Before conducting maintenance work, preparations must be made to ensure that
during maintenance and repair work there is no risk to the safety of people
working on or around the lift and also that there is no risk of damage to
equipment being used on or around the lift.
To guarantee the utmost availability and to ensure that the lift remains functional,
maintenance work contracts are organised between our clients and their local retailers.
A service must be performed at regular intervals of 3 months through the operator in
accordance with following service manual. If the lift is in continuous operation or in a
dirty environment, the maintenance rate must be increased.

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During daily operation the lift must be closely observed to ensure that it is functioning
correctly. In the case of malfunction or leakage the technical service must be informed.
7.1 Maintenance plan of the lift
• Before beginning any maintenance work isolate the power supply. Secure the
main switch (lock it). Secure the danger area around the automotive lift and secure
the lift against unintentional lowering.
• Clean and check the stripper of the cylinder.
• Clean the piston-rod using compressed air..
• Clean the protection hose at the operating column. Grease it with a multipurpose
liquid, otherwise the hose sticks to the column.
• Check the condition of ropes. If torn wires are discovered, the complete rope-set
must be changed.
• Check the condition of the electrical parts.
• Clean and lubricate the moving parts of the lift (hinge bolts, sliding pieces, sliding
surfaces) grease with a multipurpose liquid (example: Auto Top 2000 LTD.
Agip).
• Grease the lubricate nipples with a multipurpose lipid. (example: Auto Top 2000
LTD. Agip).
• Clean and check the function of the ratchet. Grease the surface with a
multipurpose lipid.
• Check all welded joints for cracks on the automotive-lift.
If any cracks are found on the lift cease use immediately. Switch-off and secure
the main switch (lock) and call the service partner.
• Check all surfaces and repair if necessary.
• Damage to external surfaces, must be immediately repaired.
If theses repairs are not made immediately, permanent damage to the powder-
coated surface may result.
Repair and clean damaged areas with an abrasive paper (grain 120). After this is
complete, use a suitable paint (observe the RAL Number).
• Check the zinc surface and repair it with a suitable tool. Use abrasive paper (grain
280).
White rust can result from moisture laying in certain areas for long periods of
time. Poor aerating can also result in rust formation.
Rust may result from mechanical damage, wear, aggressive sediments (de-icing
salt, liquids) or insufficient cleaning.
Repair and clean these areas with abrasive paper (grain 280).
After this is complete, use a suitable paint (observe the RAL Number).
• The hydraulic oil has to be changed at least once a year. To change the oil, lower
the lift into its lowest position. Empty all tanks and refill with clean oil, approx.
(see chapter 3.) per hydraulic unit are needed.