Summary of Contents for SGS HKE
- Page 1 Operating Manual and Test Log Pit lift HKE / FKE Lifting capacity 10 t, 14 t, 20 t SOMMERER PIT LIFT...
- Page 2 Important: • Release hand brake so that the vehicle can roll. ► When working under lifts with drive-on rails, always observe the shift in center of gravity when lifting axles or body parts. When the counterweight of the axle is not on the rail, the lifting platform can become overloaded or the stability can be reduced.
-
Page 3: Table Of Contents
Oil level check MALFUNCTIONS 6.1. General 6.2. Troubleshooting 6.3. Replacement equipment and repair WARRANTY ELECTRICAL- AND HYDRAULIC DIAGRAM 8.1. Electrical Diagram HKE/FKE 400 V (Standard) Electrical Diagram HKE/FKE 240 V Pit lift control HYDRAULIC DIAGRAM HKE/FKE REPLACEMENT PARTS LIST EC-DECLARATION OF CONFORMITY... -
Page 4: Data Sheet
Data Sheet Pit lift model: Lifting capacity: Year of manufacture: Factory no.: HKE/FKE HKE/FKE HKE/FKE HKE/FKE Lifting capacity 10 t 14 t 16 t 20 t Max.hydr. operating 160 bar 220 bar 205 bar 255 bar pressure Electrical connection 400 V 400 V 400 V 400 V 3 kW, 16 A Lowering speed: max. 0,15 m/s Stroke: 800 mm Controller: electrohydraulic Commissioning log: The lift was installed and commissioned in accordance with the instructions on ______________... -
Page 5: Test Log
Test Log This pit lift was subjected to a regular inspection on the specified date in accordance with the regulations of the German BGG 945 / BGR500 and the Machinery Directive.2006 / 42 / EC Date of No defects/ Yes/no Yes/no Name, address, Confirmati- inspec- defects to Deficien- Defici- occupation, on of site tion be correc- cy cor- ency employer of operator rected corrected expert... -
Page 6: Safety Regulations
1. Safety regulations 1.1. Introduction SOMMERER pit lifts are a result of many years of experience. The high quality standard and the superior design guarantee reliability, long ser- vice life and efficient operation. You should read this operating manual attentively and always observe the contents to prevent unnecessary damage and hazards. This operating manual is applicable both for rail- mounted pit lifts as well as for freely movable lifts. 1.2. Application areas of the SOMMERER pit lifts SOMMERER pit lifts are only permitted to be used for partial lifting of vehicles with support afterwards and/or for lifting and lowering vehicle parts (e.g. -
Page 7: Operation Of The Site Operator
1.4. Obligation of the site operator The site operator is obliged to only allow persons to work on the system • are familiar with the basic regulations for occupational health and safety and accident prevention and who have been instructed about handling the system. • have read and understood the safety chapter and warnings and have confirmed this with their signature. 1.5. Hazards handling the pit lift The SOMMERER pit lifts have been designed and constructed accor- ding to the state of the art and the recognised safety regulations. Ne- vertheless, unintended use may endanger life and limb of the operator or damage property. The pit lift is only permitted to be used: • for the intended use • in safe, faultless condition ► Faults which can adversely affect safety must be rectified immediately. • Only put the pit lift in motion if there are no persons in the danger area. • The movement range of the pit lift must be kept clear. • No persons are permitted to be present in the movement range of the pit lift. • The maximum permitted load capacity of the pit lift must not be exceeded. -
Page 8: Organisationals Methods
• Make the lifting and lowering movements evenly. Monitor the load during the movement. • Pit lifts and transmission lifts are not suitable for holding loads over an extended period. Therefore, the raised load must be secured using support bridges or support blocks. 1.6. Organisational measures • The operating manual must always be kept ready to hand at the operating site of the pit lift. • In addition to the operating instructions, observe and enforce the ge- nerally applicable statutory and other binding regulations concerning accident prevention and environmental protection. -
Page 9: Maintenance Tasks, Fault Clearance, Disposal
1.7. Maintenance tasks, fault clearance, disposal • Comply with the adjustment and maintenance work, inspections and dates including information about the replacement of parts/individual components specified in the operating manual. These activities must only be performed by qualified personnel. • Always tighten screw connections which have been undone or loo- sened during maintenance and repair work. • Arrange safe and environmentally sound disposal of operating and auxiliary materials (hydraulic oil) and exchange parts. 1.8. Specific hazards Hydraulics, pneumatics • Work on hydraulic equipment must only be performed by persons with knowledge and experience of hydraulics. • Check all lines, hoses and screw connections regularly for leaks and externally recognisable damage. Rectify any damage immediately. Squirting oil can result in injuries and fire. • Depressurise pressure lines to be opened (hydraulics, compressed air) before starting repair work. ► Lay and mount hydraulic and compressed air lines properly. Do not mix up connections. -
Page 10: Safety Regulations
1.9. Safety regulations Applied safety regulations The following standards were implemented in the design: • The safety devices comply with EN1494:2009-5 • The lift complies with the safety regulations of the following directi- ves: 2006/42 EC Machinery Directive.. • The CE Declaration of Conformity is part of this operating manual. Observe the following during operation: • The accident prevention regulations of your country apply • 89/391/EEC Safety and health protection of employees • 89/654/EEC Safety and health protection in work facilities. • 89/655/EEC Safety and health protection when using work equip- ment • 89/656/EEC Safety and health protection when using personal pro- tective equipment • 92/58/EEC Safety and/or health labeling in the workplace Applied safety standards • EN ISO 12100-1:2003/ DIN EN 294/ prEN 349/ EN 414/ EN 418/ ISO 1219/ ISO/DIS 11530... -
Page 11: Description
When the counterweight of the axle is not on the rail, the lifting platform can become overloaded or the stability can be reduced. ► Always comply with the detailed operating and maintenance instructions. 2.2. Description of design and functions These electrohydraulic pit lifts are designed for lifting motor vehicles above assembly pits. The pit lift can be moved lengthways and cross- ways in the pit. The pit lift HKE consists essentially of a supporting plate with axles and running rollers. The lifting cylinder is welded to the midpoint of the supporting plate. A base plate is welded underneath the lifting cylinder. At FKE, the base plate is connected to the chassis. The control is per- formed using an UP push button installed on the lift and an UP-DOWN button lowering valve. The piston rod and guide are built into the lifting cylinder. At the top, the piston rod has a hole drilled to take holding devices. An attached sup- port plate serves as the load bearing device. Other suitable supports can be attached for special load application points on vehicles (see accessories). -
Page 12: Transport
Transport The pit lift can be transported standing or lying. The oil filling nozzle with integrated oil dipstick is replaced during transport by a tightly sealing stopper. This stopper must be replaced by the oil filling nozzle- before commissioning 3. Installation 3.1. General The pit lift should be installed by the manufacturer’s or the sales company‘s trained installers. If the site operator has sufficiently trained installers (experts), the pit lift can also be installed by them. The correct installation and commissioning must be inspected by an expert and confirmed in the commissioning log on page 4. 3.2. Setup and installation location HKE Adjustable chassis: • The chassis is suited for a spacing of 860 to 1,000 mm between the running rails. • The up to 14,5 t adjustable roller axles must be set so that the dis- tance between the roller collar and the running rails is no more than 10 mm. • Push the chassis once along the entire length of the pit to ensure this. • The distance from the roller collar to the pit running rail must not exceed 10 mm at any point! • In this position, the M10 safety bolts must be drilled. To do this, first tighten the bolts so that the tip of the bolt presses into the axle. • Then drill the axle with an 8 mm drill bit. Secure the safety bolts with... -
Page 13: Bleeding
Welded chassis (from 16 t or on request): • The chassis was manufactured according to your pit size; the roller collar must make contact with the running rail. • Here again, the maximum distance between the roller collar and the running rail must not exceed 10 mm. ► In general, the following applies to both the adjustable and the welded chassis • The standard running rollers are authorized only for flat to slightly conical contact; they may need to be adapted by re-turning to more tilted running rails. For an extra charge we will provide the corres- ponding rollers (sketch required!). • It is not permitted to extend the rollers to compensate for misalign- ment. -
Page 14: Setup And Installation Location Fke
• Check oil level monitoring on the lift. Repeat the procedure if neces- sary. 3.4. Setup and installation location for FKE Depending on the model, the pit lift is guided on the pit floor in or on running rails, or it is freely movable on the floor of the pit. Chassis model Z Model Z has a chassis that runs on the floor in U-profiles, L-profiles or a flat steel plate installed at the site (preferably U100). The profiles must be aligned exactly parallel, to within 10 mm. To install the rollers, open the U-profile at a suitable location. The pit lift is also freely movable crosswise in the chassis. ► Important! Before inserting the chassis and lift in the U-profile, they must be secured so that they cannot move. Chassis model F The F model has a chassis which runs along the floor, similar to the Z model. A flat steel plate can be used for the running surface. The rollers of the lift then run on the flat steel. This chassis can be guided laterally in the pit by means of adjustable spacer rollers. Chassis model FV The chassis of this lift is freely movable up to 1,000 kg on steering rollers. Loads exceeding 1,000 kg push down on the springs, so that the frame is on the floor. The lift is bolted solidly to the midpoint. The... -
Page 15: Operation
be swapped with each other. If a connection cable, other than the one which is supplied, is used for the lift, it is essential to use an H07RNF cast rubber cable. Check supply line for damage and replace immediately if necessary. The lift is also available for 240 V mains power. Special circuit diagrams must be observed here. Cables with large cross section are required. 4. Operation The respective applicable accident prevention regulations must be complied with. • The pit lift is only permitted to be operated by trained personnel. • Only put the pit lift in motion if there is no danger to persons. • The movement range of the pit lift must be kept clear and no per- sons are permitted to be in the movement range. • The maximum permitted load capacity of the pit lift must not be exceeded. • Climbing on the pit lift, riding on it and climbing on the load are forbidden. • Only load lift centrally, lift vehicle and check the safe vehicle support; do not lift to the required height until then. • Ensure that load is centered! Hold non-centered loads with cross members (2-point support). • The load bearing device must be centred on the load. Watch out for the shift in centre of gravity during lifting. • Make the lifting and lowering movements evenly. Monitor the load during the movement. • The raised load must be supported with support bridges or support blocks. • Engines must be secured reliably against slipping, sliding and tilting... -
Page 16: Lifting Loads
on the load bearing device. • Moving the lift under load is only permitted if special safety measu- res are observed. • Attached equipment (e.g. gearbox plates) for engine and gearbox installation and removal must not be pivoted or tilted so that the structural stability is reduced. This means: all loads to be lifted are centered and evenly distributed. 4.1. Lifting loads • Before using the lift for a vehicle, release the hand brake and shift the transmission to neutral. • Attach lifting gear at even, load-bearing points which are specified by the vehicle manufacturer. • The load bearing device must be centered on the load. Watch out for the shift in centre of gravity during lifting. • You must keep the movement area of the vehicle free, and keep the vehicle being moved under observation. • It is forbidden for anyone to enter the area of movement. • In the event of malfunctions, shut down the unit immediately and notify supervisor / service department. • Always observe the applicable regulations EN 1494:2009-5/BGG 945/BGR 500 • To raise or lower, press the appropriate pushbutton.or lowering valve 4.2. Lowering loads ► Make lowering movements slowly and evenly. Monitor the load during the movement. -
Page 17: Load Bearing Devices And Support Bridges
• Remove rolling away protection (wheel chocks). • Raise vehicle slightly and remove support bridges. • Only open the threaded spindle a very little for lowering the load. • The lowering speed is continuously controlled by turning the threa- ded spindle anticlockwise. • Turn the threaded spindle as far as the stop for further lowering without load. 4.3. Load bearing devices and support bridges Various load bearing devices are available for lifting vehicles and vehic- le parts. These include support plates, cross members, gearbox plates, special mountings and extensions. Lifted vehicles must be secured with support bridges or support blocks. Support bridges are always manufactured to the pit dimensions. Their secure support must be guaranteed over the complete length of the pit. 4.4. Instructions for use The manual forces for starting the unloaded pit lift are at most 300 N, and the forces required to maintain the motion are max. 200 N. If these forces are exceeded, e.g. because of a rough runway, then a second person must assist. • Never exceed the maximum permitted load capacity of the load bearing devices. • Irrespective of the load bearing device, the load centre of gravity must always be precisely central above the pit lift. • Only use load bearing devices with appropriate studs. • Do not stack extension pieces. -
Page 18: Maintenance
• Attach all load bearing devices directly to the piston rod. • Do not use any stroke extension between lift and lifting gear (cross member, gear box plate etc.). • The lifts are not suitable for use in car wash systems; if used there, they must be suitably covered and protected to prevent damage from the high humidity. The warranty does not cover rust! Residue from underbody sealing compounds will destroy the seals. • Due to the corner load of the supporting plates, damage to the floor cannot be ruled out. Covering with tiles is only appropriate when the floor is very level. • Under normal operating conditions, this universal lifting device is completely stable. Since the chassis is not secured against tipping on the floor, you should be aware of the possible dangers. Therefo- re, side loading should always be avoided. 5. MAINTENANCE 5.1. Special instructions Original SOMMERER PIT LIFTS require minimal maintenance. It is important that the piston rod be kept clean. Damage must be immediately polished out with a gentle transition. When working with strongly adhering underbody compounds (underbody protection, wax etc.) the piston rod must be fully covered or - before lowering the lift - cleaned Such compounds gum up the upper dirt and water wiper ring, which then no longer functions properly. ► Do not clean pit lifts with high-pressure or steam cleaners, cleaning agents can penetrate the valves and cause since malfunctions. -
Page 19: Oil Level Check
Every time that it is retracted, the piston rod passes completely through the plunger system into the hydraulic oil, and is thereby automatically lubricated and protected against corrosion. The hydraulic oil must be changed after no more than six years of operation. The initial fill at the factory is with BP HLP HM 35. A comparable oil can be used when changing the oil. 5.3. Oil level check Important for oil level check ► Disconnect the pit lift from the compressed air network! ► Check oil only when unit is not under pressure ► Check oil only when lift is not in motion. ►... -
Page 20: Troubleshooting
6.2. Troubleshooting a) Lift does not pump or will not hold a load • Insufficient oil possibly lost during transport. Add low-viscosity hydraulic oil (HLP 35)as far as the upper mark on the dip stick. Ram must be fully in starting position! • Check the non-return valve on the cylinder. Remove any dirt that may be present, or replace the valve. If these first points are correct, then the groove ring in the guide must be defective. This generally does not occur until after at least four years. In this case, the lift must be overhauled. Removal of the guide: Disconnect the pit lift from the power supply. Unscrew the guide using a suitable tool. The piston rod can remain in the lift. After installation, bleed the lift; see page 13. b) Oil loss on the piston rod • Reseal the guide, replace the wiper ring and the groove ring c) Oil loss on the lifting or lowering spindle • Replace seals; lubricate all sliding parts with Molykote. -
Page 21: Warranty
7. WARRANTY Our „General terms of sale and delivery“ are always applicable. The- se have been available to the customer since conclusion of the con- tract. Warranty and liability claims for personal injuries and damage to property are void if they are attributable to one or more of the following causes: • Use of the pit lift for other than its intended purpose. • Improper installation, commissioning, operating and maintenance of the pit lift. • Operation with compressed air containing condensate and/or dirt. Operation of the pit lift with defective safety devices or with safety devices and protective equipment not properly installed or operatio- nal. • Rust due to water in compressed air or from other influences such as salt in winter. • Non-observance of the instructions in the operating manual concer- ning transport, storage, installation, commissioning. operation and maintenance of the pit lift. • Unauthorised modification of the pit lift. • Inadequate monitoring of parts which are subject to wear. • Improperly performed repairs • Disasters caused by external influence and force majeure. In order for a warranty claim to be accepted, it is necessary that you describe the claim/defect to us in as much detail as possible. Prior to returning a shipment, please contact us by telephone first, since most claims turn out to be minor problems. We request that returns are made at the expense of the customer. After examination and acknowledge- ment of the claim, we will reimburse the freight costs incurred. We cannot accept customer service requests and the costs for return arising from non-observance of the specified points. Therefore, before any return, contact the manufacturer. -
Page 22: Electrical And Hydraulic Diagram
8. Electrical and Hydraulic Diagram 8.1. Electrical Diagram HKE / FKE400 Volt (Standard) -
Page 23: Electrical Diagram Hke/Fke 240 V
8.2. Electrical diagram HKE /FKE 240 Volt (only on special request) 8.3. Lift control... -
Page 24: Hydraulic Diagram Hke/Fke
9. Hydraulic diagram HKE /FKE... -
Page 25: Replacement Parts List
Replacement parts list Position Replacement part Guide for piston rod Sealing set for piston rod Piston rod End stop, complete, for piston rod Lifting spindle with handwheel only for model with lifting spindle instead of pushbutton Lowering spindle with handwheel Sealing set for lifting and lowering spindles Non-return valve, complete End switch only for model with a lifting spindle Cover for hydraulic block Cover for hydraulic aggregate Cover for hydraulic aggregate Hydraulic hose 8 mm Pushbutton „UP“ Claw Lift roller, complete... -
Page 26: Ec-Declaration Of Conformity
Mönsheimer Straße 28 D-71292 Friolzheim Telefon: + 49(0)7044/94 52-0 Telefax: + 49(0)7044/94 52-31 hereby confirms that the following product: Designation: Pit lift: Model: HKE / FKE Year See data sheet in operating Manual/Test Log Factory no.: See data sheet in operating Manual/Test Log complies with the basic safety and occupational health requirements of the following EC derctive EG- directive:... - Page 28 Edition of the Operating Manual of May 2013 Great care was taken in reviewing the information in this edition. Never- theless, it is not possible to rule out errors altogether. This operating manual is intended for users with previous technical knowledge in the field of automotive technology. All rights reserved. Subject to modification of technical information and content. ERICH SOMMERER GMBH Mönsheimer Straße 28 D-71292 Friolzheim Telefon +49(0)7044/94 52-0 Telefax +49(0)7044/94 52-31 Email info@sommerer.com www.sommerer.com...
Need help?
Do you have a question about the HKE and is the answer not in the manual?
Questions and answers