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Related Manuals for AUTOPSTENHOJ Masterlift 2.35 Combi
Summary of Contents for AUTOPSTENHOJ Masterlift 2.35 Combi
- Page 1 Masterlift 2.35 Combi / "Check-in" Installation instructions (TRANSLATED VERSION) ALWAYS KEEP Read the operating operating instructions instructions before ready to hand on the working with the unit unit Manual no.: 9000195GB Date: 10.07.2019...
- Page 2 2 / 45 Masterlift 2.35 Combi / "Check-in" 9000195GB Before taking into operation check system compo- nents, control, emer- gency stop and safety equipment for conditi- on, damage and correct function! © AUTOPSTENHOJ GmbH Sandkampstr. 90 D – 48432 Rheine Tel.:...
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Page 3: Table Of Contents
9000195GB Masterlift 2.35 Combi / "Check-in" 3 / 45 Table of contents General ............................... 5 Information for the installation instruction .................... 5 Explanation of symbols ........................5 Liability and warranty .......................... 6 Copyright protection ..........................6 Safety ..............................7 General ............................... 7 Work safety ............................ - Page 4 4 / 45 Masterlift 2.35 Combi / "Check-in" 9000195GB Installation of superstructure ......................35 Installation of the repair platform for ML Combi ................35 Installation of the repair platform for ML Combi "Check-in"............... 36 Installation of the wheel free superstructures ..................37 5.3.1...
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Page 5: General
9000195GB Masterlift 2.35 Combi / "Check-in" 5 / 45 General Information for the installation instruction This installation instruction describes the installation of the lifting unit and the superstructure. Compliance with the notes on safety and procedural instructions is a prerequisite for the safe and proper installation of the lift. -
Page 6: Liability And Warranty
6 / 45 Masterlift 2.35 Combi / "Check-in" 9000195GB Liability and warranty All information and notes in these installation instructions are provided under due consideration of valid regula- tions, the latest technical status of development as well as our years of expertise and experience. -
Page 7: Safety
9000195GB Masterlift 2.35 Combi / "Check-in" 7 / 45 Safety This section gives an overview of all important security aspects for the optimal protection of personnel as well as for the safety and malfunction-free operation of the machine. Additionally, the individual chapters contain concrete safety notes, marked with safety symbols, for the preven- tion of immediate dangers. -
Page 8: Behavior In Case Of Danger Or Accidents
8 / 45 Masterlift 2.35 Combi / "Check-in" 9000195GB Behavior in case of danger or accidents 2.4.1 Preventative Measures • Always be prepared for accidents or fire ! • Keep first aid equipment (first aid kit, blankets, etc.) and firefighting equipment close to hand. • Make personnel familiar with the location and use of safety, accident reporting, first aid and rescue equip- ment and have this training confirmed. • Clear access routes for rescue vehicles. 2.4.2 If the worst comes to the worst: Do the right things! •... -
Page 9: Technical Data
9000195GB Masterlift 2.35 Combi / "Check-in" 9 / 45 Technical data Generally the lifts Masterlift Combi and Masterlift Combi "Check-in" differ in respect of their general function. General function of Masterlift Combi The Masterlift Combi lift is a multi-functional lift both for diagnostics and repair work. The structure basically represents to "nested"... -
Page 10: General Function Of Masterlift Combi "Check-In
10 / 45 Masterlift 2.35 Combi / "Check-in" 9000195GB General function of Masterlift Combi "Check-in" The Masterlift Combi "Check in" lift is explicitly designed for the reception area. The lift has two lifting units: the first one for the main platform lift and the second one for the wheel free devices. The piston distance for both units is 1335mm. Due to the principle of this lift, the maximum stroke is 1835 mm. The stroke can be spread on the superstructu- res, platforms or wheel free device. -
Page 11: Connected Loads
9000195GB Masterlift 2.35 Combi / "Check-in" 11 / 45 Connected loads 3.3.1 PLC control unit Supply line via main switch 400V / 3p+N+PE / 50Hz Voltage power adaptor primary/secondary 230V AC / 24V DC Control voltage 24V DC Sensor voltage... -
Page 12: Hydraulic System
12 / 45 Masterlift 2.35 Combi / "Check-in" 9000195GB 3.3.4 Hydraulic system Max. pressure of hydraulic pump 250 bar Hydraulic pump flow volume 10,6 l/min Max. flow volume of flow control valve 8,6 ± 0,8 l/min Capacity [kg] 3500 Operating pressure [bar] Setting of pressure relief valve [bar] Total oil volume in circuit Approx. -
Page 13: Requirements Of The Place Of Installation
9000195GB Masterlift 2.35 Combi / "Check-in" 13 / 45 Requirements of the place of Installation Lifts in this series consist of an above floor as well as an under floor component. They can be installed as stan- dard, basement or ceiling installation version. Hydraulic cylinder, hydraulic pump, motor, valves and parts of the control are under floor-mounted in a covered foundation frame or in a steel cassette. The foundation depth thereby depends on the design of the lift (“Te- chnical Data”). -
Page 14: Installation Of The Lifting Unit
14 / 45 Masterlift 2.35 Combi / "Check-in" 9000195GB Installation of the lifting unit Overview of components Masterlift Combi The main components diagrammed in the following illustrations belong to this series. Hydraulic valve of the Cover of the cassette hydraulic cylinder... -
Page 15: Overview Of Components Masterlift Combi "Check-In
9000195GB Masterlift 2.35 Combi / "Check-in" 15 / 45 Overview of components Masterlift Combi "Check-in" Hydraulic valve of Cover of cassette with Terminal box the hydraulic cyinder sealing Guide / Stuffing box Flow divider Hydraulic pump unit Struts Hydraulic hoses to the wheel free... -
Page 16: Placing, Aligning And Concreting The Steel Cassette
16 / 45 Masterlift 2.35 Combi / "Check-in" 9000195GB Placing, aligning and concreting the steel cassette Before beginning assembly, check and determine the general layout, the placement of the control box, the steel cassette and the foundation measurements. For the construction of the foundation and the arrangement of the steel cassette, depending on the installation (on top of floor, flush with the floor, etc.) a foundation plan, agreed-upon by the manufacturer or architect is to... -
Page 17: Installation Of The Hydraulic Components
9000195GB Masterlift 2.35 Combi / "Check-in" 17 / 45 Installation of the hydraulic components Before installation of the lifting unit, both the transport cover and the struts must be removed from the inside of the steel cassette. 4.4.1 Installation of hydraulic cylinders Masterlift Combi... -
Page 18: Installation Of Hydraulic Cylinders Masterlift Combi "Check-In
18 / 45 Masterlift 2.35 Combi / "Check-in" 9000195GB 4.4.2 Installation of hydraulic cylinders Masterlift Combi "Check-in NOTE! When mounting older cassettes before setting the cylinder, put the bracket for the sensor ladder rack in the steel cassette (it does not belong to the delivery of the lifting unit). -
Page 19: Installation Of Preassembled Cylinders
9000195GB Masterlift 2.35 Combi / "Check-in" 19 / 45 4.4.3 Installation of preassembled cylinders For lifts with flush floor device place the spacer (h=105 mm) in the steel cassette before installing the cylinders. The spacer is used for bridging the space needed for the flush floor device. Locking is not necessary. Install preassembled cylinders in the steel cassette as follows: • Place the flat gasket on the foundation frame. Screw two ring screws M 20 into the bearings and mount – for ML Combi the main cylinders – for ML •... -
Page 20: Installation Of The Hydraulic Pump Unit
20 / 45 Masterlift 2.35 Combi / "Check-in" 9000195GB 4.4.4 Installation of the hydraulic pump unit The unit will be delivered preassembled. It will be fastened onto the welded screws inside of the cassette. The unit must be leveled when mounting. The screw plug in the oil filling bore is to be replaced by the dipstick with ventilation filter. The hydraulic hoses of the hydraulic cylinder must be placed according to fig 7. Fig. 10: Pump unit type Combi / "Check-in"... -
Page 21: Installation Of The Control Unit Components
9000195GB Masterlift 2.35 Combi / "Check-in" 21 / 45 Installation of the control unit components 4.5.1 Introduction The control unit is composed of two parts, the control box (with control board and power supply unit) and the terminal box which is installed in the cassette. The connection has to be made according to the wiring diagram (No. -
Page 22: Cable Connections
22 / 45 Masterlift 2.35 Combi / "Check-in" 9000195GB 4.5.3 Cable connections For the connection between the control box and the cassette the following cables are needed: Cable Cores & sections Length Remarks Supply cable to the control 5x2,5mm² Ø12,6mm... -
Page 23: 4.5.4.1 Connection Of The Control Unit
9000195GB Masterlift 2.35 Combi / "Check-in" 23 / 45 4.5.4.1 Connection of the control unit Terminal strip X5 Attachable core Function allocation of the terminal & X8 on the control (Control cable to cable terminal box) Sensor 2 A Sensor master image identification – wheel free device (green LED) Sensor 2 B Sensor master image identification – wheel free device (yellow LED) -
Page 24: 4.5.4.2 Connection Of The Terminal Box
24 / 45 Masterlift 2.35 Combi / "Check-in" 9000195GB 4.5.4.2 Connection of the terminal box Electromagnetic Connection terminal Sensor Electromagnetic Sensor valves - wheel free block on the hy- - wheel free cylin- valves - main - main cylinder cylinder... -
Page 25: Installation Of The Sensor Ladder Rack - Combi
9000195GB Masterlift 2.35 Combi / "Check-in" 25 / 45 4.5.5 Installation of the sensor ladder rack - Combi NOTE! As long as referencing has not taken place (see chapter 6.1), a continuous acoustic signal can be heard when raising or lowering the lift. - Page 26 26 / 45 Masterlift 2.35 Combi / "Check-in" 9000195GB NOTE! The Combi-Lift lifting units are equipped with 2 Sensor blocks. • The sensor ladder rack must be oiled before it is installed • Test to make sure the sensor block slides on the ladder rack.
- Page 27 9000195GB Masterlift 2.35 Combi / "Check-in" 27 / 45 Fig. 16: Fitting on the upper bracket...
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Page 28: Installation Of The Sensor Ladder Rack - Combi "Check-In
28 / 45 Masterlift 2.35 Combi / "Check-in" 9000195GB 4.5.6 Installation of the sensor ladder rack - Combi "Check-in" NOTE! As long as referencing has not taken place (see chapter 6.1), a continuous acoustic signal can be heard when raising or lowering the lift. - Page 29 9000195GB Masterlift 2.35 Combi / "Check-in" 29 / 45 NOTE! The sensors are cast in the block. Sensor 1/2 A is labelled with the green LED and Sensor 1/2 B is labelled with the yellow LED. IMPORTANT! The sensor with the green LED is the upper one, which passes through the reference picture of the sensor ladder rack.
- Page 30 30 / 45 Masterlift 2.35 Combi / "Check-in" 9000195GB Sensor for the wheel free cylin- ders Cable clamp Sensor 2A (green LED) Sensor 2B (yellow LED) Open cross must point to the cylin- ders Sensor for the main cylinders Tappet Fig.
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Page 31: Connection Of The Synchronization Bars
9000195GB Masterlift 2.35 Combi / "Check-in" 31 / 45 Connection of the synchronization bars Thread always to the pump unit side of the steel cassette Screw head always on the Thread M8 for earthing side where the hydraulic connection hoses lie Fig. -
Page 32: Aligning The Hydraulic Cylinders
32 / 45 Masterlift 2.35 Combi / "Check-in" 9000195GB Aligning the hydraulic cylinders NOTE! As long as referencing has not taken place (see chapter 6.1), a continuous acoustic signal can be heard when raising or lowering the lift. In order to be able align the main cylinders, both cylinders must be driven out completely. -
Page 33: Installation Recessed Version (With Flush Floor Device)
9000195GB Masterlift 2.35 Combi / "Check-in" 33 / 45 4.10 Installation recessed version (with flush floor device) • Insert retaining cups for the cylinders of the flush floor device into the foundation recesses provided, using quick-curing mortar, and align them (see fig. 22). • Install the lifting cylinders analogous to chapter 4.4.1 • Istall the cylinders for the flush floor device in the retaining cups and align them, connect the hydraulic hoses (see fig. 22). • Insert the retaining plate with bulkhead connection (insert in steel cassette and bolt down for the connection of the flush floor device cylinders (see Fig. 23). -
Page 34: Installation And Adjustment Of The Cover Plates
34 / 45 Masterlift 2.35 Combi / "Check-in" 9000195GB Retaining plate with bulkhead con- Cover plate (extra lift unit) nection Fig. 23: Hydraulic connection for extra lifting cylinder - sectional view DRIVE-ON DIRECTION Four connections (8L) for the Fig. 24: Hydraulic connection for extra lifting cylinder - top view cylinders of the extra lifting unit 4.10.1... -
Page 35: Installation Of Superstructure
9000195GB Masterlift 2.35 Combi / "Check-in" 35 / 45 Installation of superstructure Attention: You have to differ between the installation of the superstructures. For the ML Combi please follow the commands you can find in chapter 5.1 and 5.3 and for the ML Combi „Check-in“ please follow the commands from chapter 5.2 and 5.3. Installation of the repair platform for ML Combi The fitting of the platforms is accomplished in af few short steps. -
Page 36: Installation Of The Repair Platform For Ml Combi "Check-In
36 / 45 Masterlift 2.35 Combi / "Check-in" 9000195GB • Depending on design (drive-on or drive-through platform) mount 2 or 4 drive-on ramps on the frontside of the platforms. For the assembly plug bolts Ø20 mm and appropriate circlips are supplied. Platforms with 2 ramps must be equipped on the opposite side with wheel stops. -
Page 37: Installation Of The Wheel Free Superstructures
9000195GB Masterlift 2.35 Combi / "Check-in" 37 / 45 Installation of the wheel free superstructures Different wheel free superstructures can be installed on the Masterlift Combi. The repair platform superstruc- tures (Type Pv, Pvv) and swivel arm superstructures (Type Saa, Saav) belong to this group. They are preas- sembled and to be screwed on the wheel free cylinders. - Page 38 38 / 45 Masterlift 2.35 Combi / "Check-in" 9000195GB...
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Page 39: Adjustment Of The Lift
9000195GB Masterlift 2.35 Combi / "Check-in" 39 / 45 Adjustment of the lift The upper end position and the signal tone can be programmed on site. The control unit has special functions for this which can be activated by different button combinations... -
Page 40: Adjusting The Safety Zone
40 / 45 Masterlift 2.35 Combi / "Check-in" 9000195GB Adjusting the safety zone Lower lift to bottom position for starting the signal tone. Attention ! The minimum distance between bottom edge of lifting platform and upper edge of floor or crushing edge must be at least 120mm ! Turn off the control unit in this position and wait 4 seconds. -
Page 41: Installation Of The Cassette Cover
9000195GB Masterlift 2.35 Combi / "Check-in" 41 / 45 Installation of the cassette cover Before the cassette is sealed and closed, an extensive performance check is to be done and the hydraulic hoses are to be tested for leakages. Place the flat iron in the U-brackets of the steel cassette near the stuffing boxes and place the rubber profile lists on it. - Page 42 42 / 45 Masterlift 2.35 Combi / "Check-in" 9000195GB Malfunctions code table: Signal tones at Meaning Procedure failure No error Non failure Nothing BCC - error Parameter check-sum is Service wrong STM32 flash error Found failure in CPU- Service flash memory Encoder 1 timeout...
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Page 43: Malfunction Analysis
9000195GB Masterlift 2.35 Combi / "Check-in" 43 / 45 Malfunction analysis In principle the cables are to be inspected after the installation and connection of the lift. In case of non-function the correct voltage supply is to be checked. The three phases and the neutral conductor of the supply cable must be firmly connected to the input terminals. After turning on the main switch the supply... -
Page 44: Overview: Wiring Diagrams
44 / 45 Masterlift 2.35 Combi / "Check-in" 9000195GB Overview: Wiring diagrams 10.1 Twin ram Combi lift 10.1.1 Connecting diagram motor terminal frame (diagram no. 34806) 10.1.2 Connecting plan PLC control unit with signal tone (diagram No.: 9000473) Overview: Hydraulic circuit diagrams 11.1... - Page 45 9000195GB Masterlift 2.35 Combi / "Check-in" 45 / 45 Index Personal safety equipment ...7 Place of Installation ...13 Protective work clothing ...7 Adjustment of the lift ...39 Recessed version, installation ...32 Recessed version (with flush floor device) ...33 Behavior in case of danger or accidents ...8 Repair platform for ML Combi, installation ...35...
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