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AUTOPSTENHOJ Masterlift 2.30 Operation And Maintenance Instruction

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ALWAYS KEEP the
Read the operation
operation instructi-
instructions before
ons ready to hand
working with the
on the unit
unit
Masterlift
2.30 / 2.35 / 2.35 Combi
Operation and maintenance
instructions
(TRANSLATED VERSION)
Manual no.:
9000114GB
Date:
15.03.2021

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Summary of Contents for AUTOPSTENHOJ Masterlift 2.30

  • Page 1 Masterlift 2.30 / 2.35 / 2.35 Combi Operation and maintenance instructions (TRANSLATED VERSION) ALWAYS KEEP the Read the operation operation instructi- instructions before ons ready to hand working with the on the unit unit Manual no.: 9000114GB Date: 15.03.2021...
  • Page 2 2 / 65 Masterlift 2.30 / 2.35 / 2.35 Combi 9000114GB Before taking into operation check system compo- nents, control, emer- gency stop and safety equipment for conditi- on, damage and correct function! © AUTOPSTENHOJ GmbH Sandkampstraße 90 D – 48432 Rheine Tel.:...

  • Page 3: Table Of Contents

    9000114GB Masterlift 2.30 / 2.35 / 2.35 Combi 3 / 65 Table of content General ............................5 Information about the operating manual ..................5 Explanation of symbols ......................5 Warranty and liability ........................6 Spare parts ..........................6 Copyright protection ........................7 Waste disposal ...........................7 Safety ............................8 General ............................8...
  • Page 4 4 / 65 Masterlift 2.30 / 2.35 / 2.35 Combi 9000114GB Installation and start-up ......................29 Installation ..........................29 Start-up ............................29 Operation ..........................30 Safety ............................30 Operating the lifting platform with repair platform superstructure ..........31 7.2.1 Rolling the vehicle on .......................31 7.2.2 Lifting the vehicle ........................31 7.2.3...

  • Page 5: General

    9000114GB Masterlift 2.30 / 2.35 / 2.35 Combi 5 / 65 General Information about the operating manual This operating manual describes the installation, operation and maintenance of the machine. Strict compliance with all the specified notes on safety and instructions is essential for safe working and proper handling of the equipment.

  • Page 6: Warranty And Liability

    6 / 65 Masterlift 2.30 / 2.35 / 2.35 Combi 9000114GB Warranty and liability All information and notes in this operation manual are provided under due consideration of valid regulations, the latest technical status of development as well as our years of expertise and experience.

  • Page 7: Copyright Protection

    9000114GB Masterlift 2.30 / 2.35 / 2.35 Combi 7 / 65 Copyright protection This operating manual is to be treated as confidential. It is solely intended for persons having to work on or with the equipment. Passing this operating manual on to third parties without a written confirmation is not permitted.

  • Page 8: Safety

    8 / 65 Masterlift 2.30 / 2.35 / 2.35 Combi 9000114GB Safety This section offers an overview of all important safety aspects for an optimal protection of personnel against danger and ensures safe and disruption-free operation of the machine. In addition to this, concrete notes on safety to avert danger are provided and marked with symbols in the indi- vidual chapters.
  • Page 9 9000114GB Masterlift 2.30 / 2.35 / 2.35 Combi 9 / 65 Example of an EC Statement of Conformity...

  • Page 10: Customer's Responsibility

    10 / 65 Masterlift 2.30 / 2.35 / 2.35 Combi 9000114GB Customer’s responsibility This operating manual should always be kept in the immediate vicinity of the machine, accessible for the • personnel entrusted with installation, operation, maintenance and cleaning. •...

  • Page 11: Work Safety

    9000114GB Masterlift 2.30 / 2.35 / 2.35 Combi 11 / 65 Work safety Compliance with the notes on safety can help to avoid personal injury and material damage when working on the machine. Failure to comply with these notes will cause a considerably risk of injury for persons and danger of damage or destruction of the machine.

  • Page 12: Operating Personnel

    12 / 65 Masterlift 2.30 / 2.35 / 2.35 Combi 9000114GB Operating personnel The device must only be operated and serviced by authorized, trained and instructed expert persons who: • are at least 18 years of age and • have been thoroughly instructed in operation and can provide evidence of their suitability to operate lifting platforms and •...

  • Page 13: Technical Data

    9000114GB Masterlift 2.30 / 2.35 / 2.35 Combi 13 / 65 Technical data Type designation 3.1.1 Model ranges with one lifting unit (standard design) ML 2.35 S aav 135 Example: Design key *) Identification of superstructure: a = telescopic aa = double telescopic...

  • Page 14: Name Plate

    14 / 65 Masterlift 2.30 / 2.35 / 2.35 Combi 9000114GB Name plate The name plate is located on the control and contains the following information: Manufacturer Type designation Machine serial-no. Year of manufacture Load bearing capacity Design key Operating pressure...

  • Page 15: Operating Values

    9000114GB Masterlift 2.30 / 2.35 / 2.35 Combi 15 / 65 3.3.3 Operating values Lifting/lowering speed approx. 6 cm/s Permanent sound level ≤ 70 dB(A) Operating temperature range -10... +60 °C Operating pressure for emergency lowering (at port A): min. 6 bar 3.3.4...

  • Page 16: Load Distribution

    16 / 65 Masterlift 2.30 / 2.35 / 2.35 Combi 9000114GB Load distribution Repair platform type superstructure Front load ratio (Fv) : rear load ratio (Fh) Fv : Fh = 3 : 2 and 2 : 3 This assumption is based on a load bearing rectangle with a width (track width) x length (wheel base) of 1.00 m x 1.40 m respectively 1.70 m x 1.40 m.
  • Page 17 9000114GB Masterlift 2.30 / 2.35 / 2.35 Combi 17 / 65 Platform Fv Uni superstructure Front load ratio (F ) : rear (F = 3 : 2 and 2 : 3 This assumption is based on a pavement projection at front (v) and rear (h) of 300 mm each from the middle of the wheel to the end of the pavement.

  • Page 18: Weight

    18 / 65 Masterlift 2.30 / 2.35 / 2.35 Combi 9000114GB Weight Superstructure: All components fastened on the hydraulic cylinders Cassette: Steel cassette concreted in the foundation to take up the lifting unit Lifting unit: Hydraulic cylinders with guides/stuffing boxes, synchronization bar, hydraulic unit incl. hydraulic oil, control and sensor ladder rack for the signal tone.

  • Page 19: Requirements To The Place Of Installation

    9000114GB Masterlift 2.30 / 2.35 / 2.35 Combi 19 / 65 Requirements to the place of installation The lifting platforms consist of an above floor and a under floor component. They can be installed as standard, basement or ceiling installation version.

  • Page 20: Structure And Function

    20 / 65 Masterlift 2.30 / 2.35 / 2.35 Combi 9000114GB Structure and function General description 4.1.1 Principle of function The lifting columns under the left and right hand side of the vehicle have the function of lifting and lowering the vehicle.

  • Page 21: Main Components

    9000114GB Masterlift 2.30 / 2.35 / 2.35 Combi 21 / 65 The lifting platforms of the Masterlift series are available in the following basic designs: 1. 2-piston lifting platform without wheel free device The lifting unit is operated with two hydraulic cylinders. Both hydraulic cylinders are mechanically connected by a rigid synchronization lever in the foundation area.

  • Page 22: Overview Of Modules

    22 / 65 Masterlift 2.30 / 2.35 / 2.35 Combi 9000114GB Overview of modules The overview of modules shows the most important modules by using the lifting platform 2.35 Combi Pv as an example. Superstructure (picture shows type "Platform") and the integrated wheel free device (picture shows type "Repair platforms") vary in dependence on the lifting platform design.
  • Page 23 9000114GB Masterlift 2.30 / 2.35 / 2.35 Combi 23 / 65 Overview of lifting unit - for Multilift installation...

  • Page 24: Description Of Modules

    24 / 65 Masterlift 2.30 / 2.35 / 2.35 Combi 9000114GB Description of modules 4.3.1 Superstructure 4.3.1.1 Repair platform Pv or Pv xy The superstructure Pv consists of flat girders (size 1200 – 1800, 1400 - 2000 mm or 1600 - 2200 mm), which are fitted with adjustable and lockable longitudinal slides.

  • Page 25: Control Box

    9000114GB Masterlift 2.30 / 2.35 / 2.35 Combi 25 / 65 4.3.2 Control box A control box with a push button control unit (PLC control) is used to operate the lifting platform. The control box is arranged outside the area of the lifting platform. It should be installed in a location from which the operator can view the danger zone during operation.

  • Page 26: Plc Control Unit "Fn" And "Combi

    26 / 65 Masterlift 2.30 / 2.35 / 2.35 Combi 9000114GB 4.3.2.2 PLC control unit "Fn" and "Combi" After switching on the main switch the control unit first runs a self test (duration approx. 20 s). To lift or lower the complete lifting platform operate the push button for the desired direction of movement of the main cylinder.

  • Page 27: Symbols Of The Short Operation Instructions

    9000114GB Masterlift 2.30 / 2.35 / 2.35 Combi 27 / 65 4.3.2.3 Symbols of the short operation instructions The lifting platform must only be operated by authorized persons. Strict compliance with the comprehensive operating manual is mandatory, especially in case of faults Climbing up or standing on lifted load or super- structure is strictly prohibited.

  • Page 28: Transport, Packing And Storage

    28 / 65 Masterlift 2.30 / 2.35 / 2.35 Combi 9000114GB Transport, packing and storage Safety notes WARNING! Danger of injury! There is a danger of injury from falling parts when lifting, swinging and lowering. The machine can be damaged or destroyed by improper transporting.

  • Page 29: Storage

    9000114GB Masterlift 2.30 / 2.35 / 2.35 Combi 29 / 65 Storage Keep packed goods packed up until installation and store such items as specified on the externally attached installation and storage information. Store packing units only under the following conditions: Do not keep in the open-air.

  • Page 30: Operation

    30 / 65 Masterlift 2.30 / 2.35 / 2.35 Combi 9000114GB Operation Safety WARNING! Danger of injury! Improper operation can lead to severe personal injury and/or material damage. The device must only be operated by authorized and instructed personnel and in full compliance with the safety regulations.

  • Page 31: Operating The Lifting Platform With Repair Platform Superstructure

    9000114GB Masterlift 2.30 / 2.35 / 2.35 Combi 31 / 65 Operating the lifting platform with repair platform superstructure 7.2.1 Rolling the vehicle on 1. Unlock and switch on the main switch. 2. Make sure that the danger zone around the lifting platform is free of persons.

  • Page 32: Operating The Lifting Platform With Swivel Arm Superstructure

    32 / 65 Masterlift 2.30 / 2.35 / 2.35 Combi 9000114GB Operating the lifting platform with swivel arm superstructure 7.3.1 Rolling the vehicle on 1. Unlock and switch on the main switch. 2. Make sure that the danger zone around the lifting platform is free of persons.

  • Page 33: Operating The Lifting Platform With Platform Fv Uni Superstructure

    9000114GB Masterlift 2.30 / 2.35 / 2.35 Combi 33 / 65 Operating the lifting platform with platform Fv Uni superstructure 7.4.1 Driving the vehicle on the platform 1. Unlock and switch on the main switch. 2. Make sure that the danger zone around the lifting platform is free of persons.

  • Page 34: Operating The Lifting Platform Type F And Fn With Platform Superstructure

    34 / 65 Masterlift 2.30 / 2.35 / 2.35 Combi 9000114GB Operating the lifting platform type F and Fn with platform superstructure 7.5.1 Driving the vehicle on the platform 1. Unlock and switch on the main switch. 2. Make sure that the danger zone around the lifting platform is free of persons.

  • Page 35: Lowering And Rolling Off The Vehicle

    9000114GB Masterlift 2.30 / 2.35 / 2.35 Combi 35 / 65 1. Unlock and switch on the main switch. 2. Make sure that the danger zone around the lifting platform is free of persons. 3. Lower the wheel free device. For this purpose keep pressing the push button "Wheel free device Down"...

  • Page 36: Operating The Combi Lifting Platform

    36 / 65 Masterlift 2.30 / 2.35 / 2.35 Combi 9000114GB Operating the Combi lifting platform 7.6.1 Driving the vehicle on the platform 1. Unlock and switch on the main switch. 2. Make sure that the danger zone around the lifting platform is free of persons.

  • Page 37: Operating The Wheel Free Device Type "Swivel Arm

    9000114GB Masterlift 2.30 / 2.35 / 2.35 Combi 37 / 65 3. Position additional pads (truncated pyramids) on the rubber pads of the flat girders exactly under the specified lifting points of the vehicle. Make sure that the additional pads are securely seated and the load application is centered! 4.

  • Page 38: Maintenance

    38 / 65 Masterlift 2.30 / 2.35 / 2.35 Combi 9000114GB Maintenance Safety WARNING! Danger of injury! Improperly performed maintenance work can lead to severe physical injury or damage to property. Any work related with care and maintenance must only be carried out by qualified and authorized expert personnel.

  • Page 39: Maintenance Work

    9000114GB Masterlift 2.30 / 2.35 / 2.35 Combi 39 / 65 These lifts must be permanently operated with non water endangering synthetic ester fluid, viscosity WARNING! System- and environmental damages! Not following these instructions may result in harmful damages at the system an environment. Leaked synthetic ester fluid must be removed, immediately.

  • Page 40: Inspections

    40 / 65 Masterlift 2.30 / 2.35 / 2.35 Combi 9000114GB Inspections Before commissioning the lift must be inspected according to the local national health and safety regulations. Operational safety and reliability can only be guaranteed when the condition and function of the lift are inspec- ted at regular intervals –...

  • Page 41: Malfunctions

    9000114GB Masterlift 2.30 / 2.35 / 2.35 Combi 41 / 65 Malfunctions 10.1 Action in case of malfunctions WARNING! Danger of injury! Unprofessional rectification of faults can lead to severe personal injury and/or material damage. Faults must therefore only be rectified by trained and authorized expert personnel.

  • Page 42: Emergency Lowering Of Lifting Platforms With Plc Control Unit

    42 / 65 Masterlift 2.30 / 2.35 / 2.35 Combi 9000114GB 10.2.1 Emergency lowering of lifting platforms with PLC control unit 10.2.1.1 Pneumatic connection The free end of the pneumatic hose (1) is located on the right (or left) side on the control housing.

  • Page 43: Fault Display Plc Control Unit

    9000114GB Masterlift 2.30 / 2.35 / 2.35 Combi 43 / 65 10.3 Fault display PLC control unit The PLC control unit is equipped with a permanent monitoring system. When an error occurs on the equipment, this error will be registered by the control unit by means of an audible signal tone and displayed when pushing a button.
  • Page 44 44 / 65 Masterlift 2.30 / 2.35 / 2.35 Combi 9000114GB 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-flash Service memory Encoder 1 timeout...

  • Page 45: Appendix: Wiring Diagrams

    9000114GB Masterlift 2.30 / 2.35 / 2.35 Combi 45 / 65 Appendix: Wiring diagrams 11.1 Hydraulic unit 11.1.1 Connecting diagram motor terminal frame (diagram No. 34806) 11.2 Superstructures without wheel free device 11.2.1 Connecting diagram PLC control unit with signal tone (diagram No.: 9000471) 11.3...
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  • Page 55: Appendix: Hydraulic Circuit Diagrams

    9000114GB Masterlift 2.30 / 2.35 / 2.35 Combi 55 / 65 Appendix: Hydraulic circuit diagrams 12.1 Superstructures without wheel free device 12.1.1 Hydraulic diagram twin ram lifting platform with PLC control unit / valve on pump unit (diagram No. 9000110) 12.1.2 Hydraulic diagram twin ram lifting platform with PLC control unit / valve on cylinders...
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  • Page 60: Appendix: Other Circuit Diagrams

    60 / 65 Masterlift 2.30 / 2.35 / 2.35 Combi 9000114GB Appendix: Other circuit diagrams 13.1 Connecting diagram "Pneumatic Emergency Lowering" (diagram No. 9000112) 13.2 Connecting diagram "Lighting / Energy Module" (diagram No. 9000113) 13.3 Connecting diagram "LED lighting" (diagram No. 9000516)
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  • Page 64 64 / 65 Masterlift 2.30 / 2.35 / 2.35 Combi 9000114GB Index Installation ... 29 Intended use ... 10 Symboler Liability ... 6 Place of installation ... 19 Lifting the vehicle ... 31, 32, 33, 34, 36 Lifting unit ... 21 Load distribution ...
  • Page 65 9000114GB Masterlift 2.30 / 2.35 / 2.35 Combi 65 / 65 Rolling the vehicle on (plates) ... 31 Rolling the vehicle on (swivel arm) ... 32 Safety ... 8, 30, 38 Safety boots ... 11 Signal tone ... 21 Spare parts ... 6 Start-up ...

This manual is also suitable for:

Masterlift 2.35Masterlift 2.35 combi

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