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ANHUA ToughLift ML-10 Maintenance Manual

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T
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ift ®
ough
MATERIAL LIFTS
ML-10/ML-15/ML-20/ML-25
MAINTENANCE MANUAL
(Serial number range: From SA700100)

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Summary of Contents for ANHUA ToughLift ML-10

  • Page 1 ift ® ough MATERIAL LIFTS ML-10/ML-15/ML-20/ML-25 MAINTENANCE MANUAL (Serial number range: From SA700100)

  • Page 2: Table Of Contents

    Contents Section 1 - Description & Specification Page Introduction Characteristics & description Intended use Modifications Terminology Technical data Section 2 – Safety During Maintenance Section 3 – Service Engineer Attributes Section 4 – Competent Person for Thorough Examination Attributes Section 5 – Periodical Maintenance & Checks Section 6 –...

  • Page 3: Section 1 - Description & Specification

    Section 1 – Description & Specification Introduction This Maintenance Manual provides detailed scheduled maintenance information, troubleshooting, repair procedures, and exploded drawings with parts lists, to enable a qualified maintenance engineer or technician to undertake work on ToughLift Material Lifts and accessories as follows: ®...

  • Page 4: Characteristics & Description

    If in doubt, please contact the manufacturer for advice: Hoisting and winching anchor. ‰ Bushed joints across the machine. Shenzhen Anhua Limited ‰ A1202-1 Tianan Cyber Park E-coated and then powder coated steel fabrications fitted with silicone rubber end caps.

  • Page 5: Terminology

    Section 1 – Description & Specification/continued Section 1 – Description & Specification/continued Terminology Terminology/continued The machine below is an ML-20. Boom accessory. Standard Forks/Boom retaining pin Shackle retaining pin Lifting shackle Lifting hook (may be removed if required) Rough Terrain Wheel Kit accessory. Load Platform accessory.

  • Page 6: Technical Data

    Section 1 – Description & Specification/continued Section 1 – Description & Specification/continued Technical data Technical data/continued Load Capacity Table MODELS ML-10 ML-15 ML-20 ML-25 LOAD CENTRE LOAD CAPACITY, WEIGHT, & OPERATING ANGLE MODEL 46cm 51cm 56cm 61cm 66cm 71cm 76cm Refer to the Load Capacity Table on the page opposite for Load capacity ML-10...

  • Page 7: Section 2 - Safety During Maintenance

    Section 2 – Safety During Maintenance Section 2 – Safety During Maintenance /continued WARNINGS ALWAYS ensure the safety of persons that may ALWAYS engage the carriage lock when moving enter the area around the machine, and keep the machine around a worksite or workshop, or Failure to adhere to the Safety Rules below and the additional Safety Rules outlined in the ‰...

  • Page 8: Section 3 - Service Engineer Attributes

    Section 3 – Service Engineer Attributes Section 4 – Competent Person for Thorough Examination Attributes The ToughLift Material Lifts and accessories service engineer should: The competent person carrying out a thorough inspection of a ToughLift Material Lift or accessory ® ®...

  • Page 9: Section 5 - Periodical Maintenance & Checks

    Section 5 – Periodical Maintenance & Checks Section 5 – Periodical Maintenance & Checks /continued WARNINGS Notes: Failure to adhere to the Safety Rules below and the additional Safety Rules outlined in the The Lifting Operations and Lifting Equipment Regulations 1998 (LOLER) requires that lifting ‰...
  • Page 10 Section 5 – Periodical Maintenance & Checks /continued Section 5 – Periodical Maintenance & Checks /continued Maintenance Inspection Report 1: Daily/Pre-Use Instructions Item Ref. Activity Make copies of this report to use for each inspection undertaken. Inspect the Instruction Handbook, decals, and plates. ‰...
  • Page 11 Section 5 – Periodical Maintenance & Checks /continued Section 5 – Periodical Maintenance & Checks /continued How to Perform Each Inspection Check the following fabrications and components for areas of damage, improperly installed or ‰ missing parts, and unauthorised modifications: 1: Daily/Pre-Use Mast columns.
  • Page 12 Section 5 – Periodical Maintenance & Checks /continued Section 5 – Periodical Maintenance & Checks /continued Deploy each of the two front legs and ensure that they can be locked in position with the retaining b. Clean the mast columns ‰...
  • Page 13 Section 5 – Periodical Maintenance & Checks /continued Section 5 – Periodical Maintenance & Checks /continued d. Carriage lock deployment and de-deployment. 3: Annually a. Inspect the mast assembly for wear. It is essential that damage to the carriage lock is identified in order that the machine can be safely used and transported.
  • Page 14 Section 5 – Periodical Maintenance & Checks /continued Section 5 – Periodical Maintenance & Checks /continued Grasp the bottom of the Standard Forks or Boom, lift around 13cm, and then drop. Holding the F-clamp, lift the first lifting column approximately 4cm to disengage the safety brake. Result: The safety brake should engage, and the carriage should stop within 8cm from the drop For ML-15, ML-20, and ML-25 models, repeat Steps 6-8 until all mast lifting columns have been height.
  • Page 15 Section 5 – Periodical Maintenance & Checks /continued Section 5 – Periodical Maintenance & Checks /continued Apply a small amount of Lithium EP2 Grease to the pinion shaft as shown in the graphic below. While holding the cable tight on the drum, rotate the drum and spool the cable onto the drum evenly.

  • Page 16: Section 6 - Troubleshooting

    Section 5 – Periodical Maintenance & Checks /continued Section 6 – Troubleshooting e. Lubrication of the braked swivel castors on the splayed legs and the front leg swivel castors. Issue: The machine has been laid down without the carriage lock engaged and the mast sections have slid Regular lubrication of the braked swivel castors on the splayed legs and the front leg swivel castors will out of alignment.

  • Page 17: Section 7 - Repair Procedures

    Section 7 – Repair Procedures Section 7 – Repair Procedures /continued Safety & instructions Safety & instructions /continued WARNINGS TORQUE SETTINGS REFERENCE GUIDE (304 STAINLESS-STEEL IMPERIAL FIXING SIZES) Machine repairs shall only be undertaken by a person trained and qualified in the maintenance of ‰...

  • Page 18: How To Remove The Chassis

    Section 7 – Repair Procedures /continued Section 7 – Repair Procedures /continued How to remove the chassis How to remove the chassis /continued WARNINGS Remove the 4 bolts shown in the graphic below. Note: One of the maintenance engineers should support the chassis as these last fixings are removed by the other maintenance engineer.
  • Page 19 Section 7 – Repair Procedures /continued Section 7 – Repair Procedures /continued Section 7 – Repair Procedures /continued How to disassemble the mast /continued How to disassemble the mast /continued How to disassemble the mast /continued WARNINGS Slide the first lifting column up approximately 15 cm to expose the 2 down stop shoulder bolts attached to the bottom end of the second lifting column if you are working on an ML-15, ML-20, or Use proper lifting techniques when removing the Standard Forks or Boom from the carriage and ‰...

  • Page 20: How To Release The Mast Safety Brake When Servicing The Mast

    Section 7 – Repair Procedures /continued Section 7 – Repair Procedures /continued How to release the mast safety brake when servicing the mast How to assemble the mast The mast safety braking system may engage when the machine is tilted horizontally if the carriage lock Refer to the graphic on Page 56 of this Maintenance Manual to see the routing of the cable in the mast is not deployed.

  • Page 21: How To Replace The Lifting Cable Using The Cable Coupler Accessory

    Section 7 – Repair Procedures /continued Section 7 – Repair Procedures /continued How to assemble the mast /continued How to replace the lifting cable using the Cable Coupler accessory Attach the swaged end of the cable (with the loop) to the cable anchor at the top of the first (front) WARNING lifting column.

  • Page 22: How To Replace An Inner Lifting Pulley Wheel With The Mast Assembled

    Section 7 – Repair Procedures /continued Section 7 – Repair Procedures /continued How to replace the lifting cable using the Cable Coupler accessory /continued How to replace an inner lifting pulley wheel with the mast assembled WARNING Note: The Cable Coupler is intended for cable replacement only. DO NOT use it as a load carrying cable splice. Refer to the pulley assembly exploded drawing below for the location of components and terminology used in this section.

  • Page 23: How To Disassemble The Winch

    Section 7 – Repair Procedures /continued Section 7 – Repair Procedures /continued How to replace an inner lifting pulley wheel with the mast assembled /continued How to replace an inner lifting pulley wheel with the mast assembled /continued Remove either the carriage down stop mounting bolt shown in Figure 1 below if replacing the WARNINGS carriage pulley wheel, or if the pulley to be replaced is in one of the columns, remove the 2 column Failure to properly route the cable could result in damage to the machine or machine failure.

  • Page 24: How To Assemble The Winch

    Section 7 – Repair Procedures /continued Section 7 – Repair Procedures /continued How to disassemble the winch /continued How to assemble the winch /continued Remove the pinion shaft from the winch housing. Screw the pinion gear back onto the threaded section of the pinion shaft. To remove both pinion shaft bushes, use a soft metal drift equal to the outside diameter of the WARNING pinion shaft bush and tap the drift with a rubber mallet.
  • Page 25 Section 7 – Repair Procedures /continued How to assemble the winch /continued Winch mount plate Cable Winch drum This page has been left blank intentionally. Cable anchor clip While holding the cable tight on the drum, rotate the drum and spool the cable onto the drum evenly.

  • Page 26: Section 8 - Exploded Drawings & Parts List

    Section 8 - Exploded Drawings & Parts List Section 8 - Exploded Drawings & Parts List /continued Mast - rear & top of fixed column - all models Mast - rear & top of fixed column - all models /continued Item Part No.
  • Page 27 Section 8 - Exploded Drawings & Parts List /continued Section 8 - Exploded Drawings & Parts List /continued Winch - all models Winch - all models /continued Item Part No. Description Quantity 630064 Winch - complete assembly including both handles 630066 Winch handle 630065...
  • Page 28 Section 8 - Exploded Drawings & Parts List /continued Section 8 - Exploded Drawings & Parts List /continued Mast – carriage & first lifting column - all models Mast – carriage & first lifting column - all models /continued Quantity Item Part No.
  • Page 29 Section 8 - Exploded Drawings & Parts List /continued Section 8 - Exploded Drawings & Parts List /continued Mast - fixed & lifting columns Mast - fixed & lifting columns /continued Quantity Item Part No. Description ML-10 ML-15 ML-20 ML-25 630002 Lifting column (total for each machine) 630042...
  • Page 30 Section 8 - Exploded Drawings & Parts List /continued Section 8 - Exploded Drawings & Parts List /continued Mast – pulleys & cable Mast – pulleys & cable /continued Quantity Item Part No. Description ML-10 ML-15 ML-20 ML-25 630016 Inner pulley mount 630017 Bolt 3/8-16*3/4 630011...
  • Page 31 Section 8 - Exploded Drawings & Parts List /continued Section 8 - Exploded Drawings & Parts List /continued Chassis - back Chassis - back /continued Quantity Item Part No. Description ML-10 ML-15 ML-20 ML-25 610001 Chassis fabrication ML-10 610040 Chassis fabrication ML-15 610041 Chassis fabrication ML-20 610042...
  • Page 32 Section 8 - Exploded Drawings & Parts List /continued Section 8 - Exploded Drawings & Parts List /continued Chassis - front Chassis - front /continued Quantity Item Part No. Description ML-10 ML-15 ML-20 ML-25 610013 Front leg for ML-10 610014 Front leg for ML-15 19 20 32 610015...
  • Page 33 Section 8 - Exploded Drawings & Parts List /continued Section 8 - Exploded Drawings & Parts List /continued Standard Forks Pipe Cradle accessory Item Part No. Description Quantity Item Part No. Description Quantity 640000 Standard Forks - complete assembly 610043 Pipe Cradle - complete assembly 640002 Standard Forks &...
  • Page 34 Section 8 - Exploded Drawings & Parts List /continued Section 8 - Exploded Drawings & Parts List /continued Rough Terrain Wheel Kit accessory Boom accessory Item Part No. Description Quantity 680000 Rough Terrain Wheel Kit - complete assembly 680006 Rough terrain wheel 680009 Washer M19*2mm 610039...

  • Page 35: Section 9 - Machine Labelling & Manuals

    For further information, refer to the Instruction 690101 Hoisting & winching anchor decal - left & right TO RELEASE THE Handbook. CAUTION! Shenzhen Anhua Ltd., PRODUCT CODE: THE LATCH PLATES TO CARRIAGE, PULL THIS A1202-1, Tianan Cyber Park, SAFETY RULES...
  • Page 36 690117 WARNING! FITTING STANDARD FORKS ACCESSORY: MANUFACTURER: CAUTION! PRODUCT CODE: Shenzhen Anhua Ltd., 1. Remove the retaining pin from A1202-1, Tianan Cyber Park, RISK OF FAILURE TO READ, UNDERSTAND, AND SERIAL NUMBER: SA No. 441 Huang Ge Road, Longgang, the carriage.
  • Page 37 Standard Forks. PN: 690114 690114 690115 690113 ACCESSORY: MANUFACTURER: PRODUCT CODE: Shenzhen Anhua Ltd., A1202-1, Tianan Cyber Park, SERIAL NUMBER: SA No. 441 Huang Ge Road, Longgang, YEAR OF CONSTRUCTION: 202 Shenzhen 518116, China. WEIGHT: EU REPRESENTATIVE: COUNTRY OF MANUFACTURE: PRC Certifi...

  • Page 38: Section 10 - Storage

    690110 WARNING! BOOM SETUP ACCESSORY: MANUFACTURER: PRODUCT CODE: Shenzhen Anhua Ltd., 1. If present, remove the retaining pin and A1202-1, Tianan Cyber Park, FAILURE TO READ, UNDERSTAND, AND SERIAL NUMBER: SA No. 441 Huang Ge Road, Longgang, Standard Forks from the carriage.

  • Page 39: Appendix - Schedule 1 - Information To Be Contained In A Report Of A

    Appendix - Schedule 1 - Information to be contained in a report of a thorough examination (The Lifting Operations and Lifting Equipment Regulations 1998 - Regulation 10 (1)) (UK only, regulations in other countries vary) The name and address of the employer for whom the thorough examination was made. The address of the premises at which the thorough examination was made.
  • Page 40 Notes Notes /continued ToughLift ® Material Lifts Maintenance Manual ToughLift ® Material Lifts Maintenance Manual...
  • Page 41 A1202-1, Tianan Cyber Park, No. 441 Huang Ge Road, Longgang, Shenzhen 518116, China. EU Representative: Certification Company B.V., Veluwezoom 42, Almere, 1327 AH, Netherlands. ToughLift is a brand of Shenzhen Anhua Ltd. ® ©2023 Shenzhen Anhua Ltd. Part number: 690202...

This manual is also suitable for:

Toughlift ml-15Toughlift ml-20Toughlift ml-25

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