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© April 2014 by Vehicle Service Group. All rights reserved. CO ML50SMS-E Rev. - 4/7/2014
ML50 SERIESSCISSOR LIFTS
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Table of Contents
1 Identification and warranty ....................................................................................... 5 1.1 Manufacturer.............................................................................................................. 5 1.2 Product description ................................................................................................... 5 1.3 Operating manual....................................................................................................... 5 1.4 Warranty ...................................................................................................................... 5 1.5 Transport damage ...................................................................................................... 5 1.6 Ordering of spare parts ............................................................................................. 5
2 Product description ..................................................................................................... 5 2.1 Mechanical design ................................................................................................... 5 2.2 Functional description............................................................................................... 5 2.3 Technical data ............................................................................................................ 6
3 Basic safety instructions ............................................................................................ 7 3.1 General safety information ...................................................................................... 7 3.2 Proper use ................................................................................................................... 8 3.3 Warning and safety notices used .......................................................................... 8 3.3.1 Structure of the warning notices. ........................................................................ 8 3.3.2 Explanation of the warning levels ........................................................................ 8 3.3.3 Explanation of the icons ........................................................................................ 9 3.4 Technical condition of the equipment .................................................................... 10 3.5 Obligations of the operating company ................................................................... 10 3.6 General work safety .................................................................................................. 11 3.7 Safety instructions in regard to specific energy systems ................................. 113.7.1 Electrical system ..................................................................................................... 11 3.7.2 Hydraulic system..................................................................................................... 11 3.7.3 Mechanical system ................................................................................................ 12 3.7.4 Surface temperature .............................................................................................. 12 3.8 Safety devices on the machine .............................................................................. 13 3.8.1 Deadman control..................................................................................................... 13 3.8.2 Independent hydraulic circuits ............................................................................ 13 3.8.3 Euro Stop .................................................................................................................. 13 3.8.4 Main switch ............................................................................................................. 13 3.8.5 Pressure limiting valve ........................................................................................... 13 3.8.6 Line breakage protection in the cylinder connection ....................................... 13 3.9 Safety and warning notices ..................................................................................... 13 3.10 Safety instructions for personnel .......................................................................... 14 3.10.1 Personnel and qualifications .............................................................................. 14 3.11 Safety instructions for auxiliary materials and consumables .......................... 143.11.1 Hydraulic oils, lubricants and cleansers .......................................................... 14
4 Transport ........................................................................................................................ 15 4.1 Basic safety instructions .......................................................................................... 15 4.2 Transport to the installation location ...................................................................... 15
5 Installation ..................................................................................................................... 16 5.1 Basic safety instructions .......................................................................................... 16 5.2 Location requirements for setup ............................................................................. 165.2.1 Installation surface ................................................................................................. 17 5.3 Assembly at the installation site ............................................................................. 20 5.3.1 Setting up ................................................................................................................. 20
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5.4 Electrical installation ................................................................................................. 25 5.4.1 AC Service................................................................................................................ 255.4.2 Sensor connections................................................................................................ 265.5 Connection of pneumatic lines ................................................................................ 26
6 Starting up...................................................................................................................... 276.1 Basic safety instructions .......................................................................................... 27 6.2 Initial commissioning................................................................................................. 276.2.1 Oil ............................................................................................................................... 286.2.2 First starting ............................................................................................................. 29 6.2.3 Checking hydraulic hoses ..................................................................................... 306.3 Settings ........................................................................................................................ 20 6.3.1 Euro stop sensor ..................................................................................................... 30
7 Operation........................................................................................................................ 31 7.1 Basic safety instructions .......................................................................................... 31 7.2 Description of the controls ....................................................................................... 32 7.3 Lifting and lowering the vehicle .............................................................................. 33
8 Shutting down ............................................................................................................... 34 8.1 Temporary shutdown ................................................................................................. 34 8.2 Permanent shutdown ................................................................................................ 34
9 Maintenance and inspections ................................................................................... 35 9.1 Basic safety instructions .......................................................................................... 35 9.2 Maintenance schedule ............................................................................................. 9.3 Cleaning the machine ...............................................................................................9.4 Inspecting the sliding bearings ............................................................................... 36 9.5 Servicing the hydraulic system ............................................................................... 36 9.5.1 Checking the hydraulic oil level ........................................................................... 36 9.5.2 Changing the hydraulic oil ..................................................................................... 369.6 Inspections.................................................................................................................. 37 9.6.1 Regular inspections ................................................................................................ 37 9.6.2 Additional inspections............................................................................................ 37 9.6.3 Inspection list .......................................................................................................... 38
10 Help for malfunctions ................................................................................................ 39 10.1 Machine does not lift............................................................................................... 39 10.2 Machine does not reach the full lift height ......................................................... 39 10.3 Electric motor does not run .................................................................................... 39 10.4 Machine does not lower (completely down) ...................................................... 40 10.5 Oil leak ...................................................................................................................... 40 10.6 Machine deflects heavily when load is changed ............................................... 40
11 Appendix A Spare parts ............................................................................................ 41
12 Appendix B Lift schematics ..................................................................................... 51
13 Appendix C Lift kit information ................................................................................ 55 13.1 Light kit ...................................................................................................................... 55 13.2 Sensor connector pinouts ...................................................................................... 55
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Identification and warranty
1.1 Manufacturer XXXXX
1.2 Product description Machine type: ML 50 Machine
no.:
Year of construc-20___
1.3 Operating manual We reserve the right to make modifications as regards content. The manufacturer is not liable for any errors in this documentation. Liability for secondary dam-ages arising in connection with the delivery or use of this documentation is excluded to the extent that legal regulations permit.
1.4 Warranty Every machine is covered under a 12-month warranty for material defects and faulty assembly. The warranty extends to all parts which are sent to us for inspection free of charge within twelve months after delivery. We will examine the parts in order to determine whether the damage has arisen under normal conditions of use. The warranty is void if the machine is overloaded, im-properly handled, or spare parts have been improperly installed and thereby cause damage.
1.5 Transport damage All deliveries are to be insured by the customer. We will not honor any claims related to transport respon-sibility. Our responsibility only extends to the transfer of the machine in new factory condition to the carrier. Should you find any damage on the machine, do not use it. Note the type of damage immediately on the bill of lading. Contact the carrier in order to review the claim.
1.6 Ordering of spare parts
Please specify the following data when ordering:
• Machine type
• Machine no.
• Year of construction
• Part name
Product description
2.1 Mechanical design
The machine consists of the following main
components:
• Two lifting units, each of which is made up of:
• base
• scissor assembly
• running rails
• Control console with integrated hydraulic unit
2.2 Functional description By pressing the «Lift» control on the control device, the electric motor of the hydraulic unit is switched on. The oil pump of the hydraulic unit pumps hydraulic oil into the hydraulic cylinders. The hydraulic cylinders extend and the scissor assembly is pressed apart and lifts the running rails.
By pressing the «Lower» control on the control device, the electronically releasable check valve is opened and hydraulic oil flows back into the hydraulic tank. The platform lowers.
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2.3 Technical data Mechanical dataLoad capacity: 5,000 kgLoad capacity, wheel-free lift: 3,500 kgOverall height: 2002 mmCollapsed height: N: 210 mm LT/LTAT: 285 mm NAT: 260 mmUsable stroke: 1,800 mmPlatform length: 4,600 mm/5,200 mmPlatform width: 738 mm (690 mm surface)Platform surface: plain sheetWeight: (each platform) ML50LT-52: 1,550kg ML50LT-46: 1,525kg ML50N-52: 1,375kg ML50N-46: 1,350kgM16 Hilti HST Stud Anchors required
202.1
2001.9
450.8
82.3
1400
2000
690
9005200
2280
6444.6
1336
900
9.5~
2000 MAXIMUM
Electrical systemConnection: 3Ph400V/PE/50Hz/20APower: 5.5 kW Current consumption: 20 AProtection type: IP54Operating voltage: 400 VControl voltage: 24 VHydraulicsOil fill quantity: 35 LSound emissionSound pressure level: <70 dB (A)Air Supply6-8 bar at 140 LPM
Fig. 2-3
*Dimensions shown are for a 5.2m runway with standard ramps.
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6.2.1 OIL Use wear proof oil for hydraulic drive, in conformity with ISO 6743/4 rules (HM class). Fina HYDRAN TS 32 or equivalent oil with features similar to those shown in the table is recommended: TEST STANDARDS FEATURES VALUE ASTM D 1298 Density 20°C 0.8 kg/l ASTM D 445 Viscosity 40°C 32 cSt ASTM D 445 Viscosity 100°C 5.43 cSt ASTM D 2270 Viscosity index 104 N° ASTM D 97 Pour point � 30 °C ASTM D 92 Flash point 215 °C ASTM D 644 Neutralization number 0.5 mg KOH/g In case where the average ambient temperature differs from 25° C contact your local specialist oil supplier to find a suitable substitute.
RECOMMENDED HYDRAULIC OIL
Recommended hydraulic oil for the lift to be used at standard temperatures (25°C - 30°C) is described below. For temperatures different from those standard, contact your dealer for suitable oil. BRAND TYPE AGIP OSO 32 API CIS 32 BP HLP 32 CASTROL HYSPIN HWS 32 ELF ELFONA DS 32 ESSO NUTO H 32 FIAT HTF 32 FINA HYDRAN TS 32 IP HYDRUS 32 Q8 HAYDYN 32 MOBIL DTE 24 ROL OIL LI 32 SHELL TELLUS OIL 32 TOTAL AZOLLA ZS 32
CHANGE HYDRAULIC OIL EVERY 5 YEARS
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For transport • Chap. 2 "Product description", page 5 • Chap. 3 "Basic safety instructions", page 7 • Chap. 4 "Transport", page 15
For setup • Chap. 2 "Product description", page 5 • Chap. 3 "Basic safety instructions", page 7 • Chap. 4 "Transport", page 15 • Chap. 5 "Installation", page 16
For startup • Chap. 2 "Product description", page 5 • Chap. 3 "Basic safety instructions", page 7 • Chap. 6 "Starting up", page 27 • Chap. 7 "Operation", page 31
Basic safety instructions
3.1 General safety information The machine was designed and manufactured under consideration of a hazard analysis and on the basis of the relevant harmonised norms as well as additional technical specifications. It corresponds to the latest techno-logical standards valid at the time of manufacture and the relevant safety regulations.
The machine is equipped with protective devices and was subject to a safety and acceptance test. However, incorrect operation or improper use can pose a threat to the lives and health of personnel. Damage to the ma-chine itself, other equipment or to the environment cannot be ruled out.
All work on the machine may only be performed by qualified and authorized persons who have read the relevant sections in this operating manual and agree to observe them.
For operation • Chap. 2 "Product description", page 5 • Chap. 3 "Basic safety instructions", page 7 • Chap. 7 "Operation", page 31
For shutting down • Chap. 2 "Product description", page 5 • Chap. 3 "Basic safety instructions", page 7 • Chap. 7 "Operation", page 31 • Chap. 8 "Shutting down", page 34
For maintenance and inspections • Chap. 2 "Product description", page 5 • Chap. 3 "Basic safety instructions", page 7 • Chap. 7 "Operation", page 31 • Chap. 9 "Maintenance and inspections", page 35
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3.2 Proper use The machine lifts vehicles continuously to any ergonomically favorable height. The permissible load capacity may not be exceeded (see load capacity plate, type plate or Chap. 2.3 "Technical data", page 6).
The machine may only be used as intended! Severe injuries or equipment damage can result from improper use! This is not the responsibility of the manufacturer of the machine, but of the operating company!
The machine is designed for the performance of work underneath the load-bearing equipment and the vehicle. It is not approved for supporting or transporting persons.
The following is especially prohibited:
• Transport of persons.
• Standing on the platform.
• Operating in areas at risk of explosion.
• Operating in areas requiring a protection type for the electrical equipment higher than IP 54.
3.3 Warning and safety notices used Warning and safety notices contain information designed to point out the unavoidable residual risks involved in handling the machine. The hazards apply to the following:
• Persons
• Machine
• Equipment
• Environment
3.3.1 Structure of the warning notices The warning notices of this operating manual have an identical basic structure.
Icon Danger sign Signal word
Type and source of danger
Possible consequences of non-observance
• Avoidance: measures / prohibitions
3.3.2 Explanation of the warning levels Warning level Consequences of non-observance
Immediate danger of severe injuries or death
WARNING Severe injuries or death are possible
CAUTION Minor injuries are possible
Equipment damage
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3.3.3 Explanation of the icons
Warning and safety notices are supplemented by visual icons if possible. An icon cannot replace the text! The text must therefore always be read in its entirety!
The following icons are examples.
Icon Meaning
Warning of a danger to persons
Warning of electrical shock
Warning of points where crushing can occur
Warning of health hazards posed by toxic substances
Warning of environmental hazards
Warning of equipment damage
The following work may only be performed by qualified and authorized persons.
General information for better understanding and optimum handling of the machine
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3.4 Technical condition of the equipment
Safe operation places particular demands on the technical condition of the machine.
• Rebuilding, manipulation or making modifications to the machine is not permitted. This also applies to the use of replacement parts that are not supplied by us.
• Care and maintenance should be performed at the specified intervals.
• Regular inspections are to be carried out.
• Complete and proper functioning of the safety devices during operation must be ensured at all times.
• Connection and setting values must correspond to the specifications.
• Load specifications must be observed.
3.5 Obligations of the operating company The highest possible level of safety can only be achieved in operating practice if all measures required for it have been taken. It is the responsibility of the operating company to plan these measures and monitor their implementation.
The operating company must ensure the following in particular:
• The machine is only used as intended (Chap. 3.2 "Proper use", page 8).
• The machine is only operated in technically flawless and functional condition.
• The safety devices are regularly checked for proper functioning. The safety devices may not be disabled nor have their functions restricted.
• The maintenance and inspection intervals specified in this operating manual are observed (Chap. 9 "Mainte-nance and inspections", page 36).
• All safety and warning notices attached to the machine are present and in legible condition. Notices on the machine that have become damaged or illegible are to be replaced immediately.
• Only qualified and authorized personnel may operate service and inspect the machine.
• These persons must be regularly instructed in all applicable aspects of work safety and environmental protection, as well as be familiar with and follow the operating manual and the safety instructions contained within it.
• The required personal protective equipment for operating, maintenance and inspection personnel must be made available and used.
• The operating manual should be complete and in legible condition and readily accessible where the machine is in use.
• Further risks must be determined in a risk assessment and the respective danger zone must be identified under consideration of the special work conditions where the machine is in use.
• All additional instructions and safety notices must be summarized in a company directive based on the risk assessment of the workstations on the machine.
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3.6 General work safety
When the machine is used, dangers due to incorrect operation or misuse may pose a hazard to persons, equip-ment or the environment.
• The machine may only be operated, serviced and inspected by qualified and authorized personnel who have read the operating manual and perform their work accordingly.
• Only operate the machine in technically flawless and functional condition.
• If damage is detected, immediately switch off the machine, attach a sign informing others that switching back on is prohibited and then inform your supervisor.
• Maintain the cleanliness of the machine and its surroundings.
• Wear personal protective equipment.
3.7 Safety instructions in regard to specific energy systems
3.7.1 Electrical system
The machine is equipped with an electrical system that operates with high voltage.
• Prior to beginning work, inspect the electrical system for visible signs of damage. Immediately replace damaged components.
• Before performing maintenance work, switch off the current to the electrical system and prevent it from being accidentally switched back on.
• Always keep the control boxes closed.
• Lay lines so that they do not pose a stumbling hazard and so that damage due to falling objects, pinching or abrasion is avoided.
• Do not lay lines around moving components and ensure that the lines cannot catch on any moving com-ponents.
• Protect the electrical system from penetration by water or other liquids.
• Regularly inspect lines, especially after maintenance work, for secure fit.
3.7.2 Hydraulic system
Hydraulic oil, lubricants and other substances, such as solvents or cleansers, can lead to irritation of the skin, eyes or respiratory tract. These also pose a hazard to the environment.
• Observe the safety instructions of the manufacturer.
• Use personal protective equipment.
• Use a breathing protection mask if necessary.
• Avoid contact with the skin. Should contact with skin arise, wash thoroughly.
• In the event of contact with eyes, rinse and consult a physician.
• Ensure that no substances contaminate the ground or enter the sewer system.
• Dispose of hydraulic oil, lubricants and cleansers in accordance with environmental regulations.
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3.7.3 Mechanical system
When using and working on the machine, mechanical hazards are present. These hazards are posed in the area of the mechanics underneath the platform.
• Do not reach into or enter the danger zone.
• Avoid standing in the danger zone.
• Remove any foreign objects from the danger zone.
Fig. 3-1 Mechanical danger zones
3.7.4 Surface temperature
Due to friction, certain components (particularly of the hydraulic system) can have high surface tempera-tures.
• Before inspections and maintenance work, allow the machine to cool down.
• Use personal protective equipment.
• Check the oil level (Chap. 9.5.1 "Checking the hydraulic oil level", page 37). If the oil level is too low, the temperature of the hydraulic system will be additionally increased. This can lead to higher wear.
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3.8 Safety devices on the machine
3.8.1 Deadman control The deadman control of the machine ensures that the function is only carried out as long as the operator holds the respective control pressed on the control device.
3.8.2 Independent hydraulic circuits Two hydraulic circuits independent of one another prevent the unintended lowering of the platform. In the event of a break in a hydraulic line in one of the hydraulic circuits, the other hydraulic circuit holds the plat-form.
3.8.3 Euro Stop When lowering the platform, the Euro Stop feature stops the lowering process in order to prevent crushing and other hazards. The stop is shipped from the factory set for a flush/recess installation. If you are perform-ing a surface installation the stop will need to be adjusted at the time of initial commissioning, chap. 6.3.1, page 31.
3.8.4 Main switch The main switch turns the current supply to the machine on and off. Padlock the switch to prevent unauthor-ized personnel from using the lift.
3.8.5 Pressure limiting valve The pressure limiting valve prevents overloading of the hydraulic system. It is factory preset and may not be adjusted by the operating company. When overloaded, the platform can no longer be raised.
3.8.6 Line breakage protection in the cylinder connection The line-break safety device in the cylinder connection interrupts the flow if a break occurs in the hydraulic lines.
3.9 Safety and warning notices The machine is labeled with various notices. The notices should always be present and in legible condition.
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3.10 Safety instructions for personnel
3.10.1 Personnel and qualifications All persons working with the machine must read the operating manual prior to beginning the work and confirm with their signature that they have understood what they have read and agree to observe it.
• Only persons of at least 18 years of age who have been instructed in the machine's operation, and have demonstrated their ability in this regard to the employer, may be delegated with operation of the machine.
• The assignment to the task of operating the machine must be given in writing.
• The respective authorizations of the person must be defined.
• Trainees must receive instruction. The instruction may only be performed by experienced persons autho-rized to do so and using this operating manual as a basis.
• Instructed persons confirm in writing the scope of instruction received and their successful completion of it.
3.11 Safety instructions for auxiliary materials and consumables
3.11.1 Hydraulic oils, lubricants and cleansers Hydraulic oil, lubricants and other substances, such as solvents or cleansers, can lead to irritation of the skin, eyes or respiratory tract. These also pose a hazard to the environment.
• Observe the safety instructions of the manufacturer.
• Use personal protective equipment.
• Use a breathing protection mask if necessary.
• Avoid contact with the skin. Should contact with skin arise, wash thoroughly.
• In the event of contact with eyes, rinse and consult a physician.
• Ensure that no substances contaminate the ground or enter the sewer system.
• Dispose of hydraulic oil, lubricants and cleansers in accordance with environmental regulations.
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Transport
4.1 Basic safety instructions
WARNING
Suspended or falling loads
Severe injuries or death
• The permitted loads of the load hoisting equipment must at least correspond to the dead weight of the ma-chine (see load capacity plate, type plate or Chap. 2.3 "Technical data", page 6).
• Do not step under suspended loads.
4.2 Transport to the installation location • Inspect the shipment for any shipping damage. Immediately report any damage to your supervisor and the
transportation firm.
• The transport can be performed with a forklift or a crane. When transporting with a crane, ensure that the machine does not sway too heavily.
• Remove packaging material (clear wrap and cardboard) from lift kits. DO NOT remove the forklift pocket brackets or the bands holding the bases to the runways at this time (see figure 4-1)
• Remove shipping brackets on each end of the runways and set each runway assembly on the floor.
Fig. 4-1 Transport
FORKLIFT POCKETBRACKETS
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Installation
5.1 Basic safety instructions
WARNING
Scissors and castors
Crushing or amputation of limbs
• Do not reach or step into the danger zone (Fig. 3-1, page 8).
Before setting up the machine
• Observe the location requirements for setup (Chap. 5.2 "Installation", page 18).
• Observe the proper procedure for transport (Chap. 4 "Transport", page 16). The preparations are completed.
5.2 Location requirements for setup • Avoid points of crushing and shearing between the machine and its surroundings.
• The machine may not be operated in areas at risk of explosion, or in places where the electrical equipment requires a protection type higher than IP 54.
• The ambient temperature must lie between -10 °C and +40 °C.
• The installation site must provide a sufficient load-bearing and level foundation.
• The flooring at the installation site must be of permissible floor loading strength, calculated as follows: (weight of machine + load capacity) + 50 %.
• When selecting the installation site, ensure that any noise emitted from the machine (due to design) is not further amplified.
• Place the controls in a location ensuring the operator has a clear view of the load and the machine, particu-larly including the danger zone (Fig. 3-1, page 8). Ensure that the operator has avenues of escape if a danger arises.
• An electrical connection conforming to Chap. 2.3 "Technical data", page 6 is to be made available for the operation of the machine.
• Observe any local regulations and rules for buildings.
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5.2.1 Installation Surface• The lift must be placed on a 425 concrete floor with FEB 215 K reinforcement, 16 cm thick at least, and in
conformity with local regulations.
• If a floor covering with the above mentioned requirements is not available, a foundation pad is needed or, some fixing points should be used, for fixing areas at least, having sufficient size and thickness (made of concrete of the same quality, as shown).
• The surface where the lift has to be installed must be even and leveled in all directions. An inclination not higher than 2 cm in drive-on lift direction and 1 cm cross-wise can be balanced with leveling wedges.
• If an installation is made in a hole, the real side of the hole must be verified (as per drawing sent at the order). For installation on raised surface, the compliance with the maximum carrying capacity of the surface is recommnded.
• Floor fixing is the same both in on-floor and in-ground installations.
• The retaining bores must have a distance of at least 110 mm from the edge of the concrete.
Note: The lift can also be installed as a recessed or flush mounted.
APPROACH
P2
P1
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205 Non-Alignment255 Alignment
790790 750
5370 ML50-524770 ML50-46
2685
835 ML50-52585 ML50-46
2000 MAXIMUM
ML50 Flush Installation
You Can Not Use A Rolling Jack With This InstallationIMPORTANT
Note 1. Foundation concrete is C20/25 2. The level tolerance of two pits � 5mm
1600 ~ 2000
Front Of Bay Or Nearest Obstruction
Pipe(Inside Diameter 100mm)
Vehicle Entering Direction
Drain Hole
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205 Non-Alignment255 Alignment
5370 ML50-524770 ML50-46
2330 2000MAXIMUM
2685
ML50 Recess Installation
You Can Use A Rolling Jack With This InstallationNOTE
Vehicle Entering Direction
Drain Hole
Note 1. Foundation concrete is C20/25
1600 ~ 2000
Front Of Bay Or Nearest Obstruction
Pipe(Inside Diameter 100mm)
835 ML50-52585 ML50-46
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5.3 Assembly at the installation site
5.3.1 Setting up
Incorrect setup or assembly of the machine can lead to equipment damage and increased wear.
RunwaySupport
Fixed Base
Runway
Slider Base
300mm
Mechanical assembly work
• Place the lift using a forklift, crane, or an other lifting equipment in the desired location. Each runway should be set on a support approximately 300mm tall as shown in Fig. 5-3.5 (See section 2.3 for runway assembly weights). The runways should be spaced apart by 900mm (Fig. 5-3.7). Once the runways are resting on the supports, carefully remove the forklift pocket brackets under each runway. Next, carefully remove the packaging holding the base plates in place and lower the base plates to the floor with the aid of a forklift or crane as shown in Fig. 5-3.6.
Fig. 5-3.5
Fig. 5-3.6
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Fitting the hydraulic hoses
• The control console can be set up to the right or the left of the scissor lift platform.
Note: Hoses were installed at the factory for a left hand installation. If you prefer a right hand installation, the hoses will need to be swapped.
• Place the control console in position as shown in Fig 2-3.
• Attach hoses as shown below in Fig. 5-3.8 (a hydraulic circuit diagram is included in the appendix).
• Remove the fill cap and fill the hydraulic power unit reservoir to the upper line on the sight glass (~35 liters) with fluid per the specifications in section 2.3.
The hydraulic hose installation is now complete.BULKHEAD FITTIN
GS
MAN
IFOLD
p1p2
P1P2
BULKHEAD FITTINGS
(A3)(A2)
(A1)
(A5)
(A4)
Fig. 5-3.8
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From fuse panel
TerminalBlock
L3 L2 L1 N
5-3.2 Electrical installation
WARNING
High electrical voltage
Severe injury or death from electrical shock
• Only trained electricians may work on the electrical system.
CAUTION
Laying of cables
Injury
• Avoid creating stumbling hazards with cables.
• Do not lay control and supply lines around mechanical components.
Secure the machine with a lockable main switch to prevent unauthorized operation or so that the machine can be safely disconnected from the mains electricity supply.
5-3.3 AC Service
• Secure L1 to L1 terminal.
• Secure L2 to L2 terminal.
• Secure L3 to L3 terminal.
• Secure N to N terminal.
• Secure Ground to terminal.
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5-3.4 AdjustmentTo adjust platforms properly, operate the lift with the control console as follows:
• Raise the lift (without the vehicle) up to a height of about 1.5 meters, remove the runway supports, and lower onto a lock.
• Verify both platforms are leveled (horizontally) independently of the supporting floor morphology (by means of a water gauge or an air bubble).
Fig. 5-3.2
• Verify the distance between the lift base and the bearing surface (floor or hole), after leveling the lift.
• If this distance is too great, or not exactly the same on the ends, other fastening points to the bases, such as cement, chemical bi-component or an iron plate, have to be provided, in order to prevent the base from bending under the weight of the lift or the vehicle.
• M16 Hilti HST Stud anchor shall be used to anchor the lift.
• Verify the based plate spacing is 2120mm and runways are spaced at 900mm before anchoring (Fig. 5-3.5 and 5-3.7).
• Anchors are to be installed in the 18mm diameter holes (2 on the fixed base and 4 on the slider base).
• Anchor as shown in Fig. 5-3.4. Six anchors are required for each runway/scissor.
• Drill holes (borehole diameter: 16mm; borehole depth: min. 115mm).
• A minimum embedment of 82mm is required.
• Clean boreholes.
• Insert anchors.
• Insert washers and nuts.
• Tighten nuts (torque 110 Nm).
• Remove the base plate spacer tool that is installed between the fixed and slider bases (Fig. 5-3.5).
• Ensure the resting bolts are secured at the proper height (112mm for lifts with lifting tables and 120mm for lifts without lifting tables) (Fig. 5-3.6).
• Seismic: Consult a qualified structral engineer and manufacturer's representative.
The mechanical installation work is complete.
Fig. 5-3.4 fastening to the floor
25
Fig. 5-3.5
Fig. 5-3.6
Slider Base
Fixed Base
Base Plate Spacer Tool
2120mm (±5mm)
26
900
REF(FIXED BASES)
934
REF(SLIDER BASES)
1130
VIEW FROM FRONT
VIEW FROM THE APPROACH END
Fig. 5-3.7
27
Ramp/Wheel Stop Installation
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5.4.2 Sensor Connections
• Main lift upper limit/Toe Gaurd.
• Out of level sensor.
• Lift table upper limit.
5.5 Connection of the pneumatic lines
Warning: The connection of the lift to the general pneumatic system must be carried out only when the platforms have been raised to the top position to prevent mechanical safties from disengaging unintentionally.
The pneumatic supply at site (to which the pneumatic system of the lift is connected) must be equipped with a servicing unit composed of water separator, oiler and pressure reducer. These devices can be supplied by the manufacturer on request.
For the connection of the pneumatic lines proceed as follows:
• Raise the lift to the final top position.
• Connect the pneumatic lines pre-assembled on the runways in the control desk according to the color marking.
• Connect the pneumatic system of the lift to the pneumatic supply at site.
• Check the pneumatic control operations for proper performance.
SW9
SW8/1
SW1SW1
SW9 SW8/1Connector
(Male)
SW1: Main lift height/toe guard sensorSW9: Platform equilibrium sensorSW8/1: Lifting table height sensor
SW9
SW8/1
SW1
SW9 (Out of level)
SW1 (Main lift height/toe gaurd)
SW8/1 (Lift table height)
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Starting up
6.1 Basic safety instructions
Prior to the initial commissioning, a safety inspection must be performed by a qualified and authorized person. This person must confirm and document the technically flawless functioning of the machine.
In Germany, inspection according to GUV-G 945 must be carried out. For this, use the inspection log book in the appendix of this operating manual.
The following is to be checked:
• correct installation
• proper functioning of safety devices
• operational readiness
6.2 Initial commissioning
Prior to initial commissioning
10 Inspect the machine for visible signs of damage. If damage is detected:
• Do not switch on the machine.
• Attach or erect a notice sign prohibiting switching on the machine.
• Notify your supervisor of the detected damage.
• Only use the machine if all damage has been repaired.
• Remove any foreign objects from the danger zone (Fig. 3-1, page 8).
• Remove materials and objects from the work area if they are not required.
• Check and ensure that all safety devices are functioning flawlessly.
The preparations are completed.
Before starting the machine, check and ensure the following:
• Only authorized persons are in the work area of the machine.
• No one will be endangered by the starting up of the machine.
• Measures have been taken to prevent unintended changes in the position of the load.
• A clear view is available of the load, the machine and particularly the danger zone (Fig. 3-1, page 8).
• Avenues of escape are available in the event of danger.
30
6.2.2 First Starting
• After positioning the lift as specified and performing electric and hydraulic connections, the lift can be oper-ated by following the specific procedure.
• Move the master switch to the "1" position and press the lifting button. If the lift does not operate but the motor runs regularly, check the motor for proper direction of rotation and switch the phases on the power supply line if necessary. Press the button again until platforms are fully lifted.
• Hold the switch "up" for 2-3 seconds in the upper position.
• Open the bleed screws (1) on the slave cylinder as shown in Fig. 6-1 and close them again after bleeding air from the cylinders. Press the lifting button again, then open the bleed screws again (1) Fig. 6-1 to bleed air from the cylinders.
• After tightening the bleed screws, repeat the operation to make sure there is no air in the circuit.
• The process is complete once there is a smooth stream of oil without air bubbles.
• Lower the lift to the ground, and perform several cycles with the lift unloaded to check there are no oil leaks and platforms are properly leveled.
• Press the lowering button to lower the lift.
• Perform the lifting/lowering operations 4/5 times.
• Repeat procedure for bleeding the lifting table slave cylinder if your lift is equipped with the wheel free device.
Bleeder Screw
Fig. 6-1
Check the following after the first startup:
10 All hydraulic hoses for airtightness.
31
6.2.3 Checking the hydraulic hoses
For hydraulic hoses, a yearly inspection of operationally safe condition is prescribed. The inspection must be performed by a qualified and authorized specialist!
Hydraulic hoses conforming to DIN EN 853/2SN or DIN EN 856/4SP are built into the machine.
Checking the hydraulic hoses
Perform a visual check of the hydraulic hoses:
• Is any damage on the exterior, such as cracks, kinks, cuts, stripped points, areas of abrasion, brittleness, etc., detectable?
• Are there any deformations of the hose in either depressurized or pressurized condition?
• Are there any leaks between hose and fittings?
• Are the fittings loose on the hose?
• Replace hydraulic hoses if damage is detected, but after every 6 years at the latest.
The inspection is completed.
6.3 Settings6.3.1 Euro Stop sensor
The toe guard sensor is adjusted so that the lift platform stops when the distance between the floor and the bottom of the runway is about 130mm.
The toe guard sensor has been set at the factory for a flush/recess installation. If this installation is a surface installation, then the outer indicator ring will need to be adjusted clockwise by 9 degrees as show below.
Fig. 6-3
ADJUSTMENT TOOL
DO NOT MOVE THEINNER INDICATOR
ROTATE THE OUTER INDICATOR 9CLOCKWISE WITH THE AID OF THE TOOL
32
Operation
7.1 Basic safety instructions
WARNING
Scissors and castors
Crushing or amputation of limbs
• Do not reach or step into the danger zone (Fig. 3-1, page 8).
WARNING
Improper placement of the load
• Death or severe injuries from falling loads
• Observe the permissible load capacity of the machine (see load capacity plate, type plate or Chap. 2.3 "Tech-nical data", page 6).
• Only place loads of the permissible type on the machine.
• The load may not protrude beyond the platform.
• Prevent unintended changes in the position of the load.
Incorrect operation
Severe damage to the machine
• Avoid repeated, sudden jolts when lifting and lowering the platform.
Before beginning each work shift
10 Inspect the machine for visible signs of damage. If damage is detected:
• Do not switch on the machine.
• Attach or erect a notice sign prohibiting switching on the machine.
• Notify your supervisor of the detected damage.
• Only use the machine if all damage has been repaired.
• Remove any foreign objects from the danger zone (Fig. 3-1, page 8).
• Remove materials and objects from the work area if they are not required.
• Check and ensure that all safety devices are functioning flawlessly.
The preparations are completed.
33
Before operating the machine each time, check and ensure the following:
• Only authorized persons are in the work area of the machine.
• No one will be endangered by the starting up of the machine.
• Measures have been taken to prevent unintended changes in the position of the load.
• A clear view is available of the load, the machine and particularly the danger zone (Fig. 3-1, page 8).
• Avenues of escape are available in the event of danger.
7.2 Description of the controls2
A
3
4
5 1
Fig. 7-1 Control device
1. Control: «Main switch»
Setting the switch to "1" switches on the power supply - control lamp (A) lights up.
Setting the switch to "0" switches off the power supply - control lamp (A) goes dark.
The «main switch» can be locked with a padlock. This secures the machine against unintentional operation.
2. Control: «Lift»
By pressing the «Lift» control, the platform raises.
The movement stops as soon as the control is no longer held pressed (deadman control).
3. Control: «Lower»
By pressing the «Lower» control, the platform lowers.
The movement stops as soon as the control is no longer held pressed (deadman control).
When the Euro Stop is reached, the lowering motion stops in order to prevent crushing and other hazards. If the lowering motion is to be resumed, press the «Lower» control again. The platform continues to lower and a warning signal sounds.
4. «Lower to latched position» control
By pressing the «Lower to latched position», control, the platform lowers into the next latched position.
After every raising or lowering, the lift platform should be moved into the latched position.
5. «Main lifting unit / Wheel-free lift» control
By switching this control, the operation switches between the main lifting unit and the wheel-free lift.A. «Lamp Provides operating status of the lift. If solid normal operation. If flashing then equalization sensor is ignored.
34
7.3 Lifting and lowering the vehicle
Incorrect driving on the platform.
Risk of damaging the scissor lift platform or the vehicle.
• The platform must be completely lowered.
• Only drive onto the platform slowly and with caution.
• Avoid sudden braking.
• For lifting, the vehicle must be centered on the platform.
Moving the platform and lifting the vehicle
• Lower the platform completely.
• Drive the vehicle slowly and cautiously to the middle of the platform.
• Press the «Lift» control and continue raising the platform.
The vehicle can now be raised to the desired height and lowered onto the nearest lock.
Lowering the platform and bringing off the vehicle
• Press the «Lower» control and lower the platform. When the Euro Stop sensor is reached, the lowering mo-tion stops.
• Press the «Lower» control again. The platform continues lowering with a warning tone.
• Lower the platform completely.
The vehicle can now be driven slowly and carefully off the platform.
35
7.4 Manually lifting and lowering the lift
Manually raising the runways
Remove the rear console panel before starting this procedure. To manually raise the lift, the blocking valve labeled “SV-0” will have to be opened by depressing the small button on the end of the valve as shown in figure 7.4. Once the valve is open, the lift can be raised by actuating the hand pump located on the power unit mani-fold.
Manually lowering the runways
Remove the rear console panel and the front access door. To manually lower the lift, the mechanical locks will have to be disengaged and the blocking valve and lowering valves will have to be actuated. Manually actu-ate the air valve to disengage the locks by pressing the small gold colored button the air valve which is located above the hydraulic manifold. Next actuate the “SV-O” valve by depressing the small button on the end of the valve as shown in figure 7.4. Once the air valve and blocking valves are open, the lift can be lowered by pressing the manual override on the “LV” lowering valve as shown in figure 7.4.
*Note: all of the valves will return to the closed position when released.
Fig. 7-4
36
Shutting down
WARNING
High electrical voltage
Severe injury or death from electrical shock
• Only trained electricians may work on the electrical system.
8.1 Temporary shutdown
Shutting down at the end of a work shift
• Lower the platform completely.
• Turn the main switch to "0".
Shutting down for storage
• Lower the platform completely.
• Disconnect the machine from the mains electricity supply.
• Transport it to the storage site (Chap. 4 "Transport", page 16).
• Carry out corrosion protection measures appropriate for the storage conditions and length of time to be stored.
• When putting the machine back into operation, perform commissioning and an additional inspection (Chap. 6 "Starting up", page 29, Chap. 9.6 "Inspections", page 39).
8.2 Permanent shutdown The handling and disposal of mineral-based oils is subject to legal regulations. Bring used oil to an authorized collection point. For more information, contact the responsible administrative offices. Take care not to spill any hydraulic oil. Take measures to prevent spills of hydraulic oil (oil-tight tarp, catch pan).
Proceed as follows:
• Clean the machine of coarse dirt.
• Lower the platform completely.
• Disconnect the machine from the mains electricity supply.
The machine can now be transported (Chap. 4, page15).
37
Maintenance and inspections
9.1 Basic safety instructions
CAUTION
Hydraulic oils, lubricants and cleansers
Irritation or chemical burning of eyes, skin or respiratory tract
• Observe the safety instructions of the manufacturer.
• Use personal protective equipment.
• Use a breathing protection mask if necessary.
• Avoid contact with the skin. Should contact with skin arise, wash thoroughly.
• In the event of contact with eyes, rinse and consult a physician.
Foreign objects in the danger zone (Fig. 3-1, page 8)
Damage to the machine
• Remove any foreign objects from the danger zone.
Before any maintenance work or inspections
• Chap. 3 "Basic safety instructions", page 7 should be read.
• Block unauthorized persons from accessing the work area of the machine.
• Attach or erect a notice sign prohibiting switching on the machine and informing that the machine is under-going maintenance.
• Remove the load.
• Secure the machine against unintended switching on.
• Have collection containers and oil-bonding agent ready to ensure that no hydraulic oils, lubricants or cleans-ers contaminate the floor or enter the sewer system.
The preparations are completed.
After any maintenance work or inspections
• Remove all used materials, tools or other objects from the danger zone (Fig. 3-1, page 8).
• Check the machine according to the inspection list (Chap. 9.6 "Inspections", page 39).
• Ensure that all safety devices are functioning flawlessly and without restriction (Chap. 3.8 "Safety devices on the machine", page 14).
• Dispose of hydraulic oil, lubricants and cleansers in accordance with environmental regulations.
The work is completed.
38
9.4 Inspecting the bearings
Inspecting the bearings
Perform a visual check for wear. The inspection is completed.
Fig.9-1 Bearing locations on the machine
9.5 Servicing the hydraulic system
The handling and disposal of mineral-based oils is subject to legal regulations. Bring used oil to an authorized collection point. For more information, contact the responsible administrative offices. Take care not to spill any hydraulic oil. Take measures to prevent spills of hydraulic oil (oil-tight tarp, catch pan).
9.5.1 Checking the hydraulic oil level
Checking the hydraulic oil level
• Lower the platform completely.
• The oil level should be at the top of the sight glass gauge.
• Top off the oil if needed.
The check of the hydraulic oil level is completed.
9.5.2 Changing the hydraulic oil
Changing the hydraulic oil
• Raise the platform and secure it.
• Place oil collection containers under the hydraulic cylinders.
• Detach the hydraulic hoses on the hydraulic cylinders and place the open ends in the oil collection con-tainers.
• Press the «Lift» control on the control device (Fig. 7-1, page 33) until no more hydraulic oil runs out of the hoses.
• Reattach the hydraulic hoses to the hydraulic cylinders.
• Remove the filler/breather from the tank.
• Fill up the hydraulic oil. Fill quantity: Chap. 2.3 "Technical data", page 6.
• Screw the filler/breather on the tank.
• Bleed the hydraulic system (Fig. 6.1 "Bleeding Screw", page 30)
The hydraulic oil change is completed.
39
9.6 Inspections
9.6.1 Regular inspections
Regular inspections of the machine are to be performed by a qualified and authorized specialist at intervals of a year at the longest.
Performing the inspection
• Copy the inspection list (Chap. 9.6.3 "Inspection list", page 40).
• Inspect every item and check it off if OK.
• Only put the machine back into operation if all points have been checked off.
• After completing the inspection, file the inspection list behind the appendix in this operating manual.
The inspection is completed.
9.6.2 Additional inspections
Additional inspections of the machine are to be performed by a qualified and authorized specialist after each servicing and every repair of a malfunction. An additional inspection is likewise re-quired if the machine is to be restarted after being temporarily put out of service.
In Germany, inspection according to GUV-G 945 must be carried out. For this, use the inspection log book in the appendix of this operating manual.
Performing the inspection
• Copy the inspection list (Chap. 9.6.3 "Inspection list", page 40).
• Inspect every item and check it off if OK.
• Only put the machine back into operation if all points have been checked off.
• After completing the inspection, file the inspection list behind the appendix in this operating manual.
The inspection is completed.
40
9.6.3 Inspection list
Sequential no.:Machine type:Machine no.:Inspector:
Mechanical system
Cylinder studs securedScissors bolts securedMachine in clean conditionNotices present and legibleWelded points undamagedAll screw connections are tightResting bolts secured at proper height (112mm for lifts with lifting tablesand 120mm for lifts without lifting tables)
Hydraulic system
No leaks in the hydraulic systemOil level is sufficient (Chap. 9.5.1, page36)No damage of the hosesHydraulic hoses not more than 6 years oldMachine holds load at least 10 minutes in the highest position
Electrical system
Cables and cable grips tightCables are secured No damage of the cablesUpper position sensor stops the lifting motionEuro Stop sensor stops the lowering motion
41
10 Help for malfunctions
Please contact our customer service department. This prevents damage due to improperly performed work, saves time and avoids unnecessary costs.
10.1 Machine does not lift
10.2 Machine does not reach the full lift height
10.3 Electric motor does not run
Cause Solution
Machine overloaded Reduce the loadLeak in hydraulic system • Tighten screw connections
• Reseal hydraulic cylinders • Replace hydraulic cylinders • Replace hydraulic hoses
Pump does not build up any pressure Replace hydraulic unit Motor turning in wrong direction Check the rotational direction of the
voltage supply (only for rotary current)Factory supplies a right-rotating field
Top sensor position was reached Lower platformSwitching valve defective Replace switching valve Solenoid on lowering valve defectiveLowering valve defective Solenoid valve plug defectiveController fuse defective Replace controller fuse
Replace the solenoidReplace lowering valve Replace solenoid valve plug
Cause Solution
lio pu poTAdjust sensor
wol oot level liOSensor not correctly set
Cause Solution
Current supply interrupted• Check fuse• Check supply line
• Check motor protection switch tinu ciluardyh ecalpeRevitcefed rotoM
42
10.4 Machine does not lower (completely down)
10.5 Oil leak
10.6 Machine deflects heavily when load is changed
Cause Solution
Obstacle (dirt) in the area of the roller bearings
Clean the area of the roller bearings
Solenoid on lowering valve defective Replace the solenoid Lowering valve defective Replace lowering valve Solenoid valve plug defective Replace solenoid valve plugController fuse defective Replace controller fuseLine-break safety device triggered Identify and replace the defective
component
Cause Solution
Leak in hydraulic system • Tighten screw connections• Reseal hydraulic cylinders • Replace hydraulic cylinders • Replace hydraulic hoses
Cause Solution
Air in hydraulic system Bleed hydraulic system
43
11 Apendix AMechanical Components
1314
28
38
1516
17
18 19
20
2322
24
21
37
2525
2627
19
32 3141
29
30
33
3435
42
36
Lock and Cylinder Detail
44
45
91
1
12
6
7
840
9
1011
2
39
Mechanical Com
ponents
3
4644
43
Standard Ramps
3
44
44
46
4543
Extended Ramps
45
Mechanical Components
47
4849
50 51
5455
53
41
5657 58
59
60
68 65
64
61
62
69
66
7071
67
12
59
46
72
74 87
73
758086
82
83
85
81
77
591
78
76
8492
79
Mechanical Com
ponentsA
lignment Kit
47
8878
90
92
89
Mechanical ComponentsAlignment Kit
48
Item Number Part Number Item Description Qty1 ML50LT-52-3100 Left hand runway weld (ML50LT-52) 1
ML50LT-52-3000 Right hand runway weld (ML50LT-52) 1ML50N-52-3100 Left hand runway weld (ML50N-52) 1ML50N-52-3000 Right hand runway weld (ML50N-52) 1ML50LT-46-3100 Left hand runway weld (ML50LT-46) 1ML50LT-46-3000 Right hand runway weld (ML50LT-46) 1ML50N-46-3100 Left hand runway weld (ML50N-46) 1ML50N-46-3000 Right hand runway weld (ML50N-46) 1
2 ML50-1300 outer leg weld 23 SM60-1132 standard ramp weld 24 ML50LT-52-2500 ramp attachment plate 25 PV4-1504 ramp hinge pin 26 ML50LT-52-4000 energy chain bracket 17 ML50-1510 slider block 88 ML50LT-52-3021 upper fixed bearing 49 ML50-1508 scissor center pin 410 ML50LT-52-3022 scissor center pin bearing 811 ML50-1905 scissor center pin nut 412 LRS-1180-303 out of level sensor 113 ML50-1904 surface intallation wheel stop 214 B11-12x30 M12x1.75x30mm long hex head cap screw 615 ML50-1000 fixed base weld 216 ML50LT-52-3020 lower fixed bearing 417 ML50-1509 lower fixed pin 418 B60-30 30mm shaft retaining ring 819 B60-35 35mm shaft retaining ring 1220 ML50LT-52-2502 lower cylinder pin 421 ML50LT-52-3024 kicker leg bearing 422 ML50-1700 kicker weld 223 ML50LT-52-3023 kicker center bearing 424 ML50-1802 kicker roller 425 ML50-1900 kicker fixed pin 426 ML50-1903 kicker center pin 227 ML50-1801 kicker roller bearing 428 ML50LT-52-6200 lift table ramp 429 ML50-1801 upper cylinder bearing 430 ML50-1600 lock bar weld 231 CJPB-15x20 lock release solenoid 232 ML50-1513 cylinder connector plate 2
49
Item Number Part Number Item Description Qty33 B20-8x30 M8x1.25x30mm Long socket head cap screw34 ML50-3001 lower cylinder bearing 435 ML50-2300 slave cylinder 236 ML50-1512 lock bar 437 ML50-1200 slider base 238 ML50LT-1000 master lifting table 1
ML50-LT-1100 slave lifting table 139 ML50-1500 inner leg weld 240 ML50-1511 upper fixed block 441 0550030000VR lock release solenoid button 242 ML50-2200 master cylinder 243 PV4-1601 ramp roller 444 PV4-1602 roller pin 245 SM40LT-51-3500 extended ramp weld 246 B60-15 15mm shaft retaining ring 647 ML50LT-52-8500 platform weld 1
ML50LT-52-8600 platform weld 148 ML50LT-52-8707 lock bar weld 249 ML50LT-52-8711 lock/slider pin 250 ML50LT-52-8714 lower slider bearing 451 ML50LT-52-8709 slider 853 CJPB-15x15 lock release solenoid 254 ML50LT-52-8713 lower fixed bearing 455 ML50LT-52-8710 lower fixed block 456 ML50-2000 master cylinder 1
ML50-2100 slave cylinder 157 ML50LT-8716 lower cylinder bearing (2 each cylinder) 458 ML50LT-52-8700 lower cylinder pin weld 259 B25-8x10 M8x1.25x10mm long button head cap screw 1260 B26-6x10 M6x1.0x10mm long flat head cap screw 861 ML50LT-52-8712 platform cushion 862 ML50LT-52-8000 inner link weld 26364 ML50LT-52-8400 extension weld 265 ML50LT-52-8705 upper cylinder pin weld 266 SM55LT-51-1007 upper fixed pin 467 ML50LT-52-8714 upper fixed bearing 468 ML50LT-8717 upper cylinder bearing 269 ML50LT-52-8300 outer link weld 2
50
Item Number Part Number Item Description Qty70 ML50LT-52-8703 center pin 471 ML50LT-52-8715 center pin bearing 272 SM65-2100G ML50-52 slip plate 473 SM65-2005G slip plate brush 874 SM65-2001G ball retainer plate 8/1275 FC5190-7 ball (84 for each ball retainer plate)76 SM60-1338 alignment kit ramp 277 ML50LT-52-2400 ramp filler plate 278 H4P-7500 locking pin 2 per
plate79 NH4D-1011 spring (2 for each ball retainer plate)80 SM65-2002 nylon bearing (4 for each ball retainer plate)81 ML50LT-52-2610 ML50-52 slip plate weldment 482 ML50LT-52-2200 120mm wide filler plate 483 ML50LT-52-2100 360mm wide filler plate 284 ML50LT-52-2000 335mm wide filler plate 285 SM65-2003 slip plate retainer plate (1 for each ball retainer plate)86 SM60-1522 spring tension ring87 SM65-2006G brush (2 for each slip plate)88 ML50LT-46-2615 ML50-46 slip plate 289 ML50LT-46-2614 brush 490 ML50LT-46-2610 ML50-46 slip plate weldment 291 B60-19 19mm shaft retaining ring 2 per pin92 B26-8x25 M8x25mm flat head screw 2 per
plateReplacement Kit Numbers
RAMP-ML50-1 single ramp assemblyEXRMP-SM40-2 single extended ramp assembly
ML50-D13 ball retainer rebuild kitHBZJ-ML50-46 slip plate assembly (4.6)HBZJ-ML50-52 slip plate assembly (5.2)
51
1
2
34
4 GB/T70.3-2000
ML50-6000 Recessed Wheel Stop
M12x25 flat head screw
3 ML50LT-52-6103 wheel stop pin
2 ML50LT-52-6100 wheel stop bar
1 ML50LT-52-6000 wheel stop weld
52
Electrical Components
12 4
5
6
311
78
916
15
17
1419
18
2021
2829
30
22
23
24
2625
13
27
10
31 32
12
53
Item Number Part Number Item Description Qty1 ML50-7102 Electrical fixed plate 12 ML50-DQ-DZP Terminal Blocks Kit 13 ML50-DQ-DSH Debug Box Kit 14 ML50-PLC-052 Logo/plc 15 ML50-PLC-055 Logo/plc Expansion module 26 ML50-7001 Cover 17 AFZ16-30-01-11 Contactor of motor 18 TF42-20 Thermal relay 19 ML50-FUKIT Fuse Kit 110 FS2C0EC0 Intermediate Relay 1
DRM270024L Intermediate Relay Base
11 S-150-24 Power Supply 112 P1-25/EV/SVB/N AC Power Switch 113 ZB4-BZ101 Selector Switch 214 ZB4-BD2 Selector Switch 215 ZB4-BV013 Power Lamp 116 ZB4-BVB1 Power Lamp 117 ML50-DQ-FMQ Beeper 118 CP9-1005 Button of raise 119 ZB2SZ3 Pluge 120 CP9-1020 Button of lower to lock 121 ML50-7000 Control box assembly 122 ST9340LT PU (with lifting table) 1
ST9430LT PU (without lifting table) 123 ML50-7100 Cover 124 GB/T70.2-2000 Bolt (M6×12) 825 GB/T845-1985 Bolt (M5×10) 626 Z15003F Cover 327 ML50-7002 Base weldment 128 GB/T95-1985 Washer (8) 629 GB/T93-1987 Spring Washer (8) 630 GB/T70.2-2000 Bolt (M8×20) 631 GB/T818-2000 Bolt (M4x30) 432 3V210-06DC24 Magnetic Exchange Valve 2
54
30 Lt.
11.5 cc 5.5 KwM
A(A3) (A2) (A1) (A5) (A4)
B C E D
MP
(25 l/min)
(9 l/min)
(250 bar)
DIRECTION OFTRAVEL
TABLE 2 TABLE 1
AUXILIARYLIFTMAIN
LIFT
LIFT 1 LIFT 2TABLE 1TABLE 2MASTER SLAVE MASTER SLAVE
MASTERSLAVE
(11 l/min) (11 l/min) (10.5 l/min) (10.5 l/min)
A1 B2 A2B1
12 Apendix BLift Schematics
55
30 Lt.
6.3 cc 5 HpM
MP
(25 l/min)
(250 bar)
MAINLIFT
LIFT 1 LIFT 2MASTER SLAVE MASTER SLAVE
(11 l/min) (11 l/min)
A1 B2 A2B1
A(A3) (A2) (A1)
B C
56
&@
&@
&@&
@
&@
PLC ControllerSEIM
ENS
LOGO! 12/24RC
-A1
PLC ExpansionSIEM
ENS
DM8 12/24RC
Q1 Q2 Q3 Q4
-A2
PLC ExpansionSIEM
ENS
DM8 12/24RC
Q1 Q2 Q3 Q4
-A3
-BHY1
Thermal
relay
-F1
DC Power
Supply
-H1
Motor
Contactor
-K1
Motor
AC 3 Pahse-M
1
+-S-SW
1
-SW9
PhotoBeam
-S2
-S2
-S3
-S3
-S4
-S4
-S9
-X1
-X2
-Y1valve
Hydraulic
-Y2valve
Hydraulic
-Y3valve
Hydraulic-Y7valve
Hydraulic
Pneumatic
-YPH1
240VAC 1P
400VAC 3P
24VDC
-F3
Raise
Lower
Lower to Locks
Platform Equalization Sensor
Main Lift Height/Toe Guard sensor
nLift Table height limit sensor
Bypass Equalization Sensor
valve
Motor Contactor
Main
Main Low
ering
Main Locks
Speaker
Lamp
Main fill 2
Table
Table fill
Table lower
Table Locks
24VDCGN
DPE
GND
24VDC
L1L2L3NPE
Main fill 1
Locks Open During Rise Feature Enabled
Slow Low
er Feature Enabled
5A240V
Light Switch
F2F1 1A, 250V
1A, 250V
Light KitPow
er Supply(Optional)
LED Bar 1
LED Bar 2
Relay
Brown
Blue
24VGN
D
I8I7I6I5I4I3I2I1ML+
1 2
Q1
1 2
Q2 1 2
Q3 1 2
Q4
L+ M I1 I2 I3 I4
1 2 1 2 1 2 1 2
L+ M I1 I2 I3 I4
1 2 1 2 1 2 1 2
+-S
1234 5 6
-S01
+PE-
+PE-
+PE-
+PE- PE-
+
L1
L2L3
PE
12
3
45
ML50N
5.5kw
57
&@
&@
&@&
@
&@
PLC ControllerSEIM
ENS
LOGO! 12/24RC
-A1
PLC ExpansionSIEM
ENS
DM8 12/24RC
Q1 Q2 Q3 Q4
-A2
PLC ExpansionSIEM
ENS
DM8 12/24RC
Q1 Q2 Q3 Q4
-A3
-BHY1
Thermal
relay
-F1
DC Power
Supply
-H1
Motor
Contactor
-K1
Motor
AC 3 Pahse-M
1
+-S-SW
1
-SW9
PhotoBeam
-S2
-S2
-S3
-S3
-S4
-S4
-S9
-X1
-X2
-Y1valve
Hydraulic
-Y2valve
Hydraulic
-Y3valve
Hydraulic-Y7valve
Hydraulic
Pneumatic
-YPH1
240VAC 1P
400VAC 3P
24VDC
-F3
Raise
Lower
Lower to Locks
Platform Equalization Sensor
Main Lift Height/Toe Guard sensor
nLift Table height limit sensor
Bypass Equalization Sensor
valve
Motor Contactor
Main
Main Low
ering
Main Locks
Speaker
Lamp
Main fill 2
Table
Table fill
Table lower
Table Locks
24VDCGN
DPE
GND
24VDC
L1L2L3NPE
Main fill 1
Locks Open During Rise Feature Enabled
5A240V
Light Switch
F2F1 1A, 250V
1A, 250V
Light KitPow
er Supply(Optional)
LED Bar 1
LED Bar 2
Relay
Brown
Blue
24VGN
D
I8I7I6I5I4I3I2I1ML+
1 2
Q1
1 2
Q2 1 2
Q3 1 2
Q4
L+ M I1 I2 I3 I4
1 2 1 2 1 2 1 2
L+ M I1 I2 I3 I4
1 2 1 2 1 2 1 2
+-S
1234 5 6
-S01
+PE-
+PE-
+PE-
+PE- PE-
+
L1
L2L3
PE
12
3
45
ML50N
4.0kw
58
&@
&@
&@&
@
&@
PLC ControllerSEIM
ENS
LOGO! 12/24RC
-A1
PLC ExpansionSIEM
ENS
DM8 12/24RC
Q1 Q2 Q3 Q4
-A2
PLC ExpansionSIEM
ENS
DM8 12/24RC
Q1 Q2 Q3 Q4
-A3
-BHY1
Thermal
relay
-F1
DC Power
Supply
-H1
Motor
Contactor
-K1M
otorAC 3 Pahse
-M1
+-S-SW
1
+-S-SW
8/1-SW9
PhotoBeam
-S2
-S2
-S3
-S3
-S4
-S4
-S5
-S9
-X1
-X2
-X3
-Y1valve
Hydraulic
-Y2valve
Hydraulic
-Y3valve
Hydraulic -Y4valve
Hydraulic -Y5valve
Hydraulic-Y6valve
Hydraulic-Y7valve
Hydraulic
Pneumatic
-YPH1
Pneumatic
-YPH2
230VAC 1P 400VAC 3P
24VDC
-F3
Raise
Lower
Lower to Locks
Select nMain/Table
Locks Open During Rise Feature Enabled
Slow Low
er Feature Enabled
Platform Equalization Sensor
Main Lift Height/Toe Guard sensor
nLift Table height limit sensor
Bypass Equalization Sensor
valve
valve
Motor Contactor
Main
Main Low
ering
Main Locks
Speaker
Lamp
Main fill 2
Table
Table fill
Table lower
Table Locks
ML50LT 5.5kw
24VDCGN
DPE
GND
24VDC
L1L2L3NPE
Main fill 1
5A240V
Light Switch
F2F1 1A, 250V
1A, 250V
Light KitPow
er Supply
LED Bar 1
LED Bar 2
Relay
Brown
Blue
24VGN
D
I8I7I6I5I4I3I2I1ML+
1 2
Q1
1 2
Q2 1 2
Q3 1 2
Q4
L+ M I1 I2 I3 I4
1 2 1 2 1 2 1 2
L+ M I1 I2 I3 I4
1 2 1 2 1 2 1 2
+-S
1234 5 6
-S01
+PE-
+PE-
+PE-
+PE-
+PE-
+PE-
+PE- PE-
+
PE-+
L1
L2L3
PE
12
3
45
(Optional)
59
&@
&@
&@&
@
&@
PLC ControllerSEIM
ENS
LOGO! 12/24RC
-A1
PLC ExpansionSIEM
ENS
DM8 12/24RC
Q1 Q2 Q3 Q4
-A2
PLC ExpansionSIEM
ENS
DM8 12/24RC
Q1 Q2 Q3 Q4
-A3
-BHY1
Thermal
relay
-F1
DC Power
Supply
-H1
Motor
Contactor
-K1M
otorAC 3 Pahse
-M1
+-S-SW
1
+-S-SW
8/1-SW9
PhotoBeam
-S2
-S2
-S3
-S3
-S4
-S4
-S5
-S9
-X1
-X2
-X3
-Y1valve
Hydraulic
-Y2valve
Hydraulic
-Y3valve
Hydraulic -Y4valve
Hydraulic -Y5valve
Hydraulic-Y6valve
Hydraulic-Y7valve
Hydraulic
Pneumatic
-YPH1
Pneumatic
-YPH2
230VAC 1P 400VAC 3P
24VDC
-F3
Raise
Lower
Lower to Locks
Select nMain/Table
Locks Open During Rise Feature Enabled
Platform Equalization Sensor
Main Lift Height/Toe Guard sensor
nLift Table height limit sensor
Bypass Equalization Sensor
valve
valve
Motor Contactor
Main
Main Low
ering
Main Locks
Speaker
Lamp
Main fill 2
Table
Table fill
Table lower
Table Locks
ML50LT 4.0kw
24VDCGN
DPE
GND
24VDC
L1L2L3NPE
Main fill 1
5A240V
Light Switch
F2F1 1A, 250V
1A, 250V
Light KitPow
er Supply
LED Bar 1
LED Bar 2
Relay
Brown
Blue
24VGN
D
I8I7I6I5I4I3I2I1ML+
1 2
Q1
1 2
Q2 1 2
Q3 1 2
Q4
L+ M I1 I2 I3 I4
1 2 1 2 1 2 1 2
L+ M I1 I2 I3 I4
1 2 1 2 1 2 1 2
+-S
1234 5 6
-S01
+PE-
+PE-
+PE-
+PE-
+PE-
+PE-
+PE- PE-
+
PE-+
L1
L2L3
PE
12
3
45
(Optional)
60
VAS6131-9802-6VAS6131-9802-6
ML50-9802-12
ML50-9802-12
ML50-9802-7
ML50-9801-920 L=450
ML50-9801-930 L=500
ML50-9801-920 L=450
ML50-9801-920= L450
ML50-9801-930= L500
ML50-9801-920 L=450
ML50-9801-941 L=6500
ML50-9801-941 L=6500
ML50-9801-941 L=6500
ML50-9802-3
ML50-9802-3
ML50-9802-3
ML50-9802-10
ML50-9802-10
ML50-9802-13
ML50-9802-13
ML50-9802-3
ML50-9801-A2 L=3000
ML50-9801-B2 L=3000
ML50-9802-12
ML50-9802-14
ML50-9802-3M
L50-9801-G L=1590M
L50-9801-D L=2730
ML50-9801-C L=2730
ML50-9802-3
ML50-9802-12
ML50-9802-12
ML50-9802-13
ML50-9802-10
ML50-9802-14
ML50-9802-4
ML50-9802-4
ML50-9802-4
C
D
BA
E
ML50-9802-12 M
L50-9802-12
ML50-9802-13
ML50-9801-B1 L=3000
ML50-9801-E L=1535
ML50-9801-F L=1645
ML50-9801-A1 L=4590
ML50-9802-7
ML50-9802-7
ML50-9802-7
61
13 Appendix CLift Kit Information
13.1 Light Kit
• Connect blue wire from LED power supply to F2.
• Connect brown wire from LED power supply to F1.
• Plug LED light strip to DC output of LED power supply.
13.2 Sensor Connector Pinouts
• Secure brown wire in pin 1 location, 24V DC.
• Secure blue wire in pin 3 location, GND.
• Secure black or white wire in pin 4 location, Signal.
1 2
4 3
LED Light StripDC Out
Blue
F2F1
Brown
LEDPowerSupply
62
Notes
63
Notes
