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MAH-Z
Pit Jack
Original Operating Instructions
BA550201-en
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MAH-ZF 14.5/120
MAH-ZF 16.5/120
MAH-ZH 14.5/120
MAH-ZH 16.5/120
MAH-Z 14.5/120
MAH-Z 16.5/120
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BA550201-en
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Contents
1 Safety ...................................................................................................................... 3
1.1 Symbols .............................................................................................................................................. 3
1.2 Intended Use ....................................................................................................................................... 3
1.3 Inappropriate Use ................................................................................................................................ 3
1.4 Requirements on Operating and Service Personnel ............................................................................. 3
1.5 Safety Instructions for Operation ......................................................................................................... 4
1.6 Safety Instructions for Handling Hydraulic Fluid ................................................................................... 6
1.7 What to Do in the Event of Defects or Malfunctions ............................................................................. 6
1.8 What to Do in the Event of an Accident ............................................................................................... 6
2 Description ............................................................................................................... 7
2.1 Design and Operating Principle ........................................................................................................... 7
2.2 Compressed Air Supply ....................................................................................................................... 7
2.3 Sample Nameplate .............................................................................................................................. 8
2.4 Specifications ...................................................................................................................................... 8
2.5 Accessories ......................................................................................................................................... 9
3 Transport and Storage ........................................................................................... 11
4 Installation and Initial Operation .............................................................................. 11
5 Operation ............................................................................................................... 12
5.1 Controls and Indicators ..................................................................................................................... 12
5.2 Raising and Lowering ........................................................................................................................ 13
5.3 General Operating Instructions for Lifting Accessories ....................................................................... 14
6 Maintenance .......................................................................................................... 15
6.1 Annual Inspection .............................................................................................................................. 15
6.2 Care Instructions ............................................................................................................................... 15
6.3 Refilling with Hydraulic Fluid .............................................................................................................. 16
6.4 Maintenance by the Operator ............................................................................................................ 17
6.5 Troubleshooting ................................................................................................................................ 19
6.6 Spare Parts ....................................................................................................................................... 21
7 Service Lifetime ...................................................................................................... 21
8 Dismantling ............................................................................................................ 21
9 Disposal ................................................................................................................. 21
10 Contents of the Declaration of Conformity .............................................................. 22
11 Company Information ............................................................................................. 23
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BA550201-en
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Safety
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Thoroughly read this manual before operating the equipment and comply with the
instructions. Always display the manual in a conspicuous location.
Personal injury and property damage incurred due to non-compliance with these
safety instructions are not covered by the product liability regulations.
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1.1
Symbols
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Important safety instructions. Failure to comply with instructions could result in
personal injury or property damage.
Important information.
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1.2
Intended Use
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The lift is intended for use in automotive workshops. Use in potentially explosive
areas and outdoors is prohibited. Use in wet or flammable areas is only permitted
with the express written permission of the manufacturer.
Pit jacks and transmission jacks are lifting devices and are not suitable for holding
the load safely over a longer period. Raised loads must be safely supported in a
suitable manner.
For vehicles that need to be lifted at two points, attachable axle crossmembers
are to be used.
Observe the maximum load carrying capacity set out on the lift’s rating plate.
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1.3
Inappropriate Use
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Use in any manner other than that intended is prohibited, such as:
• Walking or climbing on the load carrying equipment
• Using the load carrying equipment to transport personnel
• Use for other lifting work
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1.4
Requirements on Operating and Service Personnel
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All persons employed in the operation, maintenance, installation, removal and
disposal of the device must
• be mentally and physically suited for these activities,
• be at least 18 years old,
• be trained and instructed in writing,
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BA550201-en
• have read and understood the operating instructions, especially the instructions
what to do in the event of defects or malfunctions,
• be on record as having been instructed in safety guidelines,
• have practical experience in working with vehicle lifts and the hazards inherent
in such equipment.
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1.5
Safety Instructions for Operation
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• All loose parts within the package must be safeguarded by trained personnel
and work plans must be adhered to.
• Observe transport guidelines. The lifting points are defined and indicated on the
packaging.
• Work plans for packaging, suitable transport equipment and lifting accessories
must be available and used during final assembly.
• Transport must be by trained personnel using the right special tools.
• Note the instructions on the packaging concerning hazards during assembly
and proper handling.
• The lift may only be operated by trained personnel over 18 years of age.
• The employer is responsible for ensuring that the operator is trained and familiar
with the operating instructions.
• The employer must check the safety equipment before use.
• The load rating on the identification plate must not be exceeded.
• No personnel are allowed in the danger zone when a vehicle is being raised or
lowered above the lift pit.
• The positioning of the lift under the load must be carried out by trained
personnel.
• The vehicle or vehicle components may only be raised using the designated
points.
• Shortly after lifting the vehicle, check the lifting points are secure.
• Both load and lift are to be monitored by the operator during lifting and
lowering.
• Personnel are prohibited from travelling on the load or the load carrying
equipment.
• If the operator is unable to see all parts of the danger zone, a trained second
person must monitor such areas.
• During lifting and lowering, no personnel are allowed in the area where either
the lift or the load are in motion.
• After the lifting operation has stopped, remove the operating lever of the pump
(if any) and place it in the space provided.
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BA550201-en
• The load should only be raised on its centre of gravity; the vehicle must be able
to reposition itself during lifting and lowering. In this way the load can centre
itself above the lift.
• Loads are to be placed on the load carrying equipment so as to prevent any
unintended changes in position.
• If adjustable pads are present, compensate for any height differences between
the lifting points.
• It is not allowed to work under the lifted load until it has been secured by
suitable means (EN 1494).
• The lift must always be moved using both hands. If one person is unable to
provide the manual force required, another person should be called upon.
• Operators must pay attention to all movements of the pit lift so that they neither
endanger themselves or others.
• If the ground is uneven in the area where the lift is being used, secure it to
prevent it from rolling away.
• The use of the lift on a surface where the inclination is greater than 6° is
prohibited.
• No tools or other objects should be left on the loading equipment.
• Only move the lift in a retracted state when it is carrying a load. Ensure that the
load is lifted at its centre of gravity and is appropriately secured to the load
lifting equipment (e.g. by lashing).
• When installing or removing heavy vehicle components (engine / powertrain),
the centre of gravity can change. In such circumstances appropriate action
should be taken before using the lift to raise it again, such as determining the
centre of gravity and checking the loading point.
• Before lowering, the operator should ensure that there are no objects in the
area where the lift and the load are moving.
• Do not deliberately swing the lifting equipment.
• Because the chassis on the ground is not secured to prevent tipping, placing
loads at the sides is prohibited.
• The oil level in the hydraulic system must be regularly inspected by trained staff.
• The safety instructions on the lift should be examined annually for
completeness and legibility.
• In the event of a fault occurring, secure the area in which the lift and load are
moving. Take the lift out of use and advise the customer service department.
• The user must provide suitable lighting at the workplace.
• In order to prevent the load from being lifted whilst unattended (possibly as a
result of a leaky valve), when the lift is no longer in use, disconnect the lift from
the compressed air supply or shut off the compressed air supply line.
• The hydraulic components must be inspected annually.
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BA550201-en
• The pressure relief valve must not be adjusted to be above the manufacturer's
specified value, and may only be altered by authorized personnel.
• The system pressure should be monitored regularly using a pressure gauge.
• Fault finding and rectification may only be carried out by authorised personnel.
• Observe the instructions concerning proper removal in the manual.
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1.6
Safety Instructions for Handling Hydraulic Fluid
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• Neutralize hydraulic fluid spills with binder.
• Remove contaminated clothing immediately.
• Inhalation: If symptoms persist, seek medical treatment.
• Skin contact: Wash skin immediately with soap and water. If skin irritation
persists, seek immediate medical advice.
• Eye contact: Rinse thoroughly with water and seek medical advice.
• Ingestion: Do not induce vomiting. Seek immediate medical attention.
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1.7
What to Do in the Event of Defects or Malfunctions
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• If defects occur, such as the lift raising and lowering itself on its own or
distortion of the supporting components, immediately lower the lift or provide
support.
• Turn off the main switch and secure to prevent unauthorized use. Contact the
Service Department.
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1.8
What to Do in the Event of an Accident
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• The injured person is to be removed from the danger area. Find out where
dressing and bandages are kept. Seek first-aid.
• Provide first-aid (stop bleeding, immobilise injured limbs), report the accident
and seal off the accident site.
• Immediately report any accident to your supervisor. Make sure a record is kept
of every occasion first-aid is provided, e.g. in an accident book.
• Remain calm and answer any questions that may arise.
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Description
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2.1
Design and Operating Principle
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These manually operated hydraulic, combined hydraulic / pneumatic or pneumatic
pit jack / axle and transmission jacks are lifting devces for lifting vehicles and
power trains. The pit jacks can be moved in the longitudinal and transverse
direction on a chassis, the axle and transmission jack using a chassis running on
the ground using rollers.
The pump unit includes load valves, suction valves and overload valves. High and
low pressure hand pumps are installed according to the type as per the list of
spare parts. The self-closing countersunk screw is also mounted on the pump
block. An overload system is installed for automatic venting.
The load carrying equipment consists of a supporting plate attachment (support
plate / gearbox support). For more specific loading points on vehicles, other
adaptors from our range of accessories can be attached.
In hydraulic-pneumatic pit jacks with rapid lift control, the oil in the tank is
pressurised with compressed air. The oil is thus displaced and the piston rises
quickly to the point of load.
In the version using an air motor (LM), the motor is positioned on the right on the
high pressure side. It is powered by compressed air and pumps the oil.
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H-type carriages
are installed in a suspended position.
XQ / X-type carriages
are freely movable. They are designed for usage in
workshop pits and beneath vehicle lifts to raise and lower heavy components.
With the
X
-type, the jack is permanently mounted to the carriage, with the
XQ
-
type it is additionally movable in one direction inside the carriage.
UI / U / FI / F-type carriages
are designed exclusively for usage in workshop pits.
The carriage is kept in its running tracks by means of deflector rollers. The jack is
additionally movable in a transversal direction inside the carriage.
The rollers run either directly on the floor or on rails or steel profiles. The running
surface must be level, solid and clean. The slope of the floor must not exceed 2
%.
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2.2
Compressed Air Supply
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Connect pneumatically controlled jacks to a suitable compressed air supply. They
may only be operated with dry, lubricated air; install a service unit in the
compressed air line close to the equipment. Centralised systems in the
compressor are not enough.
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BA550201-en
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2.3
Sample Nameplate
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PIT JACK
Ser. No. / Date of Production: ***
Project: ***
Type: ***
Load Capacity: ***
Max. Hoisting Height: ***
Net Weight: ***
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2.4
Specifications
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Drive 8…10 bar
Installation height 890 mm
Net weight 357 kg
Full travel 1200 mm
Load capacity 14500 / 16500 kg
Pin diameter 45 mm
Ambient temperature +5…40 °C
Noise emission < 70 dB(A)
Carriages B b Net weight
XQ 1030 mm 820 mm 100 kg
X 1100 mm 750 mm 100 kg
H max. 1200 mm 680 mm 200 kg
UI/U/FI/F max. 1742 mm 1030 mm 250 kg
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BA550201-en
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2.5
Accessories
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• The optional supports meet the same technical requirements as the standard
versions.
• Each optional support is supplied with separate operating instructions. These
must be observed in conjunction with the operating instructions supplied with
the pit jack.
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MAH-ZF 14.5/120
MAH-ZF 16.5/120
MAH-ZH14.5/120
MAH-ZH16.5/120
MAH-Z14.5/120
MAH-Z16.5/120
Deflector rollers with cylindrical running rollers VZ 975614 X X X X
Carriage type U VZ 975635 X X X X
Extra wide carriage VZ 975603 X X X X
Carriage type XQ VZ 975588 X X
SAT support system VZ 975622 X X X X X X
AT 15 support system VZ 975263 X X X X X X
AT 20 axle crossmember VZ 975565 X X X X X X
AT-NB 11 axle crossmember VZ 975395 X X X X X X
AT-NB 15 axle crossmember VZ 975396 X X X X X X
ATY 13 axle crossmember VZ 975518 X X X X X X
VG 06-20 front axle fork VZ 975288 X X X X X X
AT 4.5 axle crossmember VZ 975606 X X X X X X
ABT 15 support system VZ 975269 X X X X X X
ABT 20 support system VZ 975271 X X X X X X
ABT-NB 11 support system VZ 975273 X X X X X X
ABT-NB 15 support system VZ 975274 X X X X X X
ABAY 13 support bridge VZ 975264 X X X X X X
ABAY 15 support bridge VZ 975266 X X X X X X
ABTY 13 support system VZ 975520 X X X X X X
ABTA 15 support system VZ 975275 X X X X X X
AB 13 support bridge VZ 975325 X X X X X X
AB 15 support bridge VZ 975326 X X X X X X
AB 20 support bridge VZ 975526 X X X X X X
Support 45 VZ 975278 X X X X X X
Support with rubber pad VZ 975287 X X X X X X
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MAH-ZF 14.5/120
MAH-ZF 16.5/120
MAH-ZH14.5/120
MAH-ZH16.5/120
MAH-Z14.5/120
MAH-Z16.5/120
Stroke extension 100 VZ 975289 X X X X X X
Stroke extension 150 VZ 975290 X X X X X X
Stroke extension 200 VZ 975410 X X X X X X
Gear plate 536x366 VZ 975315 X X X X X X
Gear plate 536x366 VZ 975416 X X X X X X
Gear plate VZ 975607 1 1 1 1 1 1
Gear plate VZ 975608 1 1 1 1 1 1
Lift scale VZ 975573 X X X X X X
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Transport and Storage
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Check package to ensure it is complete, in accordance with the order
confirmation. Report any transport damage to the carrier immediately.
During loading, unloading and transport always use suitable lifting equipment,
material handling equipment (e.g. cranes, forklifts, etc.) and the right load handling
attachments and slings. Always ensure that the parts to be transported are
suspended or loaded properly so that they cannot fall, taking into account size,
weight and the centre of gravity.
Store the packages in a covered area, protected from direct sunlight, at a low
humidity and with temperatures between 0...+40 °C (32…104 °F). Do not stack
packages.
When unpacking, take care to avoid any possibility of injury or damage. Keep at a
safe distance when opening the package strapping, do not allow any parts to fall
out.
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4
Installation and Initial Operation
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Installation and commissioning of the equipment must be carried out by specially
trained personnel, authorised for the task. Specialist personnel includes
authorised, trained skilled staff from the manufacturer, the dealer and the relevant
service partners.
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BA550201-en
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5
Operation
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5.1
Controls and Indicators
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I
D
F
J
A
E
H
G
B
C
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BA550201-en
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Standard Delivery
A Release spindle
B Speed lift control (foot operated)
C Load lift control (foot operated)
D Oil inspection glass
E Tool tray
F Quick coupler DN 7
Option
G Quick coupler with bleeder DN 7, max. 12 bar
H Remote control with magnetic holder
I Speed lift control (hand operated via remote control)
J Load lift control (hand operated via remote control)
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5.2
Raising and Lowering
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Speed lift without load
By activating the speed control (foot pedal or remote control) the ram moves up to
engage the load (axle, gearbox). Depending on the air pressure and the lift
achieved, the ram rises a little further after releasing the button.
Lifting the load
The load is lifted by activating the automatic load lift control (foot pedal or remote
control).
Lowering under load
When lowering under load, the lowering valve may only be opened slowly by
turning the release spindle to the left in order to achieve a controlled descent.
Lowering without load
Open the release spindle by turning to the left as far as possible. This actuates the
lowering valve and the rams are retracted.
Remote control with magnetic holder (option)
The remote control can be attached to the pit jack using the magnetic holder (e.g.
to cylinder body, cover hood, tool tray).
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5.3
General Operating Instructions for Lifting Accessories
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• Support tubes must not be extended. Risk of tilting!
• Danger of crushing at the edge of the pit and support bridge!
• The support system shall only be removed if the vehicle is in a secure stable position.
•
Beware of changes in the centre of gravity of the load, e.g. in case of different amounts
of fuel in asymmetric fuel systems. If necessary, use suitable lifting accessories.
• Take note of the operating instructions of all equipment and tools used.
• Check lifting accessories carefully for operational safety.
• Pre-position the lift and lifting accessory at the lift points.
• Always take up the load securely, without risk of slipping and central to the centre of
gravity.
• Position actuators, supports and bases at the support points and depending on type,
fix support pipes with pins and secure with cotter pins or wooden blocks with a
minimum spacing of 500 mm.
• Slowly raise or lower the load, watching it continuously.
• Set down the load without risk of slipping and central to the centre of gravity.
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Permissible Extension for Pit Jack and Support Systems
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6
Maintenance
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6.1
Annual Inspection
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• The maintenance interval prescribed by the manufacturer is
12 (twelve) months
.
This maintenance interval refers to normal workshop usage. If the equipment is
used more frequently or under severe operating conditions (e.g. outdoors), the
interval must be reduced accordingly.
• Maintenance work shall be done only by authorized and trained service
technicians provided by the manufacturer, licensed dealers or service partners.
• In case of non-compliance the manufacturer's warranty becomes void.
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6.2
Care Instructions
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• Periodically clean the equipment and treat it with a care product.
• Repair damage to the paintwork immediately to prevent corrosion.
• Usage of caustic cleaning agents or high pressure and steam jet cleaners may
lead to equipment damage.
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Regular care and maintenance is the key condition for functionality and long life
expectancy of the equipment!
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6.3
Refilling with Hydraulic Fluid
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Before checking and topping up the fluid level, make sure the piston rod is fully
retracted
and the jack is disconnected from the air and power supply. The fluid
level must be between the two notches on the screwed-in dipstick.
If the dipstick has only one notch, this indicates the maximum fluid level and the
lower end of the dipstick the minimum fluid level.
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• Replace the hydraulic fluid according to age, the amount of water absorbed
and degree of contamination, but in any event after six years.
• When filling up, only use hydraulic fluid of the same specification ─ HLPD 22.
• If the system was filled with rapeseed oil at the factory, only top up with
rapeseed oil designated BIO HY-FLUID HV 34.
• If the lift is permanently operated at a temperature of <15 °C, a hydraulic fluid
with lower viscosity must be used.
• The pressure hoses
should
be replaced as required, but in any event
must
be
replaced within six years.
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6.4
Maintenance by the Operator
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•
The pit jack must be extended to its full height at least 1 x per week and
pumped through a few times with the release spindle closed. This automatically
bleeds air from the system and any accumulated leaked oil is eliminated.
• After washing, oil all bright and moving parts.
• The ram, the load bearing pivot, rollers and other moving parts must always be
lightly oiled.
• Periodically lubricate the carriage using the lubricator nipples at the rollers
(8 pcs).
• Underseal residues and other types of dirt can destroy the seals. Clean the
piston rod regularly! Damage to the piston rod must be ground away immedi-
ately, ensuring there is a soft transition at the edges. Detergent and salt water
can freely penetrate and cause considerable damage on the inside.
• Water is dangerous! A compressed air service unit, consisting of air filter, water
separator and oil mister, must be present in the compressed air system near to
the lift (max. distance: 5 m). Drain the service unit weekly, check the level of the
oil and that it functions properly. Clean the service unit.
Adjusting the built-in maintenance unit (if any, see illustration):
The nebuliser must be set so that roughly 1 drop of oil is consumed per
lifting stroke. To do this, introduce a flat head screwdriver through the slot
on top of the cover hood.
The adjustable nozzle of the nebuliser and its oil consumption can be
checked through the opening in the guard plate beneath the cover hood.
To do this, hold a suitable light source to the company logo cut out at the
side of the cover hood.
Refilling the built-in maintenance unit (if any, see illustration):
Before refilling the oil reservoir of the maintenance unit, make sure the pit
jack is fully lowered, unpressurised and disconnected from the air supply!
Then remove and keep safe the screw plug and the seal ring on top of the
cover hood.
Top up the level using a suitable oil can, until the oil inspection glass is one
third full at the most. Then reinstall the screw plug with the seal ring and
torque to 10…20 Nm using an Allen key.
A so-called refrigeration dryer is not adequate as a compressed air service unit! A
refrigeration dryer cannot filter out the dirt in the line and does not deliver the oil
film necessary for the correct functioning of the equipment.
• Failure to observe these rules shall invalidate any guarantee by the manufac-
turer in the event of damage caused by rust, dry running and contamination of
the pipework.
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A
Slot for adjustment of nebuliser
B
Screw plug for refill system of maintenance unit
C
Adjustable nozzle of nebuliser
D
Oil inspection glass of maintenance unit
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C
D
A
B
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6.5
Troubleshooting
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Error
Cause
Remedy
Air motor is running
(typical noise), but does
not raise load
Release spindle not fully
closed; spring not fully
closed
Close release spindle
Fluid level too low due to
shipping damage or
normal consumption
Top up hydraulic fluid
Suction valves leaking Contact service
Air motor is running
(typical noise), but does
not raise load completely
Release spindle not fully
closed; spring not fully
closed
Close release spindle
Overload valve triggered;
load too heavy
Reduce load; observe
rated load capacity
Load valves leaking Contact service
Air motor is running when
unloaded (typical noise),
but gets increasingly
slower under load and
finally comes to a stop
Air motor running dry; no
oil in the maintenance unit Top up oil
Air pressure too low; local
cause Contact service
Valve levers blocked;
mechanical (local) cause Contact service
Control or valve blocked
by dirt and debris Clean
Air motor is raising load to
a certain height and then
pumping dry
Fluid level too low due to
shipping damage or
normal consumption
Top up hydraulic fluid
Air motor is raising load to
a certain height and then
gets increasingly slower
Air filter plugged; dirt from
supply network Clean
Air pressure too low; local
cause Contact service
Air flow rate too low; local
cause Contact service
Air motor is raising load to
a certain height, then gets
increasingly slower and
finally comes to a stop
Air pressure too low; local
cause Contact service
Control or valve blocked
by dirt and debris Clean
20
BA550201-en
Error
Cause
Remedy
Air motor running very
slowly, even in idle gear
Air filter plugged; dirt from
supply network Clean
Air motor running dry; no
oil in the maintenance unit Top up oil
Air pressure too low; local
cause Contact service
Air motor not running at all
Air filter plugged; dirt from
supply network Clean
Air motor running dry,
comes to a stop; no oil in
the maintenance unit
Top up oil
Air motor defective Replace
Rapid lift control does not
work
Air filter plugged; dirt from
supply network Clean
Valve levers blocked;
mechanical (local) cause Contact service
Valve levers broken;
mechanical cause Contact service
Load is lowering when in
raised condition
Release spindle not fully
closed; spring not fully
closed
Close release spindle
Load valves leaking Contact service
Unloaded rams are raising
slowly at first, then get
suddenly faster
Fluid level too low due to
shipping damage or
normal consumption
Top up hydraulic fluid
Rams are "rattling";
inaccurate controlling
Fluid level too low due to
shipping damage or
normal consumption
Top up hydraulic fluid
Hydraulic system must be
bled Contact service
Leakage at ram bleeder
If leakage remains limited
=
no error
Fully raise the ram in
regular intervals to
eliminate any leaked oil
accumulation
Leakage at valves
Too much oil from
maintenance unit Set lower
Oil dilution by water from
compressed air Check maintenance unit
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