MAHA MGH-ZB Operating instructions

Brand: MAHA

Model: MGH-ZB

Type: Operating instructions

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MGH-ZB

Pit Jack

Original Operating Instructions

BA551001-en

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MGH-ZBF 11.0/75

MGH-ZBF 14.5/75

MGH-ZBF 16.5/75

MGH-ZBF 20.0/75

MGH-ZB 11.0/75

MGH-ZB 14.5/75

MGH-ZB 16.5/75

MGH-ZB 20.0/75

MGH-ZB 4.0/75 PD TÜV-TÜRK

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BA551001-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 ............................................................................................................................................ 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 Maintenance by the Operator ............................................................................................................ 16

6.4 Refilling with Hydraulic Fluid .............................................................................................................. 17

6.5 Troubleshooting ................................................................................................................................ 18

6.6 Spare Parts ....................................................................................................................................... 20

7 Service Lifetime ...................................................................................................... 20

8 Dismantling ............................................................................................................ 20

9 Disposal ................................................................................................................. 20

10 Contents of the Declaration of Conformity .............................................................. 21

11 Company Information ............................................................................................. 22

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BA551001-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,

BA551001-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.

BA551001-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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• 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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BA551001-en

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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

-type, the jack is permanently mounted to the carriage, with the

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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BA551001-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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Load Capacity 4000 / 11000 / 14500 / 16500 / 20000 kg

Installation Height 1180 mm

Lifting Height 750 mm

Net Weight 357 kg

Pin Diameter 45 mm

Ambient Temperature 0…40 °C

Noise Emission < 70 dB(A)

Carriages (see Annex for

illustration) B b Net Weight

XQ 1030 mm 820 mm 100 kg

X 1100 mm 750 mm 100 kg

UI/U/FI/F max. 1742 mm 1030 mm 250 kg

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BA551001-en

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2.5

Accessories

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MGH-ZBF

11.0/750

MGH-ZBF

14.5/750

MGH-ZBF

16.5/750

MGH-ZBF

20.0/750

MGH-ZB 11.0/750

MGH-ZB 14.5/750

MGH-ZB 16.5/750

MGH-ZB 20.0/750

Deflector rollers w. cyl. 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 X X

Height adjustment VZ 975576 X X X X X X X X

Air motor VZ 975261 X X X X X X X X

Maintenance unit VZ 975320 X X X X X X X X

AT 15 support system VZ 975622 X X X X X X X X

AT 20 axle crossmember VZ 975263 X X X X X X X X

AT-NB 11 axle crossmember VZ 975565 X X X X X X X X

AT-NB 15 axle crossmember VZ 975395 X X X X X X X X

ATY 13 axle crossmember VZ 975396 X X X X X X X X

VG 06-20 front axle fork VZ 975518 X X X X X X X X

AT 4.5 axle crossmember VZ 975288 X X X X X X X X

ABT 15 support system VZ 975606 X X X X X X X X

ABT 20 support system VZ 975269 X X X X X X X X

ABT-NB 11 support system VZ 975271 X X X X X X X X

ABT-NB 15 support system VZ 975273 X X X X X X X X

ABAY 13 support bridge VZ 975274 X X X X X X X X

ABAY 15 support bridge VZ 975264 X X X X X X X X

ABTY 13 support system VZ 975266 X X X X X X X X

ABTA 15 support system VZ 975520 X X X X X X X X

AB 13 support bridge VZ 975275 X X X X X X X X

BA551001-en

MGH-ZBF

11.0/750

MGH-ZBF

14.5/750

MGH-ZBF

16.5/750

MGH-ZBF

20.0/750

MGH-ZB 11.0/750

MGH-ZB 14.5/750

MGH-ZB 16.5/750

MGH-ZB 20.0/750

AB 15 support bridge VZ 975325 X X X X X X X X

AB 20 support bridge VZ 975326 X X X X X X X X

AT 15 support system VZ 975526 X X X X X X X X

Support 45 VZ 975278 X X X X X X X X

Wooden support VZ 975409 X X X X X X X X

Support with rubber pad VZ 975287 X X X X X X X X

Stroke extension 100 VZ 975289 X X X X X X X X

Stroke extension 150 VZ 975290 X X X X X X X X

Stroke extension 200 VZ 975410 X X X X X X X X

Gear plate 536x366 VZ 975315 X X X X X X X X

Gear plate 536x366 VZ 975416 X X X X X X X X

Gear plate VZ 975607 1 1 1 1 1 1 1 1

Gear plate VZ 975608 1 1 1 1 1 1 1 1

Lift scale VZ 975573 X X X X X X X X

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BA551001-en

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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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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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BA551001-en

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Operation

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5.1

Controls

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Pos: 48 / Techn ische Dokument ation/ Hebetech nik/ 55 Heber /1001 MGH-Z B/BA/Inhalt: 5510 Bedienelemente (Legende) @ 27\mod_1328778294467_75.docx @ 1543295 @ @ 1

Release spindle

Rapid lift control

(automatic via remote

control)

Rapid lift control (hand

operated)

Load lift control

(automatic via remote

contro)

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BA551001-en

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5.2

Raising and Lowering

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Speed lift without load

By activating the automatic or manual speed 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 or manual / foot operated lifting

control (

Lowering under load

When lowering under load, the lowering valve may only be opened slowly by

turning the release spindle

(A)

to the left in order to achieve a controlled descent.

Lowering without load

Open the release spindle

(A)

by turning to the left as far as possible. This actuates

the lowering valve and the rams are retracted.

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BA551001-en

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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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BA551001-en

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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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BA551001-en

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6.3

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

immediately, 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.

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

manufacturer in the event of damage caused by rust, dry running and

contamination of the pipework.

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BA551001-en

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6.4

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

replaced within six years.

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BA551001-en

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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

BA551001-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

BA551001-en

Error

Cause

Remedy

Leakage at spindle guide Mechanical seal wear Contact service

Leakage at sealing plug Sealing plugs leaking Contact service

Leakage at air motor Too much oil from

maintenance unit Set lower

Lekage at pump block Mechanical seal wear Contact service

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6.6

Spare Parts

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To ensure safe and reliable operation, only use original spare parts supplied by the

equipment manufacturer.

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Service Lifetime

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In its standard version, this product is designed for 22,000 load cycles based on

EN 1493. The maximum period of normal use in relation to the possible product

life expectancy shall be evaluated and scheduled by a qualified person during the

annual safety inspection.

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Dismantling

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Decommissioning and dismantling of the equipment may be done only by

specially authorized and trained personnel provided by the manufacturer, licensed

dealers or service partners.

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Disposal

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If you want to dispose of the equipment, please contact your MAHA dealer or the

following address, indicating equipment type, date of purchase and serial number:

MAHA Maschinenbau Haldenwang GmbH & Co. KG

Hoyen 20

87490 Haldenwang

Germany

Phone: +49 (0) 8374 585 0

Fax: +49 (0) 8374 585 500

Email: [email protected]

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Alternatively, you may take the equipment to a specialised waste management

plant to ensure that all components and operating liquids are properly disposed

of.

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