MAHA MPJ 16.5/750 1S FA Operating instructions

Brand: MAHA

Model: MPJ 16.5/750 1S FA

Type: Operating instructions

This manual is also suitable for

MPJ-1S

Pit Jacks

Original Operating Instructions

BA551601-en

MPJ 4.0/750 1S HM

MPJ 4.0/750 1S HA

MPJ 16.5/750 1S HM

MPJ 16.5/750 1S HA

MPJ 16.5/750 1S FA

MPJ 16.5/750 1S TA

MPJ 20.0/750 1S HM

MPJ 20.0/750 1S HA

MPJ 20.0/750 1S FA

MPJ 20.0/750 1S TA

2 BA551601-en

BA551601-en

2022-02-24

The reproduction, distribution and utilization of this document as well as the communication of its contents

to others without explicit authorization is prohibited. Offenders will be held liable for the payment of

The contents of this edition have been checked with great care. However, errors cannot be fully excluded.

Subject to technical change without notice.

Manufacturer

MAHA Maschinenbau Haldenwang GmbH & Co. KG

Hoyen 20

87490 Haldenwang

Germany

Phone: +49 8374 585-0

Fax: +49 8374 585-590

Mail: [email protected]

Web: www.maha.de

Service

MAHA SERVICE CENTER

Maybachstraße 8

87437 Kempten

Germany

Phone: +49 8374 585-100

Fax: +49 8374 585-491

Mail: service@maha.de

Web: www.mahaservicecenter.de

 
BA551601-en 3 
 
 
Contents 
Safety ................................................................................................................................................................ 5 
1 Symbols and Signal Words ......................................................................................................................... 5 
1.1 Personal Injury ....................................................................................................................................... 5 
1.2 Property Damage .................................................................................................................................. 5 
2 Intended Use ................................................................................................................................................ 6 
3 Inappropriate Use ........................................................................................................................................ 6 
4 Requirements for the Operating Personnel ................................................................................................ 6 
5 Safety Instructions for Handling Hydraulic Fluid ....................................................................................... 6 
6 What to Do in the Event of Defects or Malfunctions ................................................................................. 7 
7 What to Do in the Event of an Accident ...................................................................................................... 7 
Description ....................................................................................................................................................... 8 
1 Design and Operating Principle .................................................................................................................. 8 
2 Service Life ................................................................................................................................................... 9 
3 Carriages .................................................................................................................................................... 10 
4 Safety Features .......................................................................................................................................... 11 
5 Compressed Air Supply ............................................................................................................................. 11 
6 Technical Data ........................................................................................................................................... 12 
7 Sample Nameplate .................................................................................................................................... 12 
8 Danger Zone ............................................................................................................................................... 13 
9 Control Description .................................................................................................................................... 14 
Transport and Storage ................................................................................................................................... 15 
Installation ...................................................................................................................................................... 16 
Operation ........................................................................................................................................................ 17 
1 Safety Instructions for Operation ............................................................................................................. 17 
2 Preparing the Lifting Operation ................................................................................................................. 19 
2.1 Initial Position ...................................................................................................................................... 19 
2.2 Positioning the Vehicle and the Pit Jack ........................................................................................... 19 
2.3 Checking the Safety Device ................................................................................................................ 19 
3 Raising and Lowering ................................................................................................................................ 20 
3.1 Manual Lifting Operation .................................................................................................................... 20 
3.2 Automatic Lifting Operation ............................................................................................................... 20 
3.3 Support ................................................................................................................................................ 20 
3.4 Lowering Operation ............................................................................................................................. 20 
4 General Operating Instructions for Lifting Accessories .......................................................................... 21 
Inspection and Maintenance ......................................................................................................................... 22 
1 Safety Information ..................................................................................................................................... 22 
2 Care Instructions ....................................................................................................................................... 22 
3 Inspection and Maintenance Plan ............................................................................................................ 22 
Troubleshooting ............................................................................................................................................. 25 
1 Safety Information ..................................................................................................................................... 25 
2 Error Chart .................................................................................................................................................. 25 
Repairs ............................................................................................................................................................ 28 
Decommissioning, Dismantling and Disposal .............................................................................................. 28 

4 BA551601-en

10 Contents of the Declaration of Conformity .................................................................................................. 28

BA551601-en 5

1 Safety

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.

1.1 Symbols and Signal Words

1.1.1 Personal Injury

DANGER

indicates an immediate hazard which, if not avoided, will result in death or

severe personal injury.

WARNING

indicates a potential hazard which, if not avoided, could result in death or severe

personal injury.

CAUTION

indicates a potential hazard which, if not avoided, could result in moderate or

minor personal injury.

1.1.2 Property Damage

NOTICE

indicates a potentially harmful situation which, if not avoided, could result in

damage to the equipment or surrounding objects.

6 BA551601-en

1.2 Intended Use

• The jack is designed exclusively for lifting and lowering passenger cars and

commercial vehicles axle by axle in the course of service and repair work.

• The jack is designed for use in automotive workshops with cars, trucks, bus-

es, trailers and agricultural machinery.

• Lifted loads must always be safely supported in a suitable manner.

• Observe the maximum axle load according to the load capacity specification

on the type plate of the jack and the load handling attachment!

• The jack must not be modified without the express written permission of the

manufacturer. Non-compliance invalidates the declaration of conformity.

• Only vehicles and vehicle components that are suitable for the lifting equip-

ment due to the shape and position of the lifting points may be lifted.

• For vehicles that need to be lifted at two points, use clip-on axle traverses.

1.3 Inappropriate Use

Any use beyond the intended use is contrary to the intended use, e.g.:

• Entering the load handling attachment, riding on the load handling attach-

ment, use for other lifting work.

• Use in explosive and flammable atmospheres is prohibited.

• Use outdoors and in damp rooms (e.g. wash halls) is prohibited.

• Pit jacks and gear jacks are lifting devices and are not designed to hold the

load safely for extended periods of time. Lifted loads must always be safely

supported in a suitable manner.

• The use of more than one pit jack per vehicle is prohibited.

1.4 Requirements for the Operating Personnel

All persons involved in the operation, maintenance, assembly, dismantling and

disposal of the equipment must

• be 18 years of age or older,

• have the mental and physical capacity for their role,

• be qualified and have the documentation to verify this,

• have read and understood the operating manual, and in particular the instruc-

tions on the procedure in the event of a malfunction,

• be instructed in safety guidelines on file, demonstrate experience and

knowledge in the use of the equipment and the hazards it presents.

1.5 Safety Instructions for Handling Hydraulic Fluid

• Neutralize spilled hydraulic oil with binding agent.

• Immediately remove soiled, saturated clothing.

• After inhalation: Medical treatment in case of complaints.

BA551601-en 7

• After skin contact: Wash skin immediately with soap and water. Consult a

physician if skin irritation persists.

• After eye contact: Rinse thoroughly with plenty of water, consult physician.

• After ingestion: Do not induce vomiting. Call a doctor immediately.

1.6 What to Do in the Event of Defects or Malfunctions

• If irregularities occur, lower or support the lifter immediately.

• In case of malfunctions and repairs, disconnect the siphon from the air supp-

ly.

• Secure the jack against unauthorized use and contact Service.

1.7 What to Do in the Event of an Accident

• Notify first aiders, the ambulance service and/or immediate care doctor:

o Where did the accident happen (address, workshop, ...)?

o What happened?

o How many are injured?

o What injuries have occurred?

o Who is reporting the accident?

• Keep calm and answer questions.

8 BA551601-en

2 Description

2.1 Design and Operating Principle

Lowering spindle

Rapid control (automatic via control bottle)

BA551601-en 9

Air motor (pneumatically operated)

Rapid control (manually operated)

Load stroke control (automatic via control bottle)

Load stroke control (manually operated)

Pressure relief valve in hydraulic block

These hand-hydraulic and pneumatic-hydraulic combined pit jacks / axle and

transmission jacks are lifting devices for lifting vehicles and vehicle

components. The pit jack can be moved longitudinally and transversely via a

carriage, the axle and gear jack via a floor-running carriage with rollers.

An attached support claw serves as a load carrying device. For special load

application points on vehicles, other suitable supports from our range of

accessories can be fitted (support plate, transmission plate, axle traverse).

The hydraulic block contains load, suction and overload valves. The self-closing

lowering screw is also mounted on the hydraulic block. An overflow system is

installed for automatic bleeding.

Special features of manually operated jacks (hand-hydraulic):

The high-pressure and low-pressure hand pumps are mounted according to the

spare parts list, depending on the type (see www.maha.de/de/support).

Compared to the high-pressure hand pump, the low-pressure hand pump has a

larger pump cross-section and thus a larger delivery volume.

Due to its smaller pump cross-section, the high-pressure hand pump has the

ability to achieve higher hydraulic pressures and thus lift heavy loads.

Special features of automatically operated jacks (pneumatic-hydraulic):

In pneumatic-hydraulic pit jacks with rapid control, the hydraulic oil in the tank is

pressurized by compressed air. This displaces the hydraulic oil and the lifting

piston quickly reaches the load application.

The air motor (LM) is an oscillating pneumatic-hydraulic pressure intensifier,

which is firmly bolted to the hydraulic block. It is driven by compressed air and

transports the hydraulic oil.

2.2 Service Life

The product is designed for 22,000 load cycles as standard in accordance with

EN 1493. The duration of the intended use in relation to the possible product

service life must be assessed and determined by an expert during the annual

equipment inspection.

10 BA551601-en

2.3 Carriages

Carriage Types

Three types of carriage are distinguished for the following jacks:

• Suspended jacks (A) are designed exclusively for use in pits. The carriage is

held in its fixed track by flanged rollers. In addition, the lifter can be moved in

the chassis transverse to the pit.

• Floor-running jacks (B) are freely movable and are used in pits as well as un-

der vehicle lifts for lifting and lowering power units.

• Rail-guided jacks (C) are designed exclusively for use in pits. The carriage is

held in its fixed track by flanged or deflector rollers. In addition, the jack can

be moved in the carriage transverse to the pit. The track rollers run directly

on rails or in steel profiles. The running surface must be level, firm and clean.

The slope of the ground must not exceed 2%.

BA551601-en 11

2.4 Safety Features

1 Pressure relief valve in hydraulic block

The pressure relief valve is a safety valve. This valve is used to limit the

maximum permissible hydraulic pressure in order to safeguard the pressure

system against excessive pressure and to prevent damage.

2 Lowering spindle

The lowering spindle is equipped with an automatic spring return which

ensures that the travel command is only executed when the star grip is

turned (dead man's control).

2.5 Compressed Air Supply

NOTE

Connect pneumatically actuated jacks to a suitable compressed air supply.

They may only be operated with dry, lubricated compressed air according to ISO

8573-1:2010 [1:4:2]. A maintenance unit, should be located immediately

upstream of the siphon.

12 BA551601-en

2.6 Technical Data

MPJ 4.0/750 1S HM

MPJ 4.0/750 1S HA

MPJ 16.5/750 1S HM

MPJ 16.5/750 1S HA

MPJ 16.5/750 1S FA

MPJ 16.5/750 1S TA

MPJ 20/750 1S HM

MPJ 20/750 1S HA

MPJ 20/750 1S FA

MPJ 20/750 1S TA

Load capacity

4000 kg

16 500 kg

20 000 kg

Inside diameter of

support (arbor)

30 mm

45 mm

Outside diameter

of support

(piston rod)

45 mm

70 mm

Dead weight of jack

75 kg

120 kg

Max. dead weight

with carriage

210 kg

260 kg

215

410

230 kg

215

410

Drive 8 to max. 10

bar at 350 L/min

---

Stroke

750 mm

Noise emission

< 70 dB (A)

Ambient

temperature

+5…40 °C

Hydraulic oil type

HLP-D 10

2.7 Sample Nameplate

PIT JACK

Ser. No. / Date of Production: ***

Project: ***

Type: ***

Load Capacity: ***

Max. Hoisting Height: ***

Net Weight: ***

BA551601-en 13

2.8 Danger Zone

The danger zone is defined as the pit jack including test vehicle plus the safety

distances specified in the following table.

Spatial limits

Safety distances

Front

Vehicle +1 m

Rear

Vehicle +1 m

Lateral

Vehicle + 2 m

Above

Vehicle + lifting height of jack + 1 m

Lifting height of jack (750/1200 mm)

1000 mm

2000 mm

14 BA551601-en

2.9 Control Description

Load stroke

Rapid stroke

Lowering spindle

1 The automatically operated (pneumatic-hydraulic) pit jack is controlled at the

remote control with two pushbuttons and the lowering spindle. The

pushbutton with double arrow actuates the rapid stroke. The pushbutton with

one arrow actuates the load stroke.

2 In the case of a manually operated (hand-hydraulic) pit jack, the pump for the

rapid stroke control is located on the left side and the pump for the load

stroke control is located on the right side.

3 The lowering spindle can be actuated by turning it to the left.

BA551601-en 15

3 Transport and Storage

NOTE

Check the scope of delivery for completeness according to the order

confirmation. Report any transport damage to the bearer immediately.

For loading, unloading and transport, always use suitable lifting equipment, load

handling devices (e.g. crane, forklift truck) and correct load attachment devices

and lifting accessories.

Always ensure that the parts to be transported are suspended or loaded

properly and in a fall-proof manner, taking into account their size, weight and

centre of gravity. Observe transport regulations!

Store the packages in a covered place, protected from direct sunlight, at low

humidity and temperatures between 0...40 °C. Do not stack packages.

When unpacking, pay attention to the risk of injury and damage: Keep a safe

distance when opening the packaging straps, do not let any parts fall out of the

packaging.

All loose parts within the packaging must be secured by trained personnel and

compliance with the work plans.

Observe transport guideline; load pick-up points are defined and marked on the

packaging.

Work plans for packaging, suitable transport equipment and slings must be

available and used during final assembly.

Transport only by trained personnel and with suitable special tools.

Observe the information on the packaging about possible hazards during

assembly or about correct handling.

16 BA551601-en

4 Installation

WARNING

The device may only be installed by specially authorised and trained personnel.

Such specialist staff include authorised, trained specialists employed by the

manufacturer, the authorised dealers and the relevant service partners.

The "Inspection report on the inspection before the first commissioning by an

expert" must be documented in the inspection book.

NOTICE

See installation instructions in the Technical Handbook.

The operator must ensure that the maximum difference between the collar and

the pit profile (guide of the carriage roller) is observed when using carriage

rollers with collar. The maximum difference is 10 mm.

≤ 10 mm

BA551601-en 17

5 Operation

5.1 Safety Instructions for Operation

WARNING

• The jack may only be operated by trained persons who have reached the age

of 18.

• The operator is responsible for ensuring that the operator has been instruct-

ed and is familiar with the operating instructions.

• The operator must check the safety devices before commissioning.

• The load capacity specified on the type plate must not be exceeded.

• For vehicles that need to be lifted at two points, use clip-on axle traverses.

• When driving a vehicle up and down the pit of the lifter, no persons may be in

the danger zone.

• Positioning of the jack under the load may only be performed by trained per-

sonnel.

• The vehicle or vehicle components may only be picked up at the points pro-

vided for this purpose.

• Only vehicles and vehicle components that are suitable for the lifting equip-

ment due to the shape and position of the lifting points may be lifted.

• During the lifting and lowering process, the operator must exercise extreme

caution and circumspection in overlooking the load and the danger area. If

this cannot be ensured by one person, another person must be called in.

• After briefly lifting the vehicle free by the jack, check that the vehicle is se-

curely picked up.

• Load and lifter must be observed by the operator during the lifting and lower-

ing process.

• Riding with the load or on the load handling attachment is prohibited.

• If the safety area cannot be completely overlooked by the operator, it must be

monitored by a trained second person.

• During the lifting and lowering process, no persons may be in the movement

area of the lifter and load.

• After completing the lifting operation, remove the pump operating lever (if

present) and place it in the designated location.

• The load may only be lifted at the component's center of gravity (axle, gear-

box, engine,...); the vehicle must be able to roll during the lifting and lowering

movement. This allows the load to center itself over the lifter.

• Loads must be applied to the load handling attachment in such a way that

unintentional changes in position are prevented.

• Height differences of the pick-up points must be compensated (for example

with adjustable pick-up plates).

18 BA551601-en

• It is not permitted to work under the lifted load unless it is secured by suita-

ble means (DIN EN 1494).

• The lifter must always be moved with both hands. If the required manual

forces cannot be provided by one person, another person must be called in.

• Operators must ensure that they do not endanger themselves or others dur-

ing all movements of the pit lift.

• If the floor is uneven in the area of the lifter, it must be secured against rolling

away.

• Use of the jack on a surface with a slope of more than 1° is not permitted.

• No tools or other objects may be placed on the load suspension means of

the jack.

• The gear unit jack may only be moved with a load when it is retracted. It must

be ensured that the load is picked up at the center of gravity of the compo-

nent and secured in a suitable manner on the load handling attachment (e.g.

by lashing straps).

• When installing and removing heavy vehicle components (en-

gine/aggregates), the center of gravity position may change. In this case,

suitable measures (determination of the center of gravity, control of the pick-

up point) must be taken to prevent tipping before the jack is lifted again.

• Before lowering, the operator must ensure that there are no objects in the

movement range of the jack and load.

• Load handling attachments must not be deliberately set in vibration.

• Since the chassis is not secured against tipping on the ground, side loading

is generally prohibited.

• The oil level in the hydraulic system must be checked regularly by trained

personnel.

• The completeness and legibility of the safety instructions on the siphon must

be checked annually.

• In the event of malfunctions, the range of movement of the jack and load

must be secured. Take the lifter out of operation and notify customer service.

• The operator must ensure suitable lighting conditions at the workplace.

• In order to secure the lifter against unauthorized use, it is essential to dis-

connect the lifter from the compressed air supply or to shut off the com-

pressed air supply line at the end of operation.

• The hydraulic components must be checked annually.

• The safety features must not be replaced or overridden.

• Troubleshooting is only permitted by authorized personnel.

• Observe the notes on correct assembly and disassembly in the operating in-

structions.

BA551601-en 19

5.2 Preparing the Lifting Operation

5.2.1 Initial Position

1 Piston rod is in lowered position.

2 Air supply is available and connected.

3 Load carrying device is attached, see section “General Operating Instructions

for Lifting Accessories”.

4 Keep support systems ready, see section “General Operating Instructions for

Lifting Accessories”. For handling and operation see Original Operating

Instructions “Lifting accessories for Pit Jacks”.

5.2.2 Positioning the Vehicle and the Pit Jack

1 Slowly and carefully position the vehicle centrally above the pit.

2 Parking brake must be released.

3 Position the pit jack below the lifting point (centre of gravity of the

component to be lifted).

5.2.3 Checking the Safety Device

The safety device can be checked by actuating the lowering spindle:

1 Turn the lowering spindle counterclockwise.

2 Release the lowering spindle, it must return to its initial position.

3 Additionally check the torsion spring for corrosion and damage.

20 BA551601-en

5.3 Raising and Lowering

(Designation A to E: see section “Description > Design and Operating Principle”)

5.3.1 Manual Lifting Operation

Unloaded Rapid Stroke

Rapid stroke is performed via the manually operated rapid control (D). Extend

the piston rod to the lifting point (axle, gearbox).

Load stroke

Load stroke takes place via the manually operated load stroke control (F).

5.3.2 Automatic Lifting Operation

Unloaded Rapid Stroke

By actuating the automatic rapid control (B), the piston rod extends to the lifting

point (axle, gearbox). Depending on the air pressure and the lifting height

reached, the piston rod extends a little further even after the pushbutton is

released! Therefore, a distance to the lifting point must be maintained.

Load Stroke

Load stroke takes place via the automatic load stroke control (E).

5.3.3 Support

After reaching the desired lifting height, support the load with original MAHA

support systems. For handling and operation, see the Original Operating

Instructions "Lifting Accessories for Pit Jacks".

5.3.4 Lowering Operation

Lowering under Load

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

slight counterclockwise rotation of the lowering spindle (A) to achieve a

controlled lowering movement.

Lowering without Load

Open the drain spindle (A) by turning it counterclockwise as far as it will go and

lower the piston rod completely. In the case of automatically operated jacks,

this will actuate the lowering valve, and the piston rod is retracted using

compressed air.

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MAHA MPJ 16.5/750 1S FA Operating instructions

Brand: MAHA

Model: MPJ 16.5/750 1S FA

Type: Operating instructions

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