MAHA MGH-E Operating instructions

Brand: MAHA

Model: MGH-E

Type: Operating instructions

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MGH-E

Pit Jack

Original Operating Instructions

BA550901-en

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MGH-E 11.0/75

MGH-E 14.5/75

MGH-E 16.5/75

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BA550901-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 .............................................................................................................................. 7

2.4 Specifications ...................................................................................................................................... 8

2.5 Accessories ......................................................................................................................................... 8

3 Transport and Storage ........................................................................................... 10

4 Installation and Initial Operation .............................................................................. 10

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 ....................................................................................................................................... 19

7 Service Lifetime ...................................................................................................... 19

8 Dismantling ............................................................................................................ 19

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

10 Contents of the Declaration of Conformity .............................................................. 20

11 Company Information ............................................................................................. 21

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BA550901-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,

BA550901-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.

BA550901-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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BA550901-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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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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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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BA550901-en

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2.4

Specifications

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Load capacity 11 000 kg 14 500 kg 16 500 kg

Full travel 750 mm

Raising time (loaded) per 100 m travel 4.4…4.5 s

Lowering time per 100 mm travel 3.2…3.3 s

Ram diameter 90 mm 90 mm 100 mm

Support hole diameter 45 mm

Working pressure 250 bar

Motor power 2.5 kW

Power supply 3 x 400 V, 50 Hz, 16 A time-delay

Cable length 5 m

Ambient temperature 5…40 °C (41…104 °F)

Noise emission < 70 dB(A)

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2.5

Accessories

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MGH-E 11.0/75

MGH-E 14.5/75

MGH-E 16.5/75

Extra wide suspended jack carriage VZ 975255 X X X

Special carriage rollers VZ 975562 X X X

Height adjustment VZ 975564 X X X

Redundant rollers VZ 975605 X X X

SAT support system VZ 975622 X X X

AT 15 axle crossmember VZ 975263 X X X

AT 20 axle crossmember VZ 975565 X X X

ATY 13 axle crossmember VZ 975518 X X X

VG 06-20 front axle fork VZ 975288 X X X

BA550901-en

MGH-E 11.0/75

MGH-E 14.5/75

MGH-E 16.5/75

AT 4.5 axle crossmember VZ 975606 X X X

ABT 15 support system VZ 975269 X X X

ABT 20 support system VZ 975271 X X X

ABAY 13 support bridge VZ 975264 X X X

ABAY 15 support bridge VZ 975266 X X X

ABTY 13 support system VZ 975520 X X X

ABTA 15 support system VZ 975275 X X X

AB 13 support bridge VZ 975325 X X X

AB 15 support bridge VZ 975326 X X X

AB 20 support bridge VZ 975526 X X X

Support 45 VZ 975278 X X X

Wooden support VZ 975409 X X X

Support with rubber pad VZ 975287 X X X

Stroke extension 100 VZ 975289 X X X

Stroke extension 150 VZ 975290 X X X

Stroke extension 200 VZ 975410 X X X

Gear plate 536x366 VZ 975315 X X X

Gear plate 536x366 VZ 975416 X X X

Gear plate VZ 975607 1 1 1

Gear plate VZ 975608 1 1 1

Lift scale VZ 975573 X X X

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Please note when using axle crossbar SAT (VZ 975622):

With a pit width (dimension "B") of less than 945 mm (SAT 910) or 795 mm (SAT

760), pit jacks with suspended jacking beam require special rollers (VZ 975562,

part # N02.31-13).

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BA550901-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 instructions for type "H" jacking beam

1 Securely attach the jacking beam to the motor crane and slide on to the lift.

2 Push on the second side panel with a second crane or by hand.

3 Push both sides together as closely as possible.

Position the pit jack in the centre and attach it to the crane

again.

Caution:

May tip over!

5 Slide the pit jacks onto the U-rails above the pit and attach them.

6 Position the side plates to position and move them until they are the same

distance apart.

7 Tighten the clamps.

Torque: 85 Nm

8 Slide the lift through the entire pit once again.

The play between the roller collar and the edge of the rail must be 5 mm at the

widest part of the pit.

Dismantle in reverse order.

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BA550901-en

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BA550901-en

Operation

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5.1

Controls

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Main switch

"Raise" button

"Lower" button

Potentiometer

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BA550901-en

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5.2

Raising and Lowering

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Main Switch

Before raising or lowering, turn the main switch (

) to position "1". The jack is

ready for operation.

Raising / Lowering

Push and hold button (

) to raise, button (

) to lower the jack. Once any button is

released, the function is disabled (dead man's type control). Before operating the

jack, make sure the raising/lowering speed is not set too high (see

"Potentiometer").

Potentiometer

The potentiometer (

) is used to set the lowering speed. The rotating direction for

increasing or reducing the lowering speed depends on the polarity of the electrical

connection.

Determine the rotating direction first without load at initial operation!

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BA550901-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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BA550901-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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BA550901-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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BA550901-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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BA550901-en

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6.5

Troubleshooting

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Problem

Possible Cause

Remedy

Pit jack does not

respond Power supply interrupted Check connection to mains supply

Check fuses inside control box

Ram does not

extend

Pump / motor defective Check pump for running noise

Control defective

Check connections inside control box

(buttons)

Replace control box (Contact service)

Ram extends only

in unloaded

condition

Potentiometer defective or

incorrectly positioned

Check potentiometer position

Check connections inside control box

Replace potentiometer (Contact

service)

Air in hydraulic system

Open bleeder screw (beneath head

plate) and push Raise button for

approx. 1 min

Hydraulic valve/block defective

(occurring in rare cases)

Remove hood, turn potentiometer to

rightmost position, push Raise button

and check valve coil using a metal

object for presence of magnetism.

Turn potentiometer to the left and

check if magnetic effect is increasing.

If not, check connections and control,

replace valve coil if necessary

Replace hydraulic block (Contact

service)

Potentiometer

does not respond

(Check with load)

Potentiometer defective

Check connections inside control box

Replace potentiometer (Contact

service)

Amplifier card defective

Check connections inside control box

Replace amplifier card (Contact

service)

Valve / coil defective

Check connections inside control box

and at solenoid valve

Slightly unfasten the valve and

retighten carefully

BA550901-en

Problem

Possible Cause

Remedy

Replace valve / coil (Contact service)

Wrong valve being used Check model name (EMP = prop.

valve)

Ram retracts

sluggishly or not at

all

Wrong valve being used Check model name (EMP = prop.

valve)

Hydraulic valve/block defective

(occurring in rare cases) See above

Mech. damage at pit jack

Check ram and guide bushing for

visible damage

Open bleeder screw and check if ram

is lowering. Try to turn ram. If ram is

lowering and can be turned, it is

undamaged

Contact service

Seal defective, leakage at

guide bushing Contact service

Ram extends

incompletely

Fluid level too low Top up hydraulic fluid (HLP-22)

Air in hydraulic system See above

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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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BA550901-en

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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Contents of the Declaration of Conformity

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MAHA Maschinenbau Haldenwang GmbH & Co. KG

herewith declares as a manufacturer its sole responsibility to ensure that the

product named hereafter meets the safety and health regulations both in design

and construction required by the EC directives stated below.

This declaration becomes void if any change is made to the product that was not

discussed and approved by named company beforehand.

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Model:

MGH-E / HEE

Designation:

Rated Load Capacity 11 000 / 14 500 / 16 500 kg

Directives:

2006/42/EC; 2014/30/EU

Standards:

DIN EN 1494

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