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Blitz DUPLEX S2 Operating Instructions Manual

In-ground truck lift
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Operating instructions
DUPLEX S2
In-ground truck lift
Type
Serial number
sss1. Foreword
Date
Rev.A 117127 07/2011

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Summary of Contents for Blitz DUPLEX S2

  • Page 1 Foreword Operating instructions DUPLEX S2 In-ground truck lift Type Serial number Date Rev.A 117127 07/2011...
  • Page 3 This declaration becomes invalid if the product is changed or modified without permission. We declare that the undermentioned machine, Product name: In-ground truck lift Duplex S2, with 1, 2, 3, 4, 5, or 6 lifting cylinders Serial / type name: T1-15-1900, T2-15-1900, T3-15-1900...

  • Page 5: Table Of Contents

    Contents Contents Foreword ............1 5.11 Drive vehicle off the lift ......14 1.1 About these operating instructions ..1 5.12 Switch off equipment......14 1.2 Important information for equipment 5.13 Operation without controls “FOR” ..14 operators ..........1 5.14 Store distance between axles –...
  • Page 6 Contents  Form “Handover certificate” 14. Disassembly ..........28  Form “Initial safety check before start-up” 15. Disposal ............28  Form “Annual safety check” 15.1 Packaging materials ......28  Form “Special safety check” 15.2 Environmental disposal regulations ..28 ...

  • Page 7: Foreword

    1. Foreword  The “Inspection book” contains forms for the ini- Foreword tial, regular and special safety inspections. Use the forms to record the inspections and leave the completed forms in the book. 1.1 About these operating instructions  Enter design modifications in the “Equipment The state-of-the-art in-ground lift complies with ap- master data sheet“.

  • Page 8: In-House Accident, Health And Environmental Information

    1. Foreword Competent persons are persons with sufficient 1.5 Warnings and symbols knowledge and experience with lifting equipment. They have attended special training at the lift Warnings are identified by the following symbols manufacturer. Competent persons are service according to their hazard classification. technicians of the manufacturer or authorized In situations identified by warnings, be especially dealer.

  • Page 9: Intended Use

    Intended use Duplex versions with 1...6 lifting cylinders The lift is intended to be used to lift and lower com-  mercial vehicles for repair, maintenance and clean- Duplex S2-T1-15-1900 ing during normal workshop operation.  Duplex S2-T2-15-1900  The lift is only to be used as intended, in technically...

  • Page 10: Equipment Overview

    3. The lift 3.3 Equipment overview The lift Illustration 1: Example of lift with 2 lifting cylinders Lifting cylinder, fixed Cross member Load-bearing equipment Control panel, mobile Control cabinet with controls Type plate Cross member Lifting cylinder, movable Load-bearing equipment 10 Cover 11 Hydraulic unit 12 Maintenance door...

  • Page 11: Permissible Load Distribution

    3. The lift 3.1 Permissible load distribution Illustration 2: Vehicle center of gravity  The overall center of gravity of the vehicle must be centered above the hydraulic cylinder. Illustration 3: Nominal load per lifting cylinder  Maximum 15 t, minimum 0.8 t ...

  • Page 12: Workplace, Danger Zones

    3. The lift 3.2 Workplace, danger zones Illustration 6: Work and danger zones Operating position Working area Danger zone Escape route 117127 ● 07/2011...

  • Page 13: Safety Mechanisms

    3. The lift 3.3 Safety mechanisms Illustrations 7 ... 10: Safety mechanisms Electric  Emergency stop switch on control panel and control cabinet  Main switch, lockable  Dead man’s control for lifting and lowering  Synchronous run control ± 45 mm ...
  • Page 14 3. The lift 117127 ● 07/2011...

  • Page 15: Control Cabinet

    3. The lift 3.4 Control cabinet Illustration 11: Controls on control cabinet Main switch, emergency stop Controls On Turns the main contactor on. The control panels are now activated. Controls Off Turns the main contactor off. The control panels are now deactivated. Buzzer Acoustic alarm during lowering the lift below 500 mm (foot protection).

  • Page 16: Control Panel

    3. The lift Illustration 12: Control panel 3.5 Control panel Mode indicator lamp Flashes: Selected lifting cylinder loaded Lights up: Synchronized operation activated Synchronized operation On/Off push button “Activate Lifting cylinder” switch  button Lift  button Lower  button Drive forward in pit ...

  • Page 17: Safety Precautions

    4. Safety precautions  Only operate the lift if no persons are at risk. Safety precautions  No persons are permitted within the load and pick-up area during lifting and lowering. Observe the following instructions under all circum-  stances! After lifting just above floor level, check that the vehicle is secure.

  • Page 18: Operation

    5. Operation Operation Danger of personal injury with malfunctions. DANGER  Immediately switch off and secure the lift, in- form a superior in case of signs of malfunc- tions, such as unusual noise, leakage or dis- played malfunction reports. 5.1 Emergency stop Press the Emergency stop button to immedi- ately stop the lift in case of emergency.

  • Page 19: Drive Vehicle On Lift

    5. Operation Place cross members suitable for the vehicle on 5.5 Drive vehicle on lift the pick-up points. Activate respective lifting cylinder on the control (switch to “1” position). Set all other switches to  the “0” position. Lift the vehicle slightly with the Up  button, ...

  • Page 20: Drive Vehicle Off The Lift

    5. Operation 5.13 Operation without controls “FOR” Lowering An alarmsounds during lowering in the danger area < 500mm. Danger due to poorly defined re- sponsibilities. Check that the vehicle is secure. WARNING Ensure that no objects are left under the vehi- ...

  • Page 21: Store Distance Between Axles - Option "Aav

    5. Operation Control lift with 1 control panel 5.14 Store distance between axles – option “AAV” – Illustrations 17 and 18: AAV controls Rotary switch to store distance between axles of a certain vehicle type Positioning button. For positioning the lifting cylinder(s) to the distance specifications.

  • Page 22: Malfunctions

    6. Malfunctions Motor is running. Vehicle cannot be lifted. Malfunctions  Cause: Vehicle too heavy. Check the lift for the following causes of malfunc- Remedy: Offload vehicle. Refer to permissible load tion. distribution in chapter 3.1.  Contact the manufacturer’s customer service if Cause: Leakage in hydraulic system.

  • Page 23: Emergency Lowering

    6. Malfunctions Lowering with FOR with defective solenoid 6.1 Emergency lowering valve  Vehicle emergency lowering only to be carried out by competent persons. Danger to life due to electric shock while working on open control cab- inet. DANGER  Only electricians are permitted to work on the open control cabinet.

  • Page 24: Malfunction Reports

    7. Malfunction reports Acknowledge malfunction rectification after repair as Malfunction reports follows: 1. Turn off the equipment with the main switch. 7.1 Malfunction indicator lamps 2. Turn the equipment back on afterwards.  Malfunctions are indicated by means of 4 mal- Contact the authorized customer service if the function indicator lamps L1 to L4 on the control malfunction is not rectified after the specified...

  • Page 25: Maintenance

    8. Maintenance 8.3 Maintenance schedule Maintenance Clean and maintain lifts in particularly dirty surroundings more often. 8.1 Qualification maintenance staff Ventilate pit adequately before start of work. Maintenance only to be carried out by competent Ensure adequate lighting. persons ( chapter 1.3). Daily 8.2 Safety precautions 1.

  • Page 26: Cleaning

    8. Maintenance 8.4 Cleaning 8.6 Permitted hydraulic oils  Clean lift regularly. Important notes  Clean lift only in unloaded condition.  Only use hydraulic oil according to DIN 51524 for  Do not use aggressive cleaning agents for lift the hydraulic system.

  • Page 27: Check Hydraulic Components For Leakages

    8. Maintenance Tightening torque for bolts 8.7 Check hydraulic components for For set screws, friction factor = 0,125 leakages Dimensions Tightening torque (Nm) Check lift only in unloaded condition. Strength category 10.9 12.9 1. Carry out visual check of rod seals and scraper rings (...

  • Page 28: Bleed Lifting Cylinder

    8. Maintenance 8.9 Bleed lifting cylinder 8.11 Carry out function test  Always bleed lifting cylinder unloaded. Danger of personal injury through  Each lifting cylinder has 3 bleeding positions. malfunctions. WARNING  Deactivate and secure lift immediately after detecting malfunctions. ...

  • Page 29: Calibrate Sensor Setting

    8. Maintenance 3. Measure vehicle height again and note the drop 8.14 Change hydraulic oil travel on each axle.  Always change the hydraulic oil for all lifting cyl- 4. Check working cylinders: Press and hold button inders. “2” (Illustration 22) approx. 1 min. ...

  • Page 30: Repair

    9. Repair Repair  Repair work only to be carried out by authorized staff with the equipment switched off and secured  Observe safety precautions in chapter 8.2.  All repair work is to be recorded ( form “Special safety check”). 9.1 Change gaskets Cause for defective seals can be for instance: ...

  • Page 31: Safety Checks

    10. Safety checks 11. Transport, storage 11.1 Storage Lift components are only to be stored dry (no corro- sion protection). Permitted storage conditions  Ambient temperature: -5 ... +50°C  Relative humidity, 30% ... 95% not condensing, at 20°C The manufacturer is not responsible for cor- rosion damage due to incorrect storage.
  • Page 32 11. Transport, storage 117127 ● 07/2011...

  • Page 33: Setting Up

    12. Setting up 12.3 Set-up remarks 12. Setting up 12.1 Set-up regulations  Lift set-up is carried out by trained technicians of the manufacturer or authorized dealer.  The standard design lift must not be positioned in explosive areas.  Before set-up an adequate foundation must be verified.

  • Page 34: Start-Up

    13. Start-up 13. Start-up 15. Disposal Carry out “Safety check” before start-up. 15.1 Packaging materials Do not dispose of with the residual waste! The If a competent person (factory-trained technician) packaging party contains recyclable materials, installs the lift, this person also carries out the safety which must not be disposed of with general waste.

  • Page 35: Annex

    ANHANG ANNEX Inspection book with  Master data sheet DUPLEX-S2 lift  Form “Set-up protocol”  Form “Handover certificate”  Form “First safety check before start-up”  Form “Annual safety check”.  Form “Special safety check”  Maintenance report Diagrams, spare part lists ...
  • Page 36 INSPECTION BOOK DUPLEX-S2 Master data sheet DUPLEX-S2 lift Manufacturer Lift BlitzRotary GmbH Type ..........Hüfinger Str. 55 78199 Bräunlingen Serial number ..........Germany Intended use  The lift is intended for lifting and lowering commercial vehicles for repair, maintenance and cleaning during normal workshop operation.
  • Page 37 INSPECTION BOOK DUPLEX-S2 Set-up protocol BlitzRotary GmbH Hüfinger Str.55 78199 Bräunlingen, Germany  Complete this form in full after successful installation, tick the appropriate boxes and sign the form.  Copy the original and send it within one week to the manufacturer. ...
  • Page 38 INSPECTION BOOK DUPLEX-S2 Handover report The in-ground truck lift Duplex-S2, Type ............. Machine/serial number: ............. was installed on .......................... (address) ............. checked for functionality and safety and was commissioned. The following persons (operators) were trained after lift installation by a trained manufacturer’s or authorized dealer’s technician (competent person) in operating the in-ground lift.
  • Page 39 INSPECTION BOOK DUPLEX-S2 First safety check before start-up only by competent person Keep completed form in inspection book (Annex)! Type ………………………………. Carry out the following test steps. Tick if appropriate. Serial number: ……………………………………. Step-by-step safety check Fault Miss- Check Remarks again ...
  • Page 40 INSPECTION BOOK DUPLEX-S2 Annual safety check Keep completed form only by competent person in inspection book (Annex)! Carry out the following test steps. Type ………………………………. Tick if appropriate. Serial number: ……………………………………. Step-by-step safety check Fault Miss- Check Remarks again  ...
  • Page 41 INSPECTION BOOK DUPLEX-S2 Annual safety check Keep completed form only by competent person in inspection book (Annex)! Carry out the following test steps. Type ………………………………. Tick if appropriate. Serial number: ……………………………………. Step-by-step safety check Fault Miss- Check Remarks again  ...
  • Page 42 INSPECTION BOOK DUPLEX-S2 Annual safety check Keep completed form only by competent person in inspection book (Annex)! Carry out the following test steps. Type ………………………………. Tick if appropriate. Serial number: ……………………………………. Step-by-step safety check Fault Miss- Check Remarks again  ...
  • Page 43 INSPECTION BOOK DUPLEX-S2 Annual safety check Keep completed in only by competent person form in inspection book (Annex)! Carry out the following test steps. Type ………………………………. Tick if appropriate. Serial number: ……………………………………. Step-by-step safety check Fault Miss- Check Remarks again ...
  • Page 44 INSPECTION BOOK DUPLEX-S2 Annual safety check Keep completed form only by competent person in inspection book (Annex)! Carry out the following test steps. Type ………………………………. Tick if appropriate. Serial number: ……………………………………. Step-by-step safety check Fault Miss- Check Remarks again  ...
  • Page 45 INSPECTION BOOK DUPLEX-S2 Annual safety check Keep completed form only by competent person in inspection book (Annex)! Carry out the following test steps. Type ………………………………. Tick if appropriate. Serial number: ……………………………………. Step-by-step safety check Fault Miss- Check Remarks again  ...
  • Page 46 INSPECTION BOOK DUPLEX-S2 Annual safety check Keep completed form only by competent person in inspection book (Annex)! Carry out the following test steps. Type ………………………………. Tick if appropriate. Serial number: ……………………………………. Step-by-step safety check Fault Miss- Check Remarks again  ...
  • Page 47 INSPECTION BOOK DUPLEX-S2 Annual safety check Keep completed form only by competent person in inspection book (Annex)! Carry out the following test steps. Type ………………………………. Tick if appropriate. Serial number: ……………………………………. Step-by-step safety check Fault Miss- Check Remarks again  ...
  • Page 48 INSPECTION BOOK DUPLEX-S2 Annual safety check Keep completed form only by competent person in inspection book (Annex)! Carry out the following test steps. Type ………………………………. Tick if appropriate. Serial number: ……………………………………. Step-by-step safety check Fault Miss- Check Remarks again  ...
  • Page 49 INSPECTION BOOK DUPLEX-S2 Annual safety check Keep completed form only by competent person in inspection book (Annex)! Carry out the following test steps. Type ………………………………. Tick if appropriate. Serial number: ……………………………………. Step-by-step safety check Fault Miss- Check Remarks again  ...
  • Page 50 INSPECTION BOOK DUPLEX-S2 Special safety check Keep completed form in inspection book only by competent person (Annex)! Carry out the following test steps. Type ………………………………. Tick if appropriate. Serial number: ……………………………………. Fault Remarks Step-by-step safety check Miss- Check again  ...

  • Page 51: Maintenance Report

    INSPECTION BOOK DUPLEX-S2 Maintenance report Keep completed form in inspection book (Annex)! Always record carried out Type ………………………………. maintenance work. Tick if appropriate. Serial number: ……………………………………. Date Maintenance report carried out by monthly annually biannually      ...
  • Page 52 INSPECTION BOOK DUPLEX-S2 Date Maintenance report carried out by monthly annually biannually                             ...
  • Page 53 PLÄNE, ERSATZTEILLISTEN Hydraulics diagram Safety cylinder Lowering brake valve1 Solenoid valve Solenoid valve Pressure sensor Pressure relief valve Suction valve Geared pump Electric motor 3kw Level sensor Intake filter Emergency relief valve Emergency relief valve M, MA G1/4" A, P, T G1/2" 117127 ●...
  • Page 54 PLÄNE, ERSATZTEILLISTEN BlitzRotary GmbH Hüfinger Straße 55 D-78199 Bräunlingen Phone +49.771.9233.0 Fax +49.771.9233.99 info@blitzrotary.com www.blitzrotary.com...

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