Scissors Lift
DUO-GN
for vehicles up to 4,200 kg gross weight
Technical Handbook
D1 0811TH1-GB06
DUO-GN
EDITION
2006-08-23
Software version V3.60
© MAHA GMBH & CO. KG
All rights reserved. Any reproductions of this document, partial or complete, are only allowed
with prior consent of MAHA GmbH & Co. KG.
All rights reserved in cases of patent granting or registration of design.
The contents of this edition have been checked with great care. However, errors cannot be fully
excluded. Please contact MAHA should you find errors of any kind.
Subject to technical change without notice.
MANUFACTURER
MAHA Maschinenbau Haldenwang GmbH & Co. KG
Hoyen 20
D-87490 Haldenwang/Allgäu
Phone:
Fax:
+49 (0) 8374 585 0
+49 (0) 8374 585 499
Internet:
E-Mail:
http://www.maha.de
maha@maha.de
SERVICE
MAHA Maschinenbau Haldenwang GmbH & Co. KG
- Service Dept. Hoyen 20
D-87490 Haldenwang/Allgäu
Hotline:
Service:
Fax:
II
+49 (0) 180 5624 260 for Brake Testers and Test Lanes
+49 (0) 180 5624 280 for Automotive Lifts
+49 (0) 180 5624 290 for Dynamometers and Emission Testers
+49 (0) 180 5624 250
+49 (0) 180 5624 255
D1 0811TH1-GB06
DUO-GN
CONTENTS
1
General Information ..................................................................................................1
1.1
1.2
1.3
1.4
1.5
1.6
2
Standard Delivery...........................................................................................................................1
Options and Accessories ...............................................................................................................1
Specifications .................................................................................................................................2
Noise Emission ..............................................................................................................................3
Installation ......................................................................................................................................3
1.5.1
Location ..........................................................................................................................3
1.5.2
Foundation......................................................................................................................4
1.5.3
Power and Air Supply .....................................................................................................4
1.5.4
Anchoring of Lift / Floor Cover ........................................................................................5
Recommended Positioning ............................................................................................................8
Installation .................................................................................................................9
2.1
2.2
Positioning......................................................................................................................................9
Provisional Connection of Hydraulic System .................................................................................9
2.2.1
Hydraulic Fluid ..............................................................................................................10
2.3 Power Supply ...............................................................................................................................10
2.3.1
Initial Raising Cycle ......................................................................................................11
2.4 Connection of Electric System .....................................................................................................12
2.4.1
Potential Equalization ...................................................................................................12
2.5 Final Connection of Hydraulic and Pneumatic Systems ..............................................................13
2.5.1
Installation Material.......................................................................................................14
2.5.2
Power Unit 2.5 kW and 5.5 kW.....................................................................................16
2.5.3
Power Unit 2 x 5.5 kW ..................................................................................................18
2.5.4
Wheel-Free Jack...........................................................................................................20
2.5.5
Hydraulic Inclination......................................................................................................22
2.5.6
Locking Latch................................................................................................................24
2.5.7
PMS ..............................................................................................................................24
2.5.8
Hose Cover (for Surface Mounted Lift).........................................................................25
2.6 Bleeding the Hydraulic System ....................................................................................................26
2.7 Adjustment and Anchoring of Base Plates...................................................................................26
2.7.1
Fastening of Shims and Adjusting screws....................................................................27
2.7.2
Adjustment of Base Plates for Standard Lifts ...............................................................28
2.7.3
Adjustment of Wheel Alignment Lifts............................................................................30
2.8 Leveling of Wheel Alignment Lifts................................................................................................32
2.8.1
Leveling in Fully Raised Position..................................................................................33
2.8.2
Leveling in Fully Lowered Position ...............................................................................36
2.8.3
Wheel Alignment Analysis Computer ...........................................................................36
2.9 Cross Connection of Runways.....................................................................................................37
2.10 Adjustment of Automatic Runway Synchronization .....................................................................39
2.10.1 Bleeding of Hydraulic System.......................................................................................39
2.10.2 Adjusting the Proximity Switches on the Latches.........................................................41
2.10.3 Adjusting the Proximity Switches for the Runway Synchronization..............................41
2.11 Checking and Adjusting the Longitudinal Light Barriers ..............................................................43
2.11.1 Operational Check ........................................................................................................43
2.11.2 Adjustment....................................................................................................................43
3
Supplementary Information....................................................................................45
3.1
3.2
Proximity Switches .......................................................................................................................45
3.1.1
Proximity Switches in the Base Plate ...........................................................................45
3.1.2
Proximity Switches in the Runway................................................................................45
Transporting the Lift .....................................................................................................................46
3.2.1
Transport Protection .....................................................................................................46
3.2.2
Transport with Hoisting Chains.....................................................................................47
D1 0811TH1-GB06
III
DUO-GN
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
4
Appendix ..................................................................................................................85
4.1
IV
Lift with Pneumatic Floor Cover ...................................................................................................48
3.3.1
Floor Cover for Center Aisle .........................................................................................48
3.3.2
Floor Cover for Axle Jack .............................................................................................49
3.3.3
Installation of Floor Cover.............................................................................................50
Controller Board A1......................................................................................................................52
3.4.1
Switch-on Check...........................................................................................................52
3.4.2
Inputs X1A1 ..................................................................................................................53
3.4.3
Power Supply X2A1......................................................................................................56
3.4.4
Outputs X3A1 ...............................................................................................................57
Infrared Hand Lamp .....................................................................................................................58
3.5.1
Channel Setting on the Infrared Hand Lamp ................................................................58
3.5.2
Channel Setting on Controller Board A1 ......................................................................58
Radio Hand Lamp ........................................................................................................................60
3.6.1
Installation.....................................................................................................................60
3.6.2
Channel Setting ............................................................................................................61
3.6.3
Transmission Channels ................................................................................................62
Cross Connection of Runways.....................................................................................................63
Troubleshooting ...........................................................................................................................64
Pneumatic System .......................................................................................................................65
3.9.1
Double Latch.................................................................................................................65
3.9.2
Quadruple Latch ...........................................................................................................66
3.9.3
Pneumatic Floor Cover / Floor Cover for Axle Jack .....................................................67
3.9.4
PMS 2/XLP ...................................................................................................................68
Bleeding .......................................................................................................................................69
Manual Lowering..........................................................................................................................71
3.11.1 Preparations .................................................................................................................71
3.11.2 Lift with Hand Pump......................................................................................................72
3.11.3 Lift without Hand Pump.................................................................................................74
3.11.4 Slider Blocks .................................................................................................................75
Compensation Rails for 280/330 mm Foundation Depth.............................................................76
Maintenance.................................................................................................................................77
3.13.1 Annual Inspection .........................................................................................................77
3.13.2 Maintenance by the Operator .......................................................................................77
Hydraulic Circuit Diagrams...........................................................................................................85
D1 0811TH1-GB06
DUO-GN
General Information
1
General Information
1.1
Standard Delivery
Š Scissors lift, model DUO-GN
Š Control desk including power unit
Š Cable covers
Š Two approach ramps (for surface mounted version) or four flaps (for flush mounted version)
Š Operating manual
1.2
Options and Accessories
Š Accelerated raising/lowering cycles
Š Automatic runway synchronization
Š Strip foundation floor cover (for defined axle jack position, incl. position monitoring)
Š Automatic roll-off protection incl. audible warning device
Š Manual lowering function incl. hand pump
Š Granulate coated runways
Š Extended runways, 4400 or 4800 mm
Š Stepped ramp for lowered vehicles
Š Exit ramp, diamond tread, 1600 mm
Š Axle jack AL2.2 (hydropneumatic scissors jack, load capacity 2200 kg)
Š Permanent inclination device, removable
Š Hydraulic inclination device
Š Wheel-free jack 4 (built-in hydraulic scissors jack, load capacity 3500 kg)
Š Runway grating
Š Runway lighting
Š Shockproof socket 230 V, 16 A
Š Safety light barrier for low shop ceilings
Š Axle play detector, model PMS 3/X or PMS 3/XL
Š Safety shutdown (in combination with brake tester)
Š Lowering device for wheel alignment
(incl. pressure indicator and automatic runway synchronization)
Š Measuring probe holder for computer-aided reference measurement
Š Prewiring for wheel alignment analyzers
Š Various swivel and slip plates
Š Various compensation and support plates
D1 0811TH1-GB06
1
General Information
1.3
DUO-GN
Specifications
Rated load capacity
Full travel
Lifting height max.
Lifting height max. with
compensating plates
Lifting height min.
Lifting height min. with
compensating plates
Dimensions of
standard version
Raising time
Lowering time
Anchoring with MKT
heavy-duty anchors
Anchoring with Fischer
heavy-duty anchors
Anchoring with UPAT
heavy-duty anchors
Motor power
Supply voltage
Wire size min.
Rated current
Fuse protection
Reservoir capacity
Petroleum-based fluid
specification
Biodegradable fluid
specification
Working pressure max.
Pump capacity
DUO-GN
2.5 kW
(Standard)
4200 kg
1850 mm
2075 mm
DUO-GN
5.5 kW
(Option)
4200 kg
1850 mm
2075 mm
DUO-GN
2 x 5.5 kW
(Option)
4200 kg
1850 mm
2075 mm
2125 mm
2125 mm
2125 mm
225 mm
225 mm
225 mm
275 mm
275 mm
275 mm
LxWxH
LxWxH
LxWxH
4000 mm x 2075 mm 4000 mm x 2075 mm 4000 mm x 2075 mm
x 225 mm
x 225 mm
x 225 mm
approx. 45 s
approx. 25 s
approx. 12 s
approx. 45 s
approx. 25 s
approx. 12 s
12x SZ-B 15/45
12x SZ-B 15/45
12x SZ-B 15/45
or
or
or
12x SZ-B 15/95
12x SZ-B 15/95
12x SZ-B 15/95
12x FH 15/50 B
12x FH 15/50 B
12x FH 15/50 B
or
or
or
12x FH 15/100 B
12x FH 15/100 B
12x FH 15/100 B
12x PS-B 15/50
12x PS-B 15/50
12x PS-B 15/50
or
or
or
12x PS-B 15/100
12x PS-B 15/100
12x PS-B 15/100
2.5 kW
5.5 kW
2 x 5.5 kW
3~ 400 V, 50 Hz
3~ 400 V, 50 Hz
3~ 400 V, 50 Hz
2.5 mm²
4 mm²
6 mm²
6.2 A
12 A
24 A
16 A
25 A
35 A
approx. 38 l
approx. 38 l
approx. 38 l
HLPD 32 min.
HLPD 32 min.
HLPD 32 min.
MAHA HLP 32
MAHA HLP 32
MAHA HLP 32
260 bar
3.1 cm3/U
260 bar
6 cm3/U
260 bar
2 x 6 cm3/U
Specifications are subject to change without notice.
2
D1 0811TH1-GB06
DUO-GN
General Information
General view of DUO-GN with wheel-free jack
1.4
Noise Emission
The sound pressure level is below 70 dB (A).
1.5
Installation
Lift installation and commissioning by authorized service personnel only.
Provision of handling means such as forklifts etc. is the owner's responsibility.
1.5.1
Location
The standard lift version may not be installed outdoors, in moist rooms, at hazardous locations,
or in the vicinity of explosives or flammable liquids.
Choice of a suitable lift location is the owner's responsibility.
D1 0811TH1-GB06
3
General Information
1.5.2
DUO-GN
Foundation
Prior to installation a sufficiently stable foundation and level lift bay floor shall be completed in
accordance with manufacturer recommendations.
Lift Version
Minimum Concrete
Thickness
DUO-GN
140 mm (reinforced)
Always use the current foundation plans.
Proof of safe floor load capacity is the owner's responsibility.
1.5.3
Power and Air Supply
Power supply cable and air hose should be run to the control desk location with an excess
length of at least 1.5 m.
1.5.3.1
Power Supply
3~ + N + PE 400 V, 50 Hz. Select a wire size appropriate for lift model and cable length.
Standard
Option
Option
1.5.3.2
Motor power in kW
2.5
5.5
2 x 5.5
Time-delay fuse in A
16
25
35
Rated current in A
6.2
12
24
Air Supply
R1/4" incl. maintenance unit; delivery rate and working pressure appropriate for lift model.
4
D1 0811TH1-GB06
DUO-GN
1.5.4
General Information
Anchoring of Lift / Floor Cover
If other anchors than those listed below are used, the anchor manufacturer must be
contacted and asked for approval.
Read the anchor manufacturer's installation instructions.
1.5.4.1
Lift Anchoring
Twelve heavy-duty anchors manufactured by MKT, Fischer or UPAT are used for anchoring the
lift.
1.5.4.2
MKT
SZ-B 15/45 or SZ-B 15/95, depending on length required
Fischer
FH 15/50 B or FH 15/100 B; depending on length required
UPAT
PS-B 15/50 or PS-B 15/100; depending on length required
Floor Cover Anchoring
Four anchors, model UPAT EXA 10/15, are used for anchoring the floor cover.
D1 0811TH1-GB06
5
General Information
1.5.4.3
DUO-GN
Anchor Specifications
1
Base material
hef
Embedment depth
2
Mark (minimum embedment depth)
d0
Drill bit nominal diameter
h1
Hole depth
Tinst
Installation torque
tfix
Fixture thickness (including floor tiles)
hmin Minimum base material thickness
ManufacturerÆ
Anchor modelÆ
MKT
Fischer
UPAT
SZ-B
15/45
SZ-B
15/95
FH
15/50 B
FH
15/100 B
PS-B
15/50
PS-B
15/100
EXA
10/15
≥ [mm]
95
95
95
95
95
95
70
hmin
[mm]
140
140
140
140
140
140
100
hef
[mm]
71
71
70
70
70
70
49*
tfix
[mm]
45
95
50
100
50
100
15
d0
= [mm]
15
15
15
15
15
15
10
Tinst
= [Nm]
50
50
40
40
40
40
45
h1
* w/o bottom wedge
If fixture thickness is < tfix, dimensions h1 and hmin must be increased accordingly.
If other anchors than those listed above are used, read the anchor manufacturer's data sheet.
6
D1 0811TH1-GB06
DUO-GN
1.5.4.4
General Information
Anchor Installation
1
Drill a hole into the base material as per anchor
manufacturer's recommendations.
2
Blow the hole clean of dust and other material.
3
Drive the anchor through the fixture into the anchor
hole.
4
Tighten the nut using a checked torque wrench.
D1 0811TH1-GB06
7
General Information
1.6
DUO-GN
Recommended Positioning
Drawing shows surface mounted version of DUO-GN. Foundation plans for flush mounted
version are available through MAHA.
C
1
2
Hose Cover, Recessed
Hose Cover, Standard
Control Desk
C
Recommended clearance:
► 1 m minimum to nearest lateral obstruction.
► 1.5 m minimum to nearest obstruction in front of and behind lift.
8
D1 0811TH1-GB06
DUO-GN
Installation
2
Installation
2.1
Positioning
See also sections "Specifications" and "Recommended Positioning".
At the installation site remove all packaging material. Determine runway separation X and
position the runways using a leveling board.
2.2
Provisional Connection of Hydraulic System
Attach labeled hoses to corresponding connections of power unit.
The hydraulic connections for lift and accessory equipment are located at the backside of the
valve blocks. They are labeled with letters.
See also section "Final Connection of Hydraulic/Pneumatic Systems".
D1 0811TH1-GB06
9
Installation
2.2.1
DUO-GN
Hydraulic Fluid
Fill reservoit with hydraulic fluid until it reaches top-level mark.
Fluid level can be checked using inspection window (1). To add fluid remove filler screw (2).
Reservoir capacity is approx. 38 l.
1.1
The top-level mark is
indicated by the upper
inspection window (1.1).
1.2
The bottom-level mark is
indicated by the lower
inspection window (1.2).
max
min
Š Petroleum-based fluid should meet HLPD 32 specifications. MAHA part # VM 999005.
Š Biodegradable fluid: Only use MAHA HLP 32. MAHA part # VM 999014.
2.3
Power Supply
Remove the mains fuse before connecting the power cable.
Run the power cable (supplied by customer,
3~/N + PE 400 V, 50 Hz) into the control
desk from the bottom to the top.
Attach wires to terminal strip X1 as per table
below.
10
D1 0811TH1-GB06
DUO-GN
Installation
Wire / Designation
Power Supply Cable
L1
L2
L3
N
PE
attach to
Terminal
Terminal Strip X1
Terminal Strip X1
Terminal Strip X1
Terminal Strip X1
Terminal Strip X1
L1
L2
L3
N
PE
After connecting wires L1, L2 and L3 place back the terminal covers.
2.3.1
Initial Raising Cycle
Before completing the installation perform an initial raising cycle.
While raising the lift press the light barrier override button on controller board A1.
After the initial raising cycle remove the transport protection (see section "Transport/Handling").
When installing lifts without locking latch, secure the runways by inserting square tubes
in the slider tracks of the base plates.
Four tubes 50 x 50 x 800 mm are required.
D1 0811TH1-GB06
11
Installation
2.4
DUO-GN
Connection of Electric System
Use the wiring diagrams supplied with the lift.
2.4.1
Potential Equalization
Run a potential equalization cable (yellow/green, wire size 4 mm²) from base plates and
floor cover to the control desk.
Attach the wires to the four grounding
bolts inside the control desk.
12
D1 0811TH1-GB06
DUO-GN
2.5
Installation
Final Connection of Hydraulic and Pneumatic Systems
When installing surface mounted lifts, connect hydraulic/pneumatic systems as per drawings
below. When installing flush mounted lifts, use the appropriate cable channels.
The hydraulic connections for lift and accessory equipment are located at the backside of the
valve blocks. They are labeled with letters.
Application
Power Unit
Connector
Lift
Connector
A
Y5
DUO-GN (and DUO 3.5)
F
Y4
DUO-GN (and DUO 3.5)
H
Y14.1
PMS
J
Y14
PMS
K
Y15.1
PMS
N
Y15
PMS
O
Y9
Wheel-free jack
R
Y10
Wheel-free jack
S
Y11
Wheel-free jack
U
Y8
Hydraulic inclination
D1 0811TH1-GB06
13
Installation
2.5.1
DUO-GN
Installation Material
C
14
D1 0811TH1-GB06
DUO-GN
Installation
Item
Qty.
1
2
Shim, 250 mm lg.
4
10
Shim, 150 mm lg.
7
1
Hydraulic Connection DUO-GN 2.5 kW and 5 kW
8
1
Locking Latch Connection
9
1
Wheel-Free Jack Connection
10
1
PMS Connection
11
1
Hydraulic Connection DUO-GN 2 x 5 kW
12
1
Hose Cover (for Surface Mounted Lift)
13
1
Hydraulic Inclination
C
D1 0811TH1-GB06
Description
Control Desk
15
Installation
C
C
B
Power Unit 2.5 kW and 5.5 kW
A
2.5.2
DUO-GN
16
D1 0811TH1-GB06
DUO-GN
Installation
Item
Qty.
Description
1
2
Hose
∅ 8x1, 7000 mm lg.
28 7008
5
1
HP Hose
2SN NW8 M16x1.5 L 750
27 0821 075
6
1
HP Hose
2SN NW8 M16x1.5 L 1250
27 0821 125
7
1
HP Hose
2SN NW8 M16x1.5 L 2000
27 0821 200
8
2
HP Hose
2SN NW8 M16x1.5 L 5000
27 0821 500
9
1
Screw Fitting
EVL 10 L Vm.
27 6630
10
1
Screw Fitting
EVW 10 L
27 6635
11
3
Screw Fitting
G 10 L
27 6637
13
2
Straight Fitting
KQH 08-00
28 9100
A
Leakage Hose
B
Compressed-Air Hose, 8 bar
C
Control Desk
Part #
Item 1:
Pneumatic connection in runway and leakage hose for slave cylinder.
D1 0811TH1-GB06
17
Installation
C
C
B
Power Unit 2 x 5.5 kW
A
2.5.3
DUO-GN
18
D1 0811TH1-GB06
DUO-GN
Installation
Item
Qty.
Description
3
2
Hose
∅ 8x1, 7000 mm lg.
28 7008
7
1
HP Hose
2SN NW10 M18x1.5 L 750
27 1021 075
8
1
HP Hose
2SN NW10 M18x1.5 L 1250
27 1021 125
9
1
HP Hose
2SN NW10 M18x1.5 L 2000
27 1021 200
10
2
HP Hose
2SN NW10 M18x1.5 L 5000
27 1021 500
11
1
Screw Fitting
EVL 12 L Vm.
27 6830
12
1
Screw Fitting
EVW 12 L
27 6835
13
3
Screw Fitting
G 12 L
27 6837
15
2
Straight Fitting
KQH 08-00
28 9100
A
Leakage Hose
B
Compressed-Air Hose, 8 bar
C
Control Desk
Part #
Item 3:
Pneumatic connection in runway and leakage hose for slave cylinder.
D1 0811TH1-GB06
19
Installation
Wheel-Free Jack
C
C
2.5.4
DUO-GN
20
D1 0811TH1-GB06
DUO-GN
Installation
Item
Qty.
4
1
HP Hose
2SN NW6 M14x1.5 L 750
27 0621 075
5
1
HP Hose
2SN NW6 M14x1.5 L 1700
27 0621 170
6
2
HP Hose
2SN NW6 M14x1.5 L 2000
27 0621 200
7
1
HP Hose
2SN NW6 M14x1.5 L 5000
27 0621 500
8
1
Screw Fitting
EVL 8 L Vm.
27 6430
9
1
Screw Fitting
EVW 8 L Vm.
27 6435
10
1
Screw Fitting
G8L
27 6437
C
D1 0811TH1-GB06
Description
Part #
Control Desk
21
Installation
Hydraulic Inclination
C
C
2.5.5
DUO-GN
22
D1 0811TH1-GB06
DUO-GN
Installation
Item
Qty.
3
2
Hydraulic Inclination
7
1
HP Hose
2SN NW6 M14x1.5 L 750
27 0621 075
8
1
HP Hose
2SN NW6 M14x1.5 L 1700
27 0621 170
9
1
HP Hose
2SN NW6 M14x1.5 L 5000
27 0621 500
1
Screw Fitting
EVL 8 L Vm.
27 6430
1
Screw Fitting
EVW 8 L Vm.
27 6435
1
Screw Fitting
G8L
27 6437
C
D1 0811TH1-GB06
Description
Part #
Control Desk
23
Installation
2.5.6
DUO-GN
Locking Latch
C
Item
Qty.
1
1
Compressed-Air Hose
∅ 6x1, 5000 mm lg.
28 7006
4
1
Tee Fitting
KQU 06-99
28 9031
C
2.5.7
Description
Part #
Control Desk
PMS
C
Item
Qty.
4
2
HP Hose
2SN NW6 M14x1.5 L 5000
27 0621 500
5
2
HP Hose
2SN NW6 M14x1.5 L 7000
27 0621 700
C
24
Description
Part #
Control Desk
D1 0811TH1-GB06
DUO-GN
Hose Cover (for Surface Mounted Lift)
C
C
2.5.8
Installation
Item
Qty.
3
3
Cable Channel
4
1
Cable Channel, Recessed
C
D1 0811TH1-GB06
Description
Control Desk
25
Installation
2.6
DUO-GN
Bleeding the Hydraulic System
At completion of hydraulic and pneumatic installation bleed the system and run the lift through a
few raising and lowering cycles.
See section 3.10.
2.7
Adjustment and Anchoring of Base Plates
Each base plate is provided with six (6) mounting brackets including adjusting screws.
a:
26
1
Shim, Short
2
Adjusting screw with Lock Nut
3
Heavy-Duty Anchor
D1 0811TH1-GB06
DUO-GN
Installation
b:
1
Shim, Long
2
Adjusting screw with Lock Nut
3
Heavy-Duty Anchor
4
Supporting Bolt with Lock Nut
Do not use the supporting bolts (item 4) for base plate adjustment.
At completion of adjustment tighten the supporting bolts and the lock nuts.
2.7.1
Fastening of Shims and Adjusting screws
Place the shim (B) under the mounting bracket in
such a way that the holes (C) are in alignment.
Tighten bolt (A) until it rests on the shim.
D1 0811TH1-GB06
27
Installation
2.7.2
2.7.2.1
DUO-GN
Adjustment of Base Plates for Standard Lifts
Fully Lowered Position
Š Fully lower the lift.
Š Check dimension X, adjust as required.
Š Check runway position using a leveling board, adjust as required.
Š Level the runways using the adjusting screws.
2.7.2.2
Fully Raised Position
Š Fully raise the lift.
Š Check dimension X, adjust as required using the adjusting screws.
28
D1 0811TH1-GB06
DUO-GN
2.7.2.3
Installation
Anchoring
At completion of base plate adjustment tighten the lock nuts.
Drill holes using a Ø 15 mm drill bit and blow
them clean of dust.
Drive anchors into holes and tighten them
using a torque wrench.
Read anchor manufacturer's installation instructions.
D1 0811TH1-GB06
29
Installation
2.7.3
DUO-GN
Adjustment of Wheel Alignment Lifts
Wheel alignment lifts are measured, leveled and adjusted during final assembly at the factory.
To obtain the required accuracy of measurement, the lifts must be set up identically at their
installation site.
Carefully level the lift in its fully lowered position.
The maximum permissible difference in height between the base plates is ±8 mm for
standard lifts and ±3 mm for wheel alignment lifts.
2.7.3.1
Fully Lowered Position
Š Fully lower the lift.
Š Check dimension X, adjust as required.
Š Check runway position using a leveling board, adjust as required.
Š Measure the runways at eight (8) points using a leveling instrument. Adjust as required using
the adjusting screws.
Careful leveling of base plates is necessary to achieve high accuracy of measurement.
30
D1 0811TH1-GB06
DUO-GN
2.7.3.2
Installation
Fully Raised Position
Š Fully raise the lift and set it on the topmost lock.
Š Check dimension X, adjust as required using the adjusting screws.
After each adjustment in fully raised position, recheck the base plates in fully lowered position
and readjust if necessary.
2.7.3.3
Anchoring
At completion of base plate adjustment tighten the lock nuts.
Drill holes using a Ø 15 mm drill bit and blow
them clean of dust.
Drive anchors into holes and torque them
according to table "Anchor Specifications" (see
section 1.5.4.3).
Read anchor manufacturer's installation instructions.
D1 0811TH1-GB06
31
Installation
2.8
DUO-GN
Leveling of Wheel Alignment Lifts
Before leveling the lift load the runways with a typical vehicle. Spot vehicle rear wheels on slip
plates, and front wheels on swivel plates. The lift must be leveled in fully raised as well as in
fully lowered position.
A leveling aid is available through the manufacturer. The leveling aid can be used in
standing as well as in hanging position.
32
D1 0811TH1-GB06
DUO-GN
2.8.1
Installation
Leveling in Fully Raised Position
The accuracy requirements are met within six serration teeth around the serration in which the
runways were leveled.
Flush Mounted Lift
Š Fully raise the lift and set it on the topmost
lock. The latch teeth automatically engage
the serrations.
Surface Mounted Lift
Š Fully raise the lift and set it on the locks.
The first three serration teeth from above
must remain free.
D1 0811TH1-GB06
33
Installation
DUO-GN
Š Set up the leveling instrument.
Make sure all measuring points, at the inner and outer wheel edges, are visible through the
instrument.
Do not move the leveling instrument while measuring.
Š Place tripod on slip/swivel plates with leveling rod pointing downward. Measure all eight
points and note down the readings.
Tolerance Limits
BMW
VAG
Others
Transversally
0.5 mm
0.5 mm
1.0 mm
Longitudinally
1.0 mm
1.0 mm
1.0 mm
Diagonally
1.0 mm
1.0 mm
1.0 mm
MAHA wheel alignment lifts are measured, leveled and adjusted during final assembly. Provided
the lift has been installed correctly, readjustment of bearings is not normally required.
2.8.1.1
Adjustment of Thrust Bearings
Location of the four thrust bearings.
Unload the lift before adjusting the thrust bearings.
34
D1 0811TH1-GB06
DUO-GN
Installation
Š Open the hex head cap screws (item 2) 1/2 turn
each.
Š Use the adjusting screws (item 1) to adjust the
bearing (same number of turns for each screw).
Once the readings are within the tolerance range, check the runway position using a leveling
board and adjust as required. Then tighten the screws.
2.8.1.2
Adjustment of Movable Bearings
Location of the four movable bearings
(= slide tracks).
Š Open fastening screws (item 2) 1/2
turn.
Š Adjust setscrews (item 1) as
required.
Š Once all setscrews evenly contact
the runway tighten the fastening
screws.
D1 0811TH1-GB06
35
Installation
2.8.2
DUO-GN
Leveling in Fully Lowered Position
Š Fully lower the lift.
Š Measure the eight measuring points using the leveling instrument.
Š Use the eight adjusting screws in the
base plate corners to adjust the runways.
See section 2.10.3.2.
At completion of lift leveling check all adjusting screws and anchors for tightness. Seal the
adjusting screws using screw locking varnish.
2.8.3
Wheel Alignment Analysis Computer
Š After installation of the computer, place the quick-clamping holders and measuring heads at
the wheels. Raise the lift to upper wheel alignment position. Note down or print out the
camber and tread values.
Fully lower the lift. Compare the values displayed with those noted down for upper position.
Maximum permissible variation between upper and lower position values is two (2) angular
minutes plus one digit.
If required, readjust fully lowered runways individually at respective footprint area. Observe
tolerance limits (see table above).
For slighter readjustments use the adjusting screws provided in the base plate corners.
Š For lifts with measuring head holders: Place the measuring heads in the holders and fully
lower the lift. Store the camber and tread values.
Computers with MKS software will show the MKS screen after start-up. Here, all values can
be set to zero position. If zero shifts of more than five (5) angular minutes should occur, the
values will be displayed in red (normally green).
When using computers without MKS software, note down the camber and tread values for
comparison purposes.
36
D1 0811TH1-GB06
DUO-GN
2.9
Installation
Cross Connection of Runways
Lifts with axle play detector are equipped with a cross member for increased stability.
A
B
for Surface Mounted Lift
for Flush Mounted Lift
D1 0811TH1-GB06
37
Installation
DUO-GN
Make sure the supports of the cross member
are on the upper side.
NOTE:
Maximum permissible variation between
dimension X in fully lowered position and
dimension X in fully raised position is 2 mm
38
D1 0811TH1-GB06
DUO-GN
2.10
Installation
Adjustment of Automatic Runway Synchronization
Bleeding of hydraulic system is necessary to ensure proper functioning of the automatic runway
synchronization and the lift control.
At initial installation repeat the bleeding procedure three times at least.
2.10.1
Bleeding of Hydraulic System
Do not bleed the system while the lift is loaded!
Disengage the cross member before bleeding the system.
The bleeding procedure explained below applies to lifts both with or without automatic runway
synchronization.
Š Fully raise the lift.
Š Insert a plastic hose (8x1, length
1 m) into the bleeding duct of the
slave cylinder valve.
D1 0811TH1-GB06
39
Installation
DUO-GN
Š Simultaneously press and hold the override button, the equalizing button and the LOWER
button until the slave cylinder runway is approx. 10 cm above the floor.
If the override button is not actuated, the synchronization check will respond. The lift movement
stops and the ERROR signal lamp flashes.
Do not completely remove the bleeder screws. The sealing balls might be lost or seals might be
damaged.
At completion of the bleeding procedure close the bleeder screws finger tight.
Š Raise the latch (2) to make the
bleeder screw (1) accessible.
Š Open bleeder screw (1) of master
cylinder approx. one turn using an
Allen key.
The runway slightly lowers.
Close the screw once fluid
streams without bubbles.
Š Use a tub to collect the escaping
fluid.
Š Open bleeder screw (3) of slave
cylinder approx. 1/4 turn using a
long Allen key.
The runway slightly lowers.
Close the screw once fluid
streams without bubbles, or
runway has reached downward
travel stop.
40
D1 0811TH1-GB06
DUO-GN
Installation
The bleeder screw of the slave cylinder is
located at the valve block.
It can be reached through a slot in the
runway.
Š After bleeding the system simultaneously press and hold override button, equalizing button
and RAISE button until both runways have the same height.
Š Fully lower the lift. Keep holding the LOWER button for approx. 10 seconds after lift has
reached bottom position.
2.10.2
Adjusting the Proximity Switches on the Latches
For wheel alignment lifts only!
1 Set the proximity switches on the latches (2 pcs.) or double latches (4 pcs.) as close to the
cylinder tube as possible (clearance approx. 1 mm).
2 Verify that LEDs 25 and 26 (with double latches also 27 and 28) on controller board A1 and
the LEDs on the proximity switches light up when the runways are fully set on the
mechanical locks.
2.10.3
Adjusting the Proximity Switches for the Runway Synchronization
The automatic runway synchronization is preset at the factory and does not normally require
adjustment, provided the lift has been installed correctly.
Otherwise proceed in the following order:
2.10.3.1
Checking Proximity Switch B15
While lowering the fully raised lift, verify that proximity switch B15 responds at a height of
325…450 mm.
To do this, check that the illumination of LED 10 at VDN 1 on controller board A1 moves from
weak to strong. If it does not, proximity switch B15 must be adjusted.
The switching point may also be checked using the LED on the proximity switch.
D1 0811TH1-GB06
41
Installation
2.10.3.2
DUO-GN
Adjusting Proximity Switches B13 and B14
Clearance x
B13
B14
Standard Lift
4 mm
4 mm
Wheel Alignment Lift
1 mm
4 mm
Proximity switches B13 and B14 are located at the approach side (A) of the base plates.
1 Set a clearance of approx. 4 mm (standard lifts) or 1 mm (wheel alignment lifts) between
proximity switch B13 and the runway.
2 Set a clearance of approx. 4 mm between proximity switch B14 and the runway.
3 Verify that LEDs 8 and 14 on controller board A1 and the LEDs on the proximity switches
light up when the runways are in bottom position.
With wheel alignment lifts be sure the master cylinder (right side) is slightly leading.
42
D1 0811TH1-GB06
DUO-GN
Installation
2.11
Checking and Adjusting the Longitudinal Light Barriers
2.11.1
Operational Check
At completion of installation check the longitudinal light barriers for proper response:
1 Position the lift at a height of approx. 10 cm.
2 Hold one hand between light barrier transmitter and receiver on the edge of the runway.
⇒ The red error lamp on the control panel lights up.
The longitudinal light barrier has responded, the lift is ready for
operation.
2.11.2
Adjustment
If the red error lamp on the control panel does not light up, the light barrier receiver must be
readjusted:
1 Turn adjusting screw (A) to MIN position.
2 Turn adjusting screw (A) slowly toward MAX position until red indicator lamp (B) lights up.
3 Repeat operational check (see above).
D1 0811TH1-GB06
43
Installation
44
DUO-GN
D1 0811TH1-GB06
DUO-GN
Supplementary Information
3
Supplementary Information
3.1
Proximity Switches
3.1.1
Proximity Switches in the Base Plate
Switch
used for:
1 (B15)
– Automatic synchronization
– Second lowering speed
– Strip foundation
– Axle jack position
– Lowerable prism wedge (PMS)
2 (B17)
– Floor cover / Stroke counter
3 (B16)
– Upward travel stop
(5.5 kW and 2 x 5.5 kW motor)
3.1.2
Proximity Switches in the Runway
3.1.2.1
Hydraulic Inclination
Lifts equipped with an hydraulic inclination
device have two proximity switches located
beneath one of the runways.
Switch
used for:
1 (B20)
– Monitoring of inclination
2 (B21)
– Monitoring of inclination
Proximity switches B20 and B21 have the same function (redundant system for safety reasons).
3.1.2.2
PMS with Lowerable Prism Wedge
Lifts equipped with PMS including lowerable prism wedge require an additional proximity switch
located in the PMS to monitor the prism wedge position (up or down). This proximity switch is
located inside the PMS.
Switch
used for:
(B18)
– Monitoring of extended position of prism wedge
if actuated hydraulically
or
– Monitoring of retracted position of prism wedge
with "10 t drive-through" version
D1 0811TH1-GB06
45
Supplementary Information
3.2
Transporting the Lift
3.2.1
Transport Protection
DUO-GN
When lifting the scissors by the base plate, use the transport protection to avoid
equipment damage.
Two blocks of wood are required for each pair of scissors. Dimensions:
Lift without wheel-free jack
213 x 95 x 22 mm
Lift with wheel-free jack
183 x 95 x 22 mm
Fasten the blocks to the scissors as per drawings below (base plate and runway removed for
illustration purposes):
A.1
A.2
A.3
A.4
46
Raised scissors (side view)
Lowered scissors with wheel-free jack (side view)
Lowered scissors without wheel-free jack (side view)
Lowered scissors (top view)
D1 0811TH1-GB06
DUO-GN
3.2.2
Supplementary Information
Transport with Hoisting Chains
When using a crane or similar
hoisting device, fasten four cable
loops to the mounting brackets of the
base plate.
Then hook in the hoisting chains.
The minimum length of each hoisting chain is 1500 mm.
D1 0811TH1-GB06
47
Supplementary Information
3.3
Lift with Pneumatic Floor Cover
3.3.1
Floor Cover for Center Aisle
1
2
3
4
5
6
7
8
9
10
48
Base Frame
Cover Plate
Binding Head Screw M6x10
Guide
Flat Head Screw M8x12
Travel Stop
Heavy-Duty Anchor UPAT EXA 10/15
Adjusting screw M16x50
Hex Head Cap Bolt M16x15
Hex Nut M16
DUO-GN
Air Bellows Cover, Bottom
Air Bellows
Air Bellows Cover, Top
Allen Screw M8x16
Support Bolt M10x29
Hex Nut M10
Hex Head Cap Screw M10x20
Washer A10.5
Compressed-Air Connector
Grating
Wood Screw Ø6x30
11
12
13
14
15
16
17
18
19
20
21
D1 0811TH1-GB06
DUO-GN
3.3.2
Supplementary Information
Floor Cover for Axle Jack
1
2
3
4
5
6
7
8
9
10
11
Base Frame
Cover Plate
Binding Head Screw M6x10
Guide
Flat Head Screw M8x12
Travel Stop
Heavy-Duty Anchor UPAT EXA 10/15
Adjusting screw M16x50
Hex Head Cap Bolt M16x15
Hex Nut M16
Air Bellows Cover, Bottom
D1 0811TH1-GB06
Air Bellows
Air Bellows Cover, Top
Allen Screw M8x16
Support Bolt M10x29
Hex Nut M10
Hex Head Cap Screw M10x20
Washer A10.5
Compressed-Air Connector
Grating
Wood Screw Ø6x30
Cover Plate
12
13
14
15
16
17
18
19
20
21
22
49
Supplementary Information
3.3.3
DUO-GN
Installation of Floor Cover
The floor covers are shipped ready-to-install and only need to be fastened and connected.
Travel stop brackets should be anchored carefully to avoid jamming with base frame.
Read anchor manufacturer's installation instructions.
Š Insert travel stops (6) into base frame (1).
Š Position base frame between both lift units.
Š Anchor travel stop using UPAT EXA 10/15
GVZ anchors (7).
Š Install compressed-air system using pneumatic plan.
Install the rapid release valves close to the air
bellows to ensure proper function. Use clamps to
fasten the valves to the base frame.
Š Adjust lifting rise of base frame using hex head cap
bolts (9), then tighten lock nuts (10).
Š Install cover plate (2) by screwing binding head
screws (3) into adjusting screws (8). Use these to
make cover plate flush with floor level. Then tighten
the lock nut (10).
Š Finally insert grating into base frame.
50
D1 0811TH1-GB06
DUO-GN
Supplementary Information
Illustration shows rapid release valve
with clamp.
3.3.3.1
Sectional View of Lift with Floor Cover
1
6
8
9
A
B
F
Base Frame
Travel Stop
Adjusting screw
Hex Head Cap Bolt
Stop (welded to base frame, contacts bolt (9) once floor cover reaches top position)
Base Frame
Runway
D1 0811TH1-GB06
51
Supplementary Information
3.3.3.2
DUO-GN
Installation of UPAT EXA 10/15 Anchors
Š Using a 10 mm diameter bit, drill a hole into the base material. Minimum hole depth 85 mm.
Š Blow hole clean of dust.
Š Drive anchor through travel stop bracket into hole.
Š Torque the nut to 45 Nm.
3.4
Controller Board A1
3.4.1
Switch-on Check
When switching on the supply voltage check that Watchdog LED VD 4 on the controller board
lights up once or twice for approx. 1/2 second. In case of malfunction check the supply voltage
(24 V) at connector X2 of the controller board (X2A1).
If VD 4 lights up or flashes permanently, controller board A1 is defective.
52
D1 0811TH1-GB06
DUO-GN
3.4.2
Supplementary Information
Inputs X1A1
X1A1
1
2
3
4
5
6
7
PORT
P0.0
P0.1
P0.2
P0.3
P0.4
P0.5
P0.6
8
P0.7
9
10
11
P2.0
P2.1
P2.2
12
P2.3
13
P2.4
14
P2.5
15
P2.6
16
17
18
19
20
21
22
23
24
25
26
P2.7
P3.0
P3.1
P3.2
P3.3
P3.4
P3.5
P3.6
P3.7
SR
SR
27
SR
28
SR
29
30
SR
SR
D1 0811TH1-GB06
Funktion
Button Raise lift
Button Lower lift
Button Set on locks
Button Lift horizontal
Button Lift inclined
Button Raise wheel-free jack
Button Lower wheel-free jack
Limit switch Master (right side) down?
(Synchronization during lowering)
Lift up
Lift in lower range (approx. 20 cm)
Lift in lower half (approx. 80 cm)
Lift in horizontal position /
Shaker plate in center position
Lift in horizontal position /
Shaker plate in center position
Limit switch Slave (left side) down?
(Synchronization during lowering)
Switch Cable lamp S5 /
Shaker plate down
Axle lift position / (Ceiling light barrier)
Manual synchronization
Button Combined
Strip foundation yes/no (open = no)
Input IR eye
Light barrier longitudinal, right side
Light barrier longitudinal, left side
Light barrier transverse
Emergency switch on controller board
Flip switch 1 – Position 1 / Input Lock left side
Flip switch 1 – Position 1 / Input Lock left side
Flip switch 2 – Position 1 / Input Lock left side
Addition; Set jumper if lock not present
Flip switch 2 – Position 2 / Input Lock left side
Addition; Set jumper if lock not present
2 x 5.5 kW (Raising time < 20 s)
Audible warning signal
down
LED on
up
down
down
LED on
LED off
LED off
LED on
LED on
down
LED on
down
LED on
on lock
on lock
LED on
LED on
on lock
LED on
on lock
LED on
53
Supplementary Information
3.4.2.1
Buttons
X1A1
1
2
3
4
5
6
7
16
17
24
3.4.2.2
3.4.2.3
DUO-GN
Button
S2
S3
S6
S8
S7
S4
S5
Function
Raise lift
Lower lift
Set on locks
Disable inclination
Enable inclination
Raise wheel-free jack
Lower wheel-free jack
S11/S12 Axle jack position
S1
Manual synchronization
S2A1
Override light barrier
LED
1
2
3
4
5
6
7
VDN
1
1
1
1
1
1
1
Light signal when
Button pressed
Button pressed
Button pressed
Button pressed
Button pressed
Button pressed
Button pressed
16
17
2
2
Button not pressed
Button pressed
24
3
Button pressed
LED
8
9
VDN
1
1
10
1
11
12
13
14
2
2
2
2
Proximity Switches
X1A1
8
9
Switch
B13
B16
10
B15
11
12
13
14
B17
B20
B21
B14
Function
- Automatic synchronization
- Upper limit switch
- Automatic synchronization
- Second lowering speed
- Strip foundation
- Axle jack position
- Floor cover / Stroke counter
- Inclination
- Inclination
- Automatic synchronization
Light signal
Weak when
unconnected
Normal when
connected
Pressure Switches
Pressure switches B27 and B28 (visual pressure monitoring) are integrated between X1A1-8
and X1A1-16. B27 and B28 switch when unpressurized. See wiring diagram supplied.
54
D1 0811TH1-GB06
DUO-GN
3.4.2.4
Supplementary Information
Infrared/Light Barriers
X1A1
21
22
23
B2
B1
B3
Receiver right
Receiver left
Receiver transverse
LED VDN Light signal when
21
3 Beam unobstructed
22
3 Beam unobstructed
23
3 Beam unobstructed
The light barriers are permanently active and self-monitoring. Operation of the self-monitoring
system is indicated by a flashing light signal from light barrier transmitter, light barrier receiver
and the respective LEDs (21/22/23 at VDN 3), and from the LED of output 29 at VDN 5 (light
barrier clock pulse).
Check that LEDs 21/22/23 at VDN 3 go out briefly once the clock pulse output X3A1-29 is
enabled.
Once the light beam is interrupted, the respective LED (21/22/23 at VDN 3) goes out, error lamp
H4 and LED of output X3A1-27 are flashing.
Once the lift has been set on the locks, the light barriers are disabled to avoid distortions of the
wheel alignment results. When lift is in bottom position, the light barriers are also disabled;
LEDs 21/22/23 at VDN 3 are out.
Light barrier error
Error lamp and LED of output X3A1-27 flashing
slowly (clock pulse approx. 1 second).
Error lamp and LED of output X3A1-27 flashing
quickly.
Error lamp and LED of output X3A1-27 flashing
quickly.
LED of clock pulse output X3A1-29 lighting up
permanently.
Possible cause
Transverse light barrier obstructed or
defective.
At least one longitudinal light barrier obstructed
or defective.
One light barrier permanently active. Make
sure transmitter and receiver are disabled.
In case of defect or obstruction the safety function of the light barriers may be disabled using
override button S2A1 on controller board A1.
To disable the safety function press and hold button S2A1 before actuating the desired control
button.
3.4.2.5
Inputs of Cable Hand Lamp
X1A1
15
25
26
27
28
D1 0811TH1-GB06
Switch position
Hand lamp switch S5
Flip switch 1 – Position 1
Flip switch 1 – Position 2
Flip switch 2 – Position 1
Flip switch 2 – Position 2
LED
15
25
26
27
28
VDN
2
3
3
3
3
Light signal when
Connected
Position 1
Position 2
Position 1
Position 2
55
Supplementary Information
3.4.2.6
DUO-GN
Optional Inputs
The DUO-GN control has inputs which can be used for setting the following options:
Input
03
04
05
06
07
19
29
30
3.4.3
Yes
+24 V
+24 V
+24 V
+24 V
+24 V
+24 V
+24 V
+24 V
No
Button
Button
Button
Button
Button
Button
Button
Button
Power Supply X2A1
X2A1
1
2
3
4
5
6
7
8
9
10
11
12
56
Option
PMS with cable lamp at input 25 26
Mechanical inclination
Mechanical inclination
10 t drive-through
10 t drive-through
Strip foundation
Raising time 12 s (2 x 5.5 kW)
Audible warning signalSignaltonsteuerung
Potential
+24 V
+24 V
+24 V
+24 V
+24 V
+24 V
GND
GND
GND
GND
GND
GND
+24 V from G1
X1A1-29 and X1A1-29 (+24 V for optional inputs)
X1A1-19 (+24 V for optional inputs)
+24 V for cable hand lamp
+24 V for cable hand lamp
+24 V for cable hand lamp
GND from G1
GND for cable hand lamp
D1 0811TH1-GB06
DUO-GN
3.4.4
Supplementary Information
Outputs X3A1
X3A1
LED
VDN
Component/Contact
Function
1
2
Digital output
+24 V
1
4
K1/A2
K1/A1
Motor 1
3
4
Digital output
+24 V
3
4
Y4/1 and Y5/1
Lower lift
5
6
Digital output
+24 V
5
4
Y9.1/2 and Y10/2 and Y11/2
Y9.1/1 and Y10/1 and Y11/1
Lower wheel-free jack
7
8
Digital output
+24 V
7
4
Y3/2
Y3/1
Lift movement quick/slow
9
10
Digital output
+24 V
9
4
Y1.1/2
Y1.1/1
Pressure limitation 120 bar for PMS
11
12
Digital output
+24 V
11
4
Y1/2
Y1/1
Raise lift
13
14
Digital output
+24 V
13
4
Y9/2
Y9/1
Raise wheel-free jack
15
16
Digital output
+24 V
15
4
Y14/2
Y14/1
PMS: front from left to left
17
18
Digital output
+24 V
17
4
Y6/2
Y6/1
Latch
19
20
Digital output
+24 V
19
4
K2/A2
K2/A1
Motor 2
21
22
Digital output
+24 V
21
5
Y7/2
Y7/1
Synchronization
23
24
Digital output
+24 V
23
5
Y14.1/2
Y14.1/1
PMS: front from left to right
25
26
Digital output
+24 V
25
5
Y16/2
Y16/1
PMS: prism wedge up
27
28
Digital output
+24 V
27
5
Error
29
30
Digital output
+24 V
29
5
Clock pulse output f. light barr. transmitter
31
32
Digital output
+24 V
31
5
33
34
Digital output
+24 V
33
5
Y15/2
Y15/1
PMS: front from right to right
35
36
Digital output
+24 V
35
5
Y15.1/2
Y15.1/1
PMS: front from right to left
37
38
Digital output
+24 V
37
5
Y12/2
Y12/1
Floor cover up/down
39
40
Digital output
+24 V
39
5
K10/A2
K10/A1
Audible warning signal
41
42
Digital output
+24 V
41
6
Y2/2 (and Y6.1/2)
Y2/1 (and Y6.1/1)
Lower lift (and latch of 2nd lock)
43
44
Digital output
+24 V
43
6
45
46
Digital output
+5 V
45
6
IR hand lamp
Power supply for IR receiver A3 and A3.3
47
48
Digital output
+24 V
47
6
Y8/2
Y8/1
Lift inclined/horizontal
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57
Supplementary Information
3.5
DUO-GN
Infrared Hand Lamp
If an infrared hand lamp is used to control the PMS axle play detectors, the transmission link
between infrared hand lamp and controller board A1 has to be activated.
If several lifts equipped with infrared hand lamps are being operated in the same shop, each lift
requires a transmission channel of its own. Four different channels can be set.
3.5.1
Channel Setting on the Infrared Hand Lamp
Set desired transmission channel using switch on infrared hand lamp.
Only the following channels can be selected: channel 0, channel 1, channel 2, channel 8.
3.5.2
58
Channel Setting on Controller Board A1
D1 0811TH1-GB06
DUO-GN
Supplementary Information
Š Pin jumper J1 to position 1-2.
Š Only switches 1 and 2 on DIP switch block S1 are available for channel setting, i.e. a
maximum of four different channels can be set.
DIP switch of
controller board
A1
Channel of
IR hand lamp
D1 0811TH1-GB06
Channel 0
Channel 1
Channel 2
Channel 8
59
Supplementary Information
3.6
DUO-GN
Radio Hand Lamp
The buttons and switches of the radio hand lamp have the same functions as those of the
infrared hand lamp.
13 devices can be coded with the radio system in comparison with the infrared system which
allows only 4. In addition, after switch-on of the radio hand lamp the light intensity is slowly
increased to ensure long service life of the halogen bulb.
3.6.1
Installation
Receiver of radio system A2
Controller board A1
The receiver is connected with the controller board via a 5-wire cable and then attached to a hat
rail inside the control desk.
Radio receiver
5-wire
Controller board A1
X3
⎯⎯⎯⎯⎯
X4
At completion of installation plug the antenna into connector X4 of the radio receiver.
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3.6.2
Supplementary Information
Channel Setting
Make sure that radio hand lamp and receiver of the same lift are set to the same transmission
channel.
Š Remove the plug from the hand lamp to
make the coding switch accessible.
Š The coding switch of the radio receiver is
freely accessible.
Make sure all switches on DIP switch block S1 are in OFF (0) position.
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61
Supplementary Information
3.6.3
DUO-GN
Transmission Channels
The radio system is operated on a license-free ISM channel.
Coding Switch
Position
Transmission
Channel
Radiofrequency
in MHz
Data Rate
in baud
RF Transmission
in ms
0
0
868.000
19200
25
1
12
869.850
19200
25
2
6
869.200
19200
25
3
9
868.300
19200
25
4
1
868.200
38400
13
5
11
869.525
38400
13
6
4
868.800
38400
13
7
7
869.800
38400
13
8
2
868.400
9600
51
9
10
868.950
9600
51
A
5
869.000
9600
51
B
8
870.000
9600
51
C
3
868.600
19200
25
D, E, F
62
not used
D1 0811TH1-GB06
DUO-GN
3.7
Supplementary Information
Cross Connection of Runways
The runways can be optionally equipped with a cross member for increased stability.
Once a certain level difference is exceeded, the cross member will automatically disengage to
avoid damage to the lift.
Periodically check the cross member for secure engagement in the holding brackets
(see illustration below, position 1).
1 Engaged position
2 Partially disengaged position
3 Fully disengaged position
To reinstall the partially or fully disengaged cross member proceed as follows:
Š Release the catch spring from the disengaged fork head of the cross member. Remove the
hinge pin (including catch spring).
Š Synchronize the runways.
Š Place the fork head in the holding bracket and insert the hinge pin.
Š Secure the hinge pin by locking the catch spring.
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63
Supplementary Information
3.8
DUO-GN
Troubleshooting
Trouble
Cause
Remedy
Runway lighting does not burn.
Fuse F2 blown.
Replace fuse F2.
POWER signal lamp does not burn. Lift does not respond.
Main switch off.
Turn on main switch.
Mains fuse blown.
Replace mains fuse.
Primary fuse F1 of power pack G1 blown.
Replace fuse F1.
Secondary fuses of power pack G1 blown. Replace fuses.
POWER and FAULT signal lamps burning. Lift does not respond.
Protective motor switches Q2/Q3 off.
Turn on protective motor switches.
Ceiling light barrier B4 dirty.
Cautiously clean light barrier.
POWER signal lamp lighting up, FAULT signal lamp flashing slowly. Lift can be raised only.
Longitudinal LBs triggered by obstacle.
Remove obstacle.
Longitudinal LBs dirty.
Cautiously clean transmitters / receivers.
Longitudinal LB maladjusted.
Readjust LB.
Longitudinal LB defective.
Replace LB.
Lift can be raised and lowered. Automatic synchronization control inactive.
Hydraulic hoses for valves Y4 and Y5
Connect hoses correctly.
interchanged.
POWER signal lamp lighting up, FAULT signal lamp flashing quickly. Lift does not respond.
Transverse LB dirty.
Cautiously clean transmitter / receiver.
Apertures of transverse LB dirty.
Clean apertures.
Transverse LB triggered by obstacle.
Remove obstacle.
Readjust LB. Max. height difference
Transverse LB maladjusted.
between runways is 50 mm ± 10 mm.
Transverse LB defective.
Replace LB.
POWER signal lamp lighting, FAULT signal lamp flashing quickly. Runways unequal in height,
lift does not respond.
Transverse LB triggered by unequal load
See section "Runway Synchronization
distribution on runways.
Check“ of operation manual.
Runways unequal in height despite equal
See section "Runway Synchronization
load distribution. Transverse LB triggered. Check“ of operation manual.
See section "Runway Synchronization
Button LOWERING DEVICE is pressed:
Check“ and "of operation manual.
Runways engage different serrations, are
unequal in height. Transverse LB triggered. Adjust proximity switches B13 / B14.
Motor running, but pressure build-up insufficient to raise lift.
Manual lowering screw open.
Close screw.
Hydraulic system leaking.
Remove leakage.
Intake tube of hydraulic pump broken.
Replace intake tube.
Pump filter dirty.
Clean or replace filter.
Low fluid level.
Check fluid level, refill as required.
Hydraulic valve Y1 inactive.
Check valve Y1, replace if required.
Vehicle too heavy.
Check vehicle weight, reduce if possible.
64
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Supplementary Information
3.9
Pneumatic System
3.9.1
Double Latch
Locking Latch
Air Supply
Axle Jack
Item
Qty.
Description
Part #
3
2
Short-Stroke Cylinder (15 mm Stroke)
28 0040
4
1
Solenoid Valve
3/2 Port G1/4", 24 V
28 4150
5
1
Tee Fitting
KQT 06-00
28 9035
6
3
Elbow Fitting
KQL 06-01 S
28 9055
7
1
Threaded Tee Fitting
KQY 08-01 S
28 9136
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65
Supplementary Information
3.9.2
DUO-GN
Quadruple Latch
Cylinder Double Latch
Locking Latch
Air Supply
Axle Jack
66
Item
Qty.
Description
Part #
3
4
Short-Stroke Cylinder (15 mm Stroke)
28 0040
4
1
Solenoid Valve
28 4150
5
1
3/2 Port Directional Control Valve with Solenoid
28 5001
6
2
Rapid Release Valve
Model 2 VSR R1/4"
28 5800
7
1
Silencer
R1/4" 165-0400
28 8165 0400
8
2
Silencer
R1/4" 165-0400
28 8165 0400 1
9
3
Tee Fitting
KQT 06-00
28 9035
10
5
Elbow Fitting
KQL 06-01 S
28 9055
11
2
Straight Fitting
KQH 08-02 S
28 9105
12
2
Elbow Fitting
KQL 08-02 S
28 9120
13
2
Elbow Fitting
KQL 08-03 S
28 9128
14
1
Tee Fitting
KQT 08-00
28 9131
15
2
Threaded Tee Fitting
KQY 08-01 S
28 9136
16
1
Threaded Tee Fitting
KQY 08-02 S
28 9137
17
1
Elbow Fitting
KQL 10-02 S
28 9210
3/2 Port G1/4", 24 V
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DUO-GN
3.9.3
Supplementary Information
Pneumatic Floor Cover / Floor Cover for Axle Jack
Floor Cover for Axle Jack
Pneumatic Floor Cover
Air Supply
Air Supply
Latch / Axle Jack
Latch / Axle Jack
Item
Qty.
3
1
Fitting
1/4" x 60 mm
27 4805
4
1
3/2 Port Directional Control Valve with Solenoid
28 5000
5
1
Manometer Maintenance Unit
200 l/min G1/4"
28 5505 2
6
2/1
Rapid Release Valve
Typ 2 VSR R1/4"
28 5800
7
1
Silencer
G1/8" 165-0200
28 8165 0200
8
3/2
Silencer
R1/4" 165-0400
28 8165 0400 1
9
1
Straight Fitting
KQH 08-00
28 9100
10
4/3
Straight Fitting
KQH 08-02 S
28 9105
11
4/2
Elbow Fitting
KQL 08-02 S
28 9120
12
2/1
Tee Fitting
KQT 08-00
28 9131
D1 0811TH1-GB06
Description
Part #
67
Supplementary Information
3.9.4
DUO-GN
PMS 2/XLP
Built-in Airbag
68
Item
Qty.
Description
Part #
3
1
3/2 Port Directional Control Valve with Solenoid
28 5000
4
1
Rapid Release Valve
3/8"
28 5802
5
1
Silencer
R1/4" 165-0400
28 8165 0400
6
1
Straight Fitting
KQH 08-02 S
28 9105
7
1
Elbow Fitting
KQL 08-02 S
28 9120
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DUO-GN
3.10
Supplementary Information
Bleeding
Do not bleed the system while the lift is loaded!
Disengage the cross member before bleeding the system (see section "Cross Member").
The bleeding procedure explained below applies to lifts both with or without automatic runway
synchronization.
Š Fully raise the lift.
Š Insert a plastic hose (8x1, length
1 m) into the bleeding duct of the
slave cylinder valve.
Š Simultaneously press and hold the override button, the equalizing button and the LOWER
button until the slave cylinder runway is approx. 10 cm above the floor.
If the override button is not actuated, the synchronization check will respond. The lift movement
stops and the ERROR signal lamp flashes.
Do not completely remove the bleeder screws. The sealing balls might be lost or seals might be
damaged.
At completion of the bleeding procedure close the bleeder screws finger tight.
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69
Supplementary Information
DUO-GN
Š Raise the latch (2) to make the
bleeder screw (1) accessible.
Š Open bleeder screw (1) of master
cylinder approx. one turn using an
Allen key.
The runway slightly lowers.
Close the screw once fluid streams
without bubbles.
Š Use a tub to collect the escaping
fluid.
Š Open bleeder screw (3) of slave
cylinder approx. 1/4 turn using a long
Allen key.
The runway slightly lowers.
Close the screw once fluid streams
without bubbles, or runway has
reached downward travel stop.
The bleeder screw of the slave cylinder
is located on the valve block.
It can be reached through a slot in the
runway.
Š After bleeding the system simultaneously press and hold override button, equalizing button
and RAISE button until both runways have the same height.
Š Fully lower the lift. Keep holding the LOWER button for approx. 10 seconds after lift has
reached bottom position.
Lifts without automatic runway synchronization may require manual runway synchronization.
70
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Supplementary Information
3.11
Manual Lowering
3.11.1
Preparations
Authorized personnel only! Do not restart the lift before the error has been remedied!
Lifts with floor cover for axle jack: Verify that axle jack is in defined home position.
Lifts with floor cover: Lower the floor cover by mechanically actuating air valve Y12.
Lift with double latch:
Depressurize the system by opening the
screw at pneumatic valve Y6.1.
Close the screw at completion of manual
lowering procedure.
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71
Supplementary Information
3.11.2
DUO-GN
Lift with Hand Pump
Solenoid valve Y5
(at slave cylinder)
Solenoid valve Y4
(at master cylinder)
When opening solenoid valves
Y5 and Y4, adhere strictly to the
following sequence.
Arrow: Bleeder screw at solenoid
valve Y5.
Š Open the setscrew (1) approx.
one turn, first at solenoid valve
Y5, then at solenoid valve Y4.
Š Open the control desk cover to
make the power unit accessible.
Š Use the hand pump (2) to disengage the locking latches (3.1).
72
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Supplementary Information
Š Push the slider blocks (3) under
the latches as shown.
The slider blocks prevent the
latches (3.1) from engaging the
serrations.
Š Open the setscrew (4) at the valve
block of the power unit until the lift
begins to lower slowly.
Š Once lift is in bottom position close the setscrew (4) finger tight.
Š Drive the vehicle off the lift.
Š After the error has been remedied, raise the lift without load and close the setscrews at
solenoid valves Y4 and Y5 finger tight.
Once the lift raises, the slider blocks fall to the ground and can be locked in the control desk.
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73
Supplementary Information
3.11.3
DUO-GN
Lift without Hand Pump
In some cases, lifts without hand pump cannot be lowered manually. Contact your MAHA
service representative.
Solenoid valve Y5
(at slave cylinder)
Solenoid valve Y4
(at master cylinder)
When opening solenoid valves
Y5 and Y4, adhere strictly to the
following sequence.
Arrow: Bleeder screw at solenoid
valve Y5.
Š Open the setscrew (1) approx.
one turn, first at solenoid valve
Y5, then at solenoid valve Y4.
Š Push the slider blocks (2) under
the latches as shown.
The slider blocks prevent the
latches (2.1) from engaging the
serrations.
74
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Supplementary Information
Š Open the control desk cover to
make the power unit accessible.
Š Open the setscrew (3) at the valve
block of the power unit until the lift
begins to lower slowly.
Š Once lift is in bottom position close the setscrew (3) finger tight.
Š Drive the vehicle off the lift.
Š After the error has been remedied, raise the lift without load and close the setscrews at
solenoid valves Y5 and Y4 finger tight.
Once the lift raises, the slider blocks fall to the ground and can be locked in the control desk.
3.11.4
Slider Blocks
Lock the slider blocks in the control desk to prevent unauthorized usage.
The slider blocks prevent the latches from engaging the
serrations during manual lowering.
Lock the slider blocks in the control desk to prevent unauthorized usage. Use the holder provided on the power unit.
D1 0811TH1-GB06
75
Supplementary Information
3.12
DUO-GN
Compensation Rails for 280/330 mm Foundation Depth
Item
Qty.
Description
Part #
3
10
Compensation Rail, Short
4
2
Compensation Rail, Long
8
24
Heavy-Duty Anchor
UPAT or Fischer
23 5050
11
13
Washer
A17 DIN 125
22 0125 16 1
12
13
Hex Head Cap Screw
M16x40-8.8 DIN EN 24017
22 0933 16040 1
Compensation rails for other foundation depths are available upon request.
76
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3.13
Supplementary Information
Maintenance
Turn off and lock the main switch before servicing the lift.
3.13.1
Annual Inspection
Have your lift inspected by authorized service personnel at least once annually.
3.13.2
Maintenance by the Operator
Establish a periodic preventive maintenance procedure to ensure troublefree operation and long
service life.
Use commercial multipurpose grease such as
Š Aral / K2K-30
Š Kuwait Petroleum / Rembrand EP-2
or similar products.
3.13.2.1
Hydraulic System
Monthly check the fluid level and refill as required. Visually check all hydraulic pipes and hoses
for tightness. Make sure the lift and all accessories (wheel-free jack, hydraulic inclination device
etc.) are in fully lowered position.
Peiodically replace the hydraulic fluid depending on aging, soiling and water absorption.
D1 0811TH1-GB06
77
Supplementary Information
3.13.2.1.1
DUO-GN
Determining the Fluid Level
Use the inspection windows to check
the fluid level.
Fluid level should be between topand bottom-level marks.
The power unit is located in the lower
part of the control desk.
Reservoir capacity is approx. 38 l.
The top-level mark is indicated by the dot in the upper inspection window.
The bottom-level mark is indicated by the dot in the lower inspection
window.
78
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3.13.2.1.2
Supplementary Information
Refilling
Open the filler screw and refill as
required.
Š Petroleum-based fluid should meet HLPD 32 specifications. MAHA part # VM 999005.
Š Biodegradable fluid: Only use MAHA HLP 32. MAHA part # VM 999014.
3.13.2.2
Greasing Points
4
4
3
2
1
5
5
D1 0811TH1-GB06
79
Supplementary Information
3.13.2.2.1
DUO-GN
Cylinder
Quarterly grease the cylinder and plunger hinges through lubricators 1.1 and 1.2. Remove
waste grease.
In the case of lifts equipped with double latch, also grease the hinges of the pneumatically
actuated lowering device cylinders.
3.13.2.2.2
Scissors Pins
Quarterly grease the scissors pins on the outside and inside through lubricators 2.1 and 2.2.
Remove waste grease.
3.13.2.2.3
Base Plate Tracks
Quarterly clean and slightly grease the base plate tracks (3).
3.13.2.2.4
Runway Tracks
Quarterly clean and slightly grease the runway tracks (4).
Lifts equipped with runway inclination have rollers instead of slider blocks. In this case, clean
but do not grease the tracks.
3.13.2.2.5
Thrust Bearings
Quarterly grease the thrust bearings through the lubricators (5). Remove waste grease.
Lift should be greased monthly for severe use applications.
80
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Supplementary Information
3.13.2.3
Pneumatic Floor Cover
3.13.2.3.1
Greasing the Pneumatic Floor Cover
The plastic guides of the limit stops should be cleaned and greased every three months.
3.13.2.3.2
Checking the Pneumatic Valves
Once a year clean or replace the foam silencers
at the rapid release valves and at the directional
control valve (see below).
The rapid release valves are located
near the floor cover bellows.
Remove the grating to make the
valves accessible.
D1 0811TH1-GB06
81
Supplementary Information
3.13.2.4
DUO-GN
Cleaning
Do not use high pressure / steam jet cleaners or caustic cleaning agents.
Risk of damage!
Periodically wash off aggressive substances and treat the lift with oil or wax spray.
Repair damage to the paintwork immediately to prevent corrosion. The RAL number is available
through the manufacturer.
3.13.2.5
Greasing Points at Accessory Equipment
3.13.2.5.1
Wheel-Free Jack
Tracks inside the Lift Runway (1):
Quarterly clean and slightly grease the tracks inside the runway (1).
Tracks inside the Wheel-Free Jack (2):
Quarterly clean and slightly grease the tracks inside the wheel-free jack (2).
82
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3.13.2.5.2
Supplementary Information
Axle Play Detector PMS
Before removing the test plates unpressurize the hydraulic system of the PMS.
Every 200 operating hours grease through the lubricators of the PMS guides (see arrows).
Remove waste grease.
Unpressurizing the-Hydraulic System of the PMS
Š Release solenoid valves Y14/Y14.1
and Y15/Y15.1. Then move the
respective test plate by hand.
Y14/Y14.1
Y15/Y15.1
D1 0811TH1-GB06
83
Supplementary Information
84
DUO-GN
D1 0811TH1-GB06
DUO-GN
4
Appendix
Appendix
Always use the latest hydraulic circuit diagrams available through MAHA.
4.1
Hydraulic Circuit Diagrams
D1 0811TH1-GB06
85
Appendix
86
DUO-GN
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DUO-GN
D1 0811TH1-GB06
Appendix
87
Appendix
88
DUO-GN
D1 0811TH1-GB06
DUO-GN
D1 0811TH1-GB06
Appendix
89
Appendix
90
DUO-GN
D1 0811TH1-GB06
DUO-GN
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Appendix
91
Appendix
92
DUO-GN
D1 0811TH1-GB06