RACK AND PINION HOIST

MABER

ONE-PHASE

INSTRUCTION AND MAINTENANCE MANUAL

THIS MANUAL IS AN INTEGRATED PART OF THE MACHINE

IMPORTANTE WARNING:

This instruction manual should be completely read carefully before putting the equipement to use; all the assembly instructions, the use and maintenance must be precisely precluded to unauthorized personnel.

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MABER costruzioni srl

36050 Bressanvido (VI) Italy via S. Benedetto, 14/P z.a.

Telefono: +39-0444-660871 Fax: +39-0444-660872

14/09/98 –libretto uso manutenzione MB500/120 - SP

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PREFACE

This manual is supplied along with the sold machine and contains guidelines for its transportation, assembly, operation and maintenance, as specified in the guidelines outlined in the EU 89/392 Machine directive.

CONTENTS

List of sections and paragraphs with page references:

* Analytical index

1. CE declaration of Compliance

2. Machine identification page 38

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03

04

3. Description of the machine

4. Machine application

Unauthorised uses of lift

5. Guarantee

6.

7.

How to consult the manual

Technical description

8. Specifications

11. Packaging

9. Safety regulations

10. Machine transportation

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07

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08

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10

12

13

14

14

12.

13.

Loading/unloading support

Installation

14. Assembling the vertical column

14a. Emergency brake test

15. Standard wall mounting

15a. Special wall mounting

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16

18

19

22

23

16. Trial before use

Machine operation:

Operator’s guide

20. Start-up

17. Machine controls

18.

19.

Checks and tips before use

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25

25

26

21. Setting the machine up for idling

22. Adjustments and regulations

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26

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Maintenance:

23. Periodic maintenance

24. Non-routine maintenance

25. Technical support service

26. Maintenance schedule

27. Lubricants

28.

29.

Electrical diagram

Failures

30. Spare parts (legend)

Spare parts diagram

31. Disposing of the machine page 28

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30

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31

32

33

35

36

37

Employment and intructions of the safety landing gate page

Technical Drawings page

39

48

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1. “CE” DECLARATION OF COMPLIANCE

This declaration issued by the manufacturer must be stamped and signed by the same and stored with the original machine documentation.

MABER Costruzioni s.r.l. whose legal head office is in 35014 Fontaniva - Padova - Italy - Via Casoni Basse, 16 and whose offices and plant are in Via S. Benedetto, 14/P - 36050 Bressanvido -

VICENZA - (ITALY)

in the capacity of the manufacturer of the machine concerned identified as: model: MB 500/120 SP serial N°:_______________ year of manufacture:____________ max. height 120 m max. load 300 kg confirms that it complies to the safety regulations specified in the health and safety regulations and guidelines as defined in enclosure N° 01 of:

The planning refers, when it is possible, at the following rules:

DPR 27.04.55 n° 547

DPR 07.01.56 n° 164

CNR-UNI 10011/88 manufacturer.

Machine directive 98/37/E.E.C., Section V including all supplementary guidelines.

The trial conducted on ___________ had a positive result.

The machine serial plate is printed with the initials of the Inspector:

(B.L.) Bertoncello Luciano.

The inspector is responsible.

Inspector’s signature

__________________

COPY

MABER Costruzioni s.r.l.

________________________

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2. MACHINE IDENTIFICATION

The equipment of which to the present manual is identified by the following elements, that which must be cited with a request for additional information of replacement:

MANUFACTURER:

CLIENT:

MACHINE:

MODEL:

MAX. LOAD:

MAX. HEIGHT:

MABER Costruzioni s.r.l. Via S.Benedetto, 14/P

36050 Bressanvido VICENZA (ITALY)

CITY/TOWN:

RACK AND PINION ELEVATOR

MB 500/120 SP

300 Kg

120 m.

POWER SUPPLY VOLTAGE

:

ONE PHASE 220/50 Hz

YEAR OF MANUFACTURE:

SERIAL NUMBER :

DELIVERY DATE:

EXPIRY DATE OF THE GUARANTEE (12 MONTHS):

AREA AGENT:

AFTER SALE SERVICE:

The identification data are printed on a special plate attached directly to the machine in the position shown in the diagram below:

Important: Do not use the machine without its identification plate.

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3. DESCRIPTION OF THE MACHINE

The MB 500/120 SP RACK AND PINION HOIST is a goods lift that allows elevation up to

120 m. in height, along the support column, anchored to a wall or scaffolds designed to bear loads transmitted up to a max. load. of 300 kg.

The lift is basically made up of the following parts: x A base fitted with adjustable worm screws. x A vertical column (fitted with a rack), composed of modular latticed elements, that must be joined every 6 m. to a wall or a support frame. x An loading deck driven by an electric motor via a rack and pinion coupling. x A series of securing bolts let the frame be held vertically (every 6m.). x A series of safety devices.

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The drawing illustrates the standard basic version of the machine:

The machine is fitted with a separate centrifugal-mechanical emergency brake

(patented) that automatically starts up if the descent speed exceeds approx. 20% of the normal preset values. The device enables a ratchet gear that allows the deck to stop in a damped and gradual way at any point of the vertical column. declaration itself (see page 3).

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4. MACHINE APPLICATION

The MB 500/120 SP RACK AND PINION HOIST must be used only to lift goods and equipment up to a maximum loaded weight evenly distributed on the deck of 300 kg.

The equipment may be only used for professional purposes by personnel authorised by the owner over 18 years of age and who have been previously trained in compliance with the regulations and guidelines of this manual.

The lift must be used only: x After correctly installing the base on a stable and adequately strong support surface (see page 16), x After correctly installing the vertical columns and securing bolts on the wall as required by specifications, x After checking the safety devices and accesses to the various storeys, x After checking the emergency brake works properly.

x In winds up to maximum speed of 70 km/hour . x In ambient temperatures ranging between -15° and + 45° C.

Persons may only be carried during the assembly and disassembly stages, by carefully following all safety regulations .

The diagram illustrates the loading conditions that must always be heeded:

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YES NO

MAXIMUM LOAD 300 KG.

Place goods as near as possible to the vertical column.

Fasten the material adequately.

Do not use the MB 500/120 RACK AND PINION HOIST when

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In MB 500/120 RACK AND PINION HOIST operation any misuse of the equipment is not allowed. This particularly includes:

- carrying persons and animals ,

- carrying protruding loads ,

- carrying goods that have not been properly tied,

- carrying loose goods,

- Operation in harsh weather conditions (thunder storms, wind, snow etc.)

Operation in conditions of poor visibility (fog, night darkness etc..)

- Operation in wind speeds over 40 km/hour when assembling the rack

- Operation in wind speeds over 70 km/hour when using the rack

- Operation in very harsh temperatures or with ice that might

stop the ratchet gear of the emergency brake,

DO NOT USE - Operation at ambient temperatures over +45°,

- Operation at ambient temperatures below -15°,

- Machine operation

- Operation without without terminal switches

periodic maintenance ,

,

- Operation when the column has not been firmly secured,

- Operation after tampering or modification unauthorised

by the manufacturer,

- Use of unoriginal spare parts,

- Machine operation in explosive environments

- Use when submerged in liquids,

- Use near free flames.

!!! CAUTION !!!

In all cases in which the lift cannot be used the deck must be lowered to ground level and the machine must be set up for idling, as described in the relevant paragraph.

NO NO COPY

5. GUARANTEE

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The manufacturer’s guarantee is valid for 12 months a fter the delivery date of the equipment and is limited to the replacement of parts that are to the incontrovertible judgement of the manufacturer defective due to materials used or to manufacturing .

La guarantee is always and only valid for goods delivered ex works and any other kinds of compensation, besides the description in the above point, are not considered.

The guarantee is not valid and the manufacturer can be exempted from any responsibility if: x The user tampers , without prior written authorisation from the manufacturer, with any parts or accessories of the appliance itself, x Damage is caused by misuse of the equipment or by failure to comply with the operating regulations and guidelines, x Damage is caused by neglecting to apply the maintenance instructions. x Operation is contrary to specific directives, x It has been badly installed, x electric power supply failures occur, x The instructions given are not heeded even in part. x Replacement of any parts or components must always be previously authorised by the manufacturer.

The guarantee does not cover the electric parts of the machine.

The law court of PADOVA ITALY is responsible for any litigation.

6. HOW TO CONSULT THE MANUAL

The operating and maintenance manual is an integral part of the machine.

Before commencing any installation jobs and machine operation the operator must carefully read the text with particular regard to all operational safety regulations and guidelines. COPY to the constant and continuous improvements made by manufacturer to the product, the supplied machine might differ in some technical details from that described in this manual. However, any variation is always accompanied by specific enclosed documents illustrating functionality and features. Should there be any discrepancies compared to the content of the handbook, the user may immediately ask for supplementary technical data sheets.

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7. TECHNICAL DESCRIPTION

The MB 500/120 RACK AND PINION HOIST is a machine designed to elevates goods up to 300 kg. A motor-powered moving deck slides on a special vertical column up to 120 m in height. The vertical column is attached to the wall or support frame every 6m.

The base (1) is made up of a welded tubular frame, at the end of which 4 worm screws (2) are installed to regulate vertical alignment of the machine.

The vertical column (3) 1.50 m. in length, is made with latticed and welded tubular bars and a rack. It must be bolted with appropriate securing bolts (4) every 6 m. to a support wall or a frame able to bear the transmitted loads indicated in paragraph 15 on page 22.

The loading deck (5) consists of a welded sheet walkway on a support frame made of section bars. The walkway is limited by a pair of fixed guards (6) along the longer sides and two access gates are provided on the shorter sides equipped with tilting bar (7) and lower walkway (8) that can be let down. As soon as the latter is opened, the lift is automatically locked.

To prevent accidental dropping on people or goods a gridiron guard (9) is installed to stop machine movement when it touches a foreign body.

Key to drawing

1. base

2. worm screws

3. vertical column

4. wall mounting

5. loading deck

6. guards

7. upper bar

9. gridiron guard

10. turning plate

8. loading ramp COPY

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The motor drive unit (11) is made up of a welded tubular bar and section bar frame. It is fitted with a series of guide rollers. It is driven by a self-acting electric gear motor (12) that enmeshes on the rack of the vertical column (3) via a pinion,.

An emergency brake (14) starts when (in descent) the normal operating speed is exceeded. A special ratchet gear for centrifugal force expands and activates the brake. If the brake is enabled, a special terminal switch stops movement.

The electric power for the gear motor is supplied via a power supply cable and controls

(15) . To prevent the cable interfering with the machinery, special cable clamps (16) must be attached every 9 m. (In windy areas at least every 6 m). The cable is gathered in a special container (17) placed on the base.

To make easier the loading and unloading of the deck, two ramps (8) are lowered to form a support deck. When the ramps are opened and closed, the movement of the lift is stopped. The lift movement is controlled via a suspended control panel (18) that is located to the ground or directly connected to the electric board during the assembly and disassembly stages of the column.

Moreover, the loading deck can be turned by 90 degrees, which allows getting closer the scaffolding or building. If the deck is not properly closed, a purposely-designed terminal switch stops any movement.

COPY electric

15.power supply cable

16.cable clamp

17.cable container

18.control panel

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8. SPECIFICATIONS

Working capacity on the storey (evenly distributed load) 300 kg.

Max. height of the vertical column:

Lifting speed:

Height of the vertical column modules:

Weight of the vertical column modules:

120 m.

20 m/min.

1.5 m/each

33 kg/each

Max. vertical distance of the wall securing bolts: 6 m.

Height from ground of the temporary assembly and disassembly bolt: 2 m.

Deck width:

Deck length:

1.5 m.

1.3 m.

Weight of the complete unit (deck at base):

Guard height:

440 kg.

1 m.

Height of the loading deck from ground (at bottom terminal switch): 0.25 m.

Three-phase electric power supply. 230/50 Hz

Voltage for low tension controls:

Electric gear motor power:

Input current while working:

Rack module:

48 Volts

2.5 kW

18 A

5 mm.

Lifting pinion teeth: N° of teeth 20

Emergency brake pinion teeth:

Outer diameter of the guide and sliding rollers:

“ “ 18

48 mm. COPY

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9. SAFETY REGULATIONS

The MB 500/120 SP RACK AND PINION HOIST has been designed and produced in compliance with the current safety regulations.

The user has to heed all safety regulations required for the type of equipment used, the work environment and the effective operating conditions, for him/herself and for other working in the vicinity.

The equipment may only be used if the following safety regulations are heeded: x The base must be installed on a sufficiently strong support surface according to the loads indicated on page 16. x The whole ground area of the equipment must be adequately cordoned off and signposted. x Access to the operating area must be reserved only to operators. x Install the special signs: “suspended loads - no access and thoroughfare - danger of falling objects - safety helmet must be worn - etc..-” x Operators must wear a safety helmet. x Connect the electric power line with the earth wire. x Check the stability of the wall on which the vertical column is to be mounted (loads applicable as per diagrams given on page 22). x Check that the accesses to the loading / unloading decks are adequately cordoned off and that these barriers can be removed only after the lift has reached its height and are compulsorily refitted when the lift is not on the storey. x The machinery assembly and disassembly workers must be supplied with a safety belt. x Do not assemble the machinery if the wind speed exceeds 40 km/hour. x Do not use the lift if the wind speed exceeds 70 km/hour. In this case the deck must be returned to the ground.

NB: Benchmark wind speed according to C.N.R.10012/85, ground roughness: cat.3-4.

MAIN SAFETY DEVICES:

The machine is fitted with the following safety devices: x Down terminal switch x Up terminal switch x Deck turning closing control sensor x Vertical column guard closing control sensor x Loading ramp closing control sensor x Emergency brake enabling control sensor x Storey stop control sensor x Up and down over-limit switch x Damped bottom buffers x Self-acting gear motor

COPY x Centrifugal mechanical brake with damped stop x Non-skid gridiron (located under the loading deck)

The lift can also be lowered even when there is no power supply, by operating the release lever of the motor brake (see relevant section).

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10. MACHINE TRANSPORTATION

The machine is delivered completely assembled (base, initial column, loading deck) and equipped with fittings, fixed to pallets with metal straps; a set of modular elements of the column is packed under the base, on the same pallet.

The other modular elements of the column are packaged (approx. 30 pieces) on another pallet.

The pallets must be unloaded and handled by a forklift truck ( min. required capacity

1000 kg. with protrusion of approx. 1.20 m).

Should machine be moved with a crane or another hook lifting tool, insert the hook only in the column flange plates as shown in the figure below. properly.

11. PACKAGING reach

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Make sure that the machine has not been damaged before delivery. If it has, immediately inform the salesperson or manufacturer before using the machine.

Check that the moving parts of the machine are fitted (adjusting screws, nuts and bolts, ramps, guards, electric system etc..) and comply with supply specifications.

Check for any discrepancies compared to the ordered equipment. If there are any, always advise the dealer or manufacturer before use.

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12. LOADING - UNLOADING SUPPORT

To make easier the loading or unloading of the lift on motor vehicles, some detachable supports can be optionally requested, which allows the operation to be carried out without using any other lifting devices.

Two uprights (1) , 1 left-hand cross-piece and 1 right-hand cross-piece (2-3) are required. Before starting any operation, unload any vertical column (with the exception of the one fixed to the base).

A. Loading the machine on a vehicle: x connect the machine to the supply mains (following the instructions detailed above). x move the deck up to about 1 m. using the control panel. x insert the left-hand cross-piece (2) in the upright (1) and lock it at the height required using the pegs supplied. The same applies to the right-hand cross-piece (3) . x fit the two units in the relevant tubes (4) welded at the bottom of the lift deck. x lower the deck so that the uprights (1) touch the ground, the base is thus lifted. Follow this procedure to reach the height required. x place the vehicle under the lift base. x start raising. The deck will now lower to allow the base to rest on the vehicle platform.

Continue this operation until the uprights (1) can be removed. Disconnect the mains supply and fasten the machine for transport.

B. Unloading the machine from the vehicle: x connect the machine to the supply mains. x follow the instructions detailed in “A” in reverse order.

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3. Right-hand cross-piece for loading-unloading support

4. Tubes to be inserted

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13. INSTALLATION

The lift must be installed only by skilled workers authorised for operation.

The machine must be installed on a floor able to bear the following loads relative to the height of the vertical column

Column height m.

1,5

25

50

75

100

120

Machine weight

Kg.

440

1090

1740

2390

3040

3560

Working capacity

Kg.

300

300

300

300

300

300

Total load

Kg.

740

1395

2040

2690

3340

4860

Lay underneath the support worm screws some shimming plates compatible with the total applied load.

The placement area must comply with the following minimum dimensions, to allow access around the machine for the various installation and operation jobs.

To assemble the machine use a pair of 24 mm. hexagonal wrenches.

.

After the above check, install the machine strictly following the guidelines below: x Lay the base on the ground. x Check that its distance from the wall is regular x x matching the type of bolting supplied ( minimum distance 50 cm).

x Use a spirit level to check the horizontal alignment of the base and the vertical alignment of the column.

Make the necessary adjustments with the 4 lateral adjusting screws the base (1) are firmly tightened. Otherwise tighten them properly. arms (9) work regularly . x Swivel the cable-guide arm (10) to its regular position and lock it.

(1) with their ring nuts (2) .

Make sure that the screws (4)

Check the access ramps x Fit the 2 nd column (11) and lock it with the screws provided.

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Caution: Regular tightening of the 4 vertical column screws ensure the necessary operating machine stability.

Periodically check they are tightened.

Only use class 8.8 (12) screws.

x Check the vertical alignment of the column again in both directions and make the necessary corrections by always turning the worm screws on the base, and finally clamping after the operation.

Before connecting the machine to the electric power line make sure that:

1. The line is regularly “earthed” and is fitted with a differential cutout switch (0.3)

2. The power supply matches the machine voltage.

3. The power supply cable is of the right width.

4. The earth wire of the machine has been connected. x About 1.3 m. above the ground attach the first cable-guide arm (1) and fix it with a clamp. x Place the box (2) of the electric power supply cable (3) to ensure that it is regularly unwound and rewound during up and down movements. x Plug the machine into the electric power line by inserting the plug (4).

x Couple the connector (5) of the control x operated . x Then enable ascent. A safety device, proximity switch, stops the vertical column motor unit from going off course.

The lift is ready for installation of the following vertical columns.

(6) fitted on the door lock mechanism of the control panel box (7) needs then to be

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14. ASSEMBLING THE VERTICAL COLUMN

After installing the base of the lift, the modular elements of the column can now be assembled. For this purpose two operators may board the lift and operate as described in this section.

!!! WARNING!!! While assembling the machine, never turn the deck, and keep it in the locked position.

The deck can be turned only after the column has been fastened to the wall through the clamps, as shown in sections 15 and 15a. x Make sure the installation procedure described above has been followed.

!!! CAUTION!!! In case of an emergency that requires the machine to be stopped immediately, press the red

STOP button located on the control board.. x Get onto the deck: by lifting the traverse bars that must then be closed again and locked using the relevant locking pegs.

!!! CAUTION!!! The vertical column, for safety purposes, must always be assembled (and disassembled) on the deck by TWO AUTHORISED WORKERS wearing a safety helmet and quick coupling safety belt x Deck operation is allowed only when the guard (1) is closed (vertical position). x Load the 1 st vertical column on the deck, lower the guard (1) . Fit and connect the 1 st vertical column with the screws provided. Close securely. x Alight and fit, 2 m. above the ground, the 1 st securing bolt (temporary safety bolt for assembly and disassembly). x Press the emergency “stop” button to stop any movement.

Start.

CAUTION: A photocell control unit built into the motor drive unit automatically stops the lift near the end of the column.

If stopped, only the deck down movement remains activated.

CAUTION: In case of accidental opening, stops due to collisions etc. all stoppers for pressed.

1. Refit and clamp the guard (1)

COPY deck.

3. Release movement by turning the “stop” button. The press

4. Then assemble the vertical columns and the first securing bolt that must be fitted 6m. above the ground..

5. Restart descent down to the ground and leave the deck to conduct the braking tests on the emergency brake (see page 19).

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14a. !!! CAUTION - EMERGENCY BRAKE TESTS !!!

The test must be conducted about every 3 months and/or whenever the machine is assembled by personnel trained in compliance with the guidelines outlined below:

To conduct the test the following conditions must be met: x The machine must be firmly secured. x The access area under the loading deck must be completely cleared and cordoned off to prevent access. x The loading deck must be raised to a height of 3.5 m. above the ground. x The machine must be unloaded. x The red emergency button must be pressed on the pendant control.

To simulate the operation of the emergency brake, the motor brake must be disabled. By disabling the brake, the loading deck accelerates down until the emergency brake is applied.

Therefore, this operation must be performed with utmost care by previously trained and authorised workers.

Take the following steps: x Take the release lever (1) that is screwed on the motor casing and screw it onto the nearby threaded hole. x Connect the lever (1) with a rope made of nylon or similar material 6-8 mm. in diameter. x Move about 3 m. from the loading deck and pull the rope. This action will open the motor brake. x At this point the machinery always descends faster until it activates the emergency brake which must be applied 2.5 m. above the ground.. The run, from when the x x x around 300 mm.

COPY x After checking the efficiency of the emergency brake, release the emergency button, press the start button ( so as to reactive the emergency brake), then lower the machine to the ground pressing first the up button and immediately afterwards the down button. x The loading deck will stop at the bottom terminal switch. x Remove the rope. Unscrew the lever (1) and place it in the casing.

NEVER LEAVE THE RELEASE LEVER COUPLED IN THE BRAKE

Should the braking of both the motor brake and of the emergency brake be either too slow or too sudden, the brake control must be adjusted by acting as described in the “NON-

ROUTINE MAINTENANCE” section.

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If you are in the assembly stage, take the following steps:

CAUTION: Load at most 3 vertical column modules on the deck.

The operators on the deck must always work with their safety belt fastened to the deck to ensure they are suspended if they slip off. x Raise the deck up to the top limit of the pre-assembled column, lower the guard (1) and couple the new module, making sure with utmost care that the screws are tightened. x To reactivate ascent, always refit the guard

(1) . x Then proceed likewise for the remaining modules up to the desired height.

!!! CAUTION!!!

2 m. above the ground the temporary assembly and disassembly wall bolt must be attached by clamping it with wall plugs or other tools as shown in the diagram on page 22. The wall or the support scaffold must be able to bear the transmitted loads.

Then attach the wall mounting at least every 6 m. x If necessary attach stroke limit stop runners on the storey (3) so as to ensure it stops at a preset height. x Make sure that the storey accesses are adequately cordoned off and fitted with warnings on special signs attached to the x inside of the building well stating “free fall hazard”. x Every 9 m. (every 6 m in windy areas) attach cable-guides (4) onto the vertical column.

After assembling the last vertical column, fit the up terminal switch runner. from the previous one is less than 6m.

After assembling the vertical column lower the deck to ground level. x Remove the control board coupled directly on the control panel. x Couple the control board onto the connector to operate from the ground.

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2-RELEASE

1-LOCK

!!! CAUTION!!!

Should the electric power supply fail while assembling or disassembling the vertical column and consequently the deck stops at a height with persons on board, the lift can be lowered by operating the motor brake:

TAKE THE RELEASE LEVER (1)

SCREWED ON THE MOTOR CASING

AND SCREW IT ONTO THE NEARBY

HOLE.

RELEASE THE BRAKE BY PULLING

THE LEVER (1) VERY SLOWLY TO

PERFORM A VERY SLOW DESCENT

(6/7 m/min.) DOWN TO THE HEIGHT

WHERE ONE CAN ALIGHT.

CAUTION

A quick descent will activate the emergency brake and therefore if there is a power failure it will no longer be possible to alight since the lift needs to move up to activate the brake.

After completing the operation reset the lever to its original position.

NEVER leave the lever coupled in normal machinery operating conditions.

!!! CAUTION!!!

From now on nobody must be allowed access to the deck. the operating area concerned.

COPY deck are very dangerous.

Moreover, before removing the bolt located 6 m. Above the ground, insert the temporary bolt (to be fitted 2 m. Above the ground).

While both assembling and disassembling the vertical column modules and the securing bolts we suggest that they be secured temporarily with a safety rope to be untied only after definitive mounting.

15. STANDARD WALL MOUNTING

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The wall mounting, that must be secured every 6 m., is used to vertically support the whole frame and is this a very important element of the machine. Therefore, very firmly tighten all screws and clamps and frequently check they are tightened properly.

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Warning!!!

Not to interfere with the bolts, fasten the release lever (a) of the turning plate parallel to the deck wall.

15a. SPECIAL WALL MOUNTING

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Place the element (1) by first loosing the screw (3) . Then place the element (2) and adjust its distance. Fit elements (1) and (2) to a wall with wall-plugs or to a metal frame with

Loosen the screw (3)

Should the lift be fitted on fixed scaffolds or a tubular scaffolds make sure that they can bear the transmitted loads.

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Warning!!!

Not to interfere with the bolts, fasten the release lever (a) of the turning plate parallel to the deck wall.

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16. TRIAL BEFORE USE

After assembling the whole vertical column and before starting up the machine, a complete up and down run needs to be completely travelled for a general check of the installation.

This specifically includes: x Checking safety devices, x Checking the vertical column has been regularly assembled, x Checking the barriers on the storeys and on the base, x Checking for any interference of the deck with obstacles present along the run, x Checking that all screws are properly tightened.

After conducting the above checks, the machine manager is advised to sign an operation authorisation form, according to the guidelines laid down.

MABER MB 500/120 RACK AND PINION HOIST OPERATION

The machine must be used only after carefully reading the following paragraphs. Should you have any doubts on lift operation or on any malfunctions that may occur immediately before operation consult the manufacturer’s technical support service.

17. MACHINE CONTROLS

In regular operation, the lift must be controlled only by the pendant control at the ground, whichis connected to the power supply functions:

(1) Stop

(2) Run

Red

Green

(3) Up

(4) Down skip).

(5) Landing skip with button No.5 (landing skip). To go downwards, press button No. 4 (down) together with button No.5 (landing

Release button No.5, just before approaching the floor where you want to land. In this way, the platform will stop at each landing stop.

The electrical panel includes a general activate power supply .

White

Black

Black

In order to go upwards, press button No. 3 (up) together

COPY doorblocking switch (pos. 7), which also works as phase inverter. Turn the general switch to

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18. CHECKS AND TIPS BEFORE START UP

Before using the lift make sure that: x All safety measures have been enabled, x The operating area is regularly cordoned off, x The storey accesses are properly closed with moving or similar barriers, x The machine is properly placed on the ground and it can bear the total weight, x The vertical column is firmly secured to the wall every 6 m., x The machine has not been tampered with, x Electric connections have been made properly, x The control board is connected, x Safety devices are enabled and in good working order (in order to try to enable the sensors of the non-skid gridiron and of the guard of the vertical column, check all movements are correctly locked). x Environmental conditions are favourable (max. wind speed of 70 km/h, etc..)

19. OPERATOR’S GUIDE

The lift operator must always do the following: x Be previously authorised for machine operation. He or she answers totally for any action performed by the equipment and is fully legally responsible. x Stand in a place where full visibility can be ensured over the whole vertical column and x x x x especially over the storey accesses.

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20. START-UP

To start up the machine: x Enable the main power knob on the control panel, x Grip the control board, x Press the start button, x Press the up button to raise the deck a few metres, x Release the control and check the machine stops regularly (must stop instantly), x Press the down button and return to the bottom terminal switch.

Repeat the above steps making sure that: x Movements are regular, x The deck stops regularly when the up and/or down button is released, x The power supply cable unwinds and rewinds regularly from its container.

Load the deck making sure that: x The required loads are compatible with the machine operating guidelines, as described in paragraph “3”. x The load is evenly distributed on the deck, x The load is stable and tied, if necessary, secured with ropes or fasteners. x After loading the access ramps and the guard upper protecting bars have been regularly closed.

!!! CAUTION!!!

In a case of emergency requiring the machine to be immediately stopped, press the red STOP button on the control board or switch off (“0”) the switch located on the main control panel. x Enable ascent until the required storey has been reached, x The exact stop at a storey is ensured by the preset moving stop switch runner: See page 24. x When the required height has been reached the operator on the storey may open the barrier, release the stop lock of the turning plate and turn the deck. x Lift the protecting bar and lower the access ramp. x Unload goods. x Refit the ramp, lower the bar again and turn the deck to the regular position again. x Close the barriers again.

21.

COPY x Lower the deck down to ground level, x Disable the main power knob on the control panel (turning it to “0”), x Unplug the control board from the power supply cable and keep it in a safe place inaccessible to other people, x Remove the power supply cable, x Take all possible measures to prevent unauthorised persons from using and gaining access to the lift.

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22. ADJUSTMENTS AND REGULATIONS

The MB 500/120 SP RACK AND PINION HOIST does not require any special adjustment after being delivered. However, if need be, take the following steps to adjust the service and emergency brakes:

A. Should the machinery not be moving and tend to slip, the service brake needs adjusting. This operation must be carried out only by the technical support centre or by a trained and authorised technician: x Lower the deck to ground level.

x Disable the electric power line by using the main power knob door lock (1) on the control panel. x Open the motor crankcase (2). x By screw the motor brake ring nut (4) with a wrench clockwise about 180° so as to increase pressure of the springs (5) on the brake disc (6) . Conduct an unloaded operation test and a fully loaded operation test. x Refit the motor crankcase and enable the main power knob of the control panel.

B.

COPY

Enable machine operation only after making sure it brakes regularly enough in all operating conditions.

These jobs must be carried out by the technical support centre or by trained, skilled and authorised personnel.

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MAINTENANCE OF THE MB 500/120 SP RACK AND PINION HOIST

The MB 500/120 SP RACK AND PINION HOIST has been designed and produced by selecting the right components to reduce maintenance to ensure its efficient operation.

However, the user has to make sure periodic maintenance is regularly carried out to always maximise machine efficiency.The simple operations and the few check required, if performed regularly let you always keep the machine in efficient and safe working order.

The main steps that the user has to take are described below.

23. PERIODIC MAINTENANCE

At least once a week and in any case always after adverse weather conditions check the whole machine.

This specifically includes: x Efficiency of electric safety devices, x Wall-mounted securing bolts are stable and tightened. t least once a fortnight, and in any case according to operating requirements check: x Screws are tightened on every vertical column and on every mounting, x Gear motor unit clamping screws are tightened, x Elements on the vertical column have not yielded, x The motor drive guide and sliding rollers regularly run on the column, x the gear motor unit works efficiently. Also check its noise level to verify the presence of any irregular clearances in the gears, x The gear reducer is correctly lubricated and motor brake works efficiently, x The emergency brake works efficiently, by greasing the pins and the ratchet gear, x the power supply cable and the control board cable are in good working order, x The whole machine is clean, especially by removing grease and oil deposits from the access ramps and x

COPY

!!! CAUTION !!!

Before carrying out any maintenance, repair or cleaning jobs under the raised deck, make sure it cannot accidentally drop by propping up the deck or locking the cart on the column.

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24. NON-ROUTINE MAINTENANCE

At least once a month, or whenever you doubt their efficiency, check the service and emergency brakes work properly.

These operations need to be performed only by trained and authorised personnel since the efficiency and safety of the machine depend fundamentally on these parts.

All maintenance jobs must be carried out with the deck on the ground, at the bottom terminal switch, and with the power off (Unplug the power supply cable and switch off the main power knob on the control panel).

Gear motor: x Change oil for the first time after 100 hours of operation. x Then change oil every 2000 hours of operation or at least once a year. x Empty and fill through the caps provided. x The gear reducer is immediately emptied after operation with hot oil to prevent deposits of dregs. x Clean the caps (especially the magnetic cap) before refitting them. x We suggest you wash with detergent before refilling with new lubricant.

Adjusting the Service Brake:

See section “22”, page 27.

Also make sure the distance between magnet and counter magnet is about 0.2 mm.. The distance is adjusted with the three screws.

Adjusting the Emergency Brake (Fall Stopper): x The machine must be lowered to ground level. x Disable the electric power line with the main power knob door lock on the control panel. x Open the emergency brake guard, by removing the x x fastening screws.

Adjust all brake disc pressure screws load has been reached.

Use the lubricator

(6).

(5) x Conduct an operational test before using the machine as described in paragraph 14 (page 19).

(4) until the required jobs must be carried out only by the technical support service who will issue a regular maintenance declaration, and enter it in this manual in the assigned spaces.

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25. TECHNICAL SUPPORT SERVICE

In all cases of non-routine maintenance (excluding the operations described above), when repairing the machine, when replacing damaged parts or defects, contact only the

Manufacturer or the official TECHNICAL SUPPORT CENTRE, represented in your country by:

Specially trained technicians are able to carry out all required MAINTENANCE jobs.

26. MAINTENANCE SCHEDULE

Dat e

Hours of operation

Type of maintenance job Operator’s signature

Result

COPY

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27. LUBRICANTS

The machine employs gear trains with maintenance-free oil-sealed ball bearings.

Lubrication must be checked and ensured only for following components:

Gear motor Only use one of the following lubricants:

Lubricant

AGIP

ARAL

BP MACH

CASTROL

ELF

ELF

ESSO

I.P.

MOBIL

MOBIL

MOBIL

SHELL

TOTAL

Temperature -20 ° / +45 °

C.

ISO 3448 VG150-220

BLASIA S 220

DEGOL GS 220

SGR XP 220

ALPHA SN 6

ORITIS 125 MS

SYNTHERMA P30

COMPRESSOR

LG150

TELESIA OIL 150

GLYGOYLE 22

GLYGOYLE 30

SHC 630

-

-

OIL

Temperature -20 ° / +5 °

C.

ISO 3448 VG100

BLASIA 100

DEGOL BG 100

GR XP 100

ALPHA SP 100

REDUCTELF SP 100

-

SPARTAN EP 100

MELLANA 100

-

-

-

OMALA OIL 100

CARTER EP 100 N

Check the oil level in the gear reducer every month.

Check levels if you notice any oil leaks from the gear reducer. Before restoring the level, check for cause of leak.

Rack Periodically lubricate the pinions of the driving cart so that they cannot work “dry” on the rack using:

- INDUSTRIAL GREASE.

Emergency brake ratchet gear

- Grease with a ball lubricator.

(5)

COPY

31

28. ELECTRICAL DIAGRAM MB 500/120 SP RACK AND PINION HOIST, ONE PHASE

~ ~

COPY

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29. FAILURES

The potential failures that may occur on the lift can mainly be attributed to the electric system. In this case is always advisable to contact the manufacturer’s technical support service.

Part Control panel

Problem The deck is jammed

Cause Electric power supply has failed.

Remedy Restore power supply.

Part Control panel

Problem The deck is jammed

Cause The fuse has broken

Remedy Replace the fuse inside the main control panel on the cart.

Procedure Open the main control panel.

!!! The operation must be only assigned to workers from the technical support service !!!

Should the deck be elevated you need to climb on it.

Take all the necessary precautions by entering from the nearest storey door.

Move along the column fastened to the safety belt.

Replace the fuse inside the main control panel.

Alternatively:

Release the service motor brake lever (see page 21).

Get down slowly and start to repair.

Part Emergency brake

Problem The deck is jammed

Cause The ratchet gear spring is broken

Remedy Replace the spring with an original part.

Procedure This operation must be carried out by an authorised and pre-trained technician .

To this purpose, move the deck to first storey immediately above.

COPY x Uncouple the ratchet gear locking the emergency brake, x tie the ratchet gear so that it will not recouple, x Climb back on the building, x Remove the section beam or plank, x Relower the deck to ground level controlling it from the ground, x Replace the spring with an original part.

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Part Service Brake

Problem Slow or inadequate braking cause Linings are worn out

Electromagnet is broken remedy Replace linings or the electromagnet. procedure This operation must be carried out by an authorised and pre-trained technician.

To this purpose, lower the deck to ground

level.

Unplug the electric power line

Descend to ground level manually

(see page 19)

Remove the gear motor (1) crankcase

Detach the cooling fan (2) , the pressure ring nut

(3) , clamping screws (4)

Slide out the electromagnet (5) , replace it and refit all parts.

Alternatively:

Slide out the disc (6) with the linings and replace it; refit all parts.

Intervention of the emergency device

The hoist is provided with an emergency device that intervenes when the hoist exceeds the speed of 20% while going down.

The intervention of the emergency device blocks the downhill of the hoist mechanically.

Call immediately the assistance service in case there are some breakdowns to the emergency device.

When the hoist is near the bottom limit switch, do a check of the emergency brake: padlock and keep the key.

- Disconnect the power supply from the cable basket. sides of the oil sump.

- Remove the oil sump and check if there are problems with the emergency brake.

- In this case call immediately the assistance service.

!!! IMPORTANT !!!

To ensure safety, reliability and the validity of the guarantee always use only original spare parts!

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30. SPARE PARTS

The technical support service normally stocks the full range of spare parts for the machine.

In the spare parts order the following items must always be quoted:

TYPE OF MACHINE

SERIAL N° (see section 2 “Machine identification)

YEAR OF MANUFACTURE

N° OF ORDERED PART (see list and diagram below)

ORDERED QUANTITY

Spare Parts Legend:

Referring to the figure on the following page.

Pos. Description

1 Base Frame

2 Base levelling jack

3 Base lavelling jack top nut

4 Base levelling jack bottom nut

5 Mast bolt and nut

Pos. Description

31 Diagonal adjustable tie

32 Plate for adjustable tie

33 Cable guide

34 Spring – platform lock

35 Protection bar for erecton platform

6 Descent limit switch skid

7 Rubber buffer

8 Mast section

9 Anti crush grid

10 Springs

11 Photocell

12 Brake spring

36

37

38

39

40

41

42

Loading ramp

Loading ramp handle

Limit switch on loading ramp

Complete control panel

Gearbox

Electric motor 240V 1ph / 400V 3ph

13 Brake lining

14 Brake wheel

15 Rachet gear- safety brake

16 Spring

17 Upper platform pivot

18 Lower platform pivot

19 Complete wheel(special plastic)

20 Steel side roller

21 Steel front roller

22 Guide roller bearing

23 Circlip

24 Safety brake pinion

25 Idler pinion

26

27

Drive pinion

Standard U-tie

28 Standard tie clamp

43

44 Cable support arm

45 Complete pendant (+5 m cable)

46 Manins connector

47

49 Levelling jack

50 Mast guard

53

54

56

Unloading support- base

Limit swicth type1

Limit swicth type3

57 Spring for loading ramp

58 Landing limit skid

29 Gear box cover

30 Straight adjustable tie

59 Guide roller short pin

60 Guide roller long pin

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COPY

36

31. DISPOSING OF THE MACHINE

When the machine in question must be definitively set up for idling it must be completely disabled and sent to a differentiated scrap recycling service in your area.

Take the following steps:

- Disconnect the electric system from the main power supply.

- Disassemble the whole column

- Remove all plastic parts of the machine (pegs, guards, cables, terminal switches etc..)

- Remove all electrical parts (junction box, connections, control board, switches etc..)

- Detach the gear motor

- Remove the gear reducer, empty oil and dispose of it only via a special waste disposal service operating in your area.

- Send the electric motor to a specific waste disposal service; unless all parts of motor

(iron, copper, other materials) can be separated to send them to differentiated waste collection.

If the unused the machine has to be preserved before it is definitively scrapped, make sure that:

- It is stored in a place that is inaccessible, especially to children, or inexpert people,

- All movements are impeded,

- It is placed stably so as to prevent accidental falls, even in case of knocks,

- All moving parts are removed (ramps and deck accessories),

- The vertical column is completely detached, stacked and strapped.

COPY

37

*

17.

2.

10.

26.

24.

19.

11.

23.

9.

21

15.

30.

15a.

8.

20.

7.

25.

16.

28.

14a.

29.

5.

6.

13.

12.

27.

4.

22.

14.

1.

18.

3.

31.

ANALYTICAL INDEX

Adjustments and regulations

Assembling the vertical column

‘CE’ Declaration of compliance

Checks and tips before use

Copy of TÜV Certificate

Description of the machine

Disposing of the machine

Electrical diagram

Emergency brake (test)

Unauthorised uses

Failures

Guarantee

How to consult the manual

Installation

Loading - Unloading support

Lubricants

Machine application

Machine controls

Machine identification

Machine transportation

Maintenance schedule

Non-routine maintenance

Operator’s guide

Packaging

Periodic maintenance

Safety regulations

Setting the machine up for idling

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“

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Page 27

“ 18

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3

25

6

5

37

32

19-20-21

8

33-34

9

9

“

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16-17

15

“ 31

“ 7

24

4

14

30

29

25

14

28

13

26

Standard wall mounting

Spare parts (spare parts list)

Special wall mounting

Specifications

Start-up

Technical description

Technical support service

Trial before use

“

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22

35

23

12

26

10-11

30

24

EMPLOYMENT AND INSTRUCTIONS OF THE SAFETY LANDING GATE

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Code C1200327

1-DESCRIPTION OF THE GATE

The gate is mainly composed of:

- n. 2 battens (upper and intermediate) made of tubular structures;

- stop band at the base;

- lateral closing hook of the gate and mechanical blocking system fixed to the gate structure. It has an appropriate mechanism that does not allow any manumission;

- lateral clamps for tightening the gate structure;

- bayonet opening of the gate which rotates around a point fixed on the lateral left standard of the gate.

2-ERECTION AND INSTRUCTIONS

The erection and the instructions for the gate block go for the safety landing gate with a width of 1300mm.

In order to assemble the gate in a correct way, please follow these instructions:

Erect all the masts useful to reach the final height for the gate employment.

Tie all the masts.

Assemble the stop landing slide (adjusting its cam) as the working floor of the transport drum exceeds of about 100mm the top of the landing floor (this operation is necessary for the use of the machine, when loaded, since this difference in level will be cancelled).

Position the landing floor (use tubes and joints) on the scaffolding or the wall. Make a structure to fix the safety landing gate that should support the load transported by the machine.

Study the following picture to know the size of the gate: COPY

39

Assemble the unblocking lever on the chassis of the transport drum by fastening it through suitable screws. This position must allow the unblocking lever to be fitted in the unblocking gate box:

Load the safety landing gate and the box with the blocking gate mechanism on the transport drum.

Come back to the landing floor.

-

Rotate the transport drum, COPY open unloading ramp unload the and the saferty landing gate at the landing floor. gate on the scaffolding or on the wall by using tubes and joints assembled before. Use all the safety belts possible safety systems (use to work in safe conditions on the scaffolding). Study the following picture for the correct position of the safety landing gate:

40

Open the gate (putting it in vertical position) and assemble the blocking gate box. Use clamps and fix them on the tube of 48mm. Follow the measures specified in the following pictures for the correct position of the blocking gate box.

Front view of the transport drum

COPY

View from the drum of the landing floor of the safety landing gate.

41

Lower the gate properly in horizontal position.

Check if the gate block respect the following features: i The central line of the upper slit is lined up to the ‘U’ blocking hook fixed on the gate. i The measures specified must be followed.

Correct any possible mistakes through proper regulations only at the safety gate.

Press lightly the safety gate in order to unblock the rotation of the transport drum.

Rotate the transport drum and go on with assembling or working operations.

Close the space (see dimension ‘x’ that changes depending on the width of the scaffolding) between the vertical tube, where the box of the gate is fixed, and the standard of the scaffolding with protections according to law, in order to avoid any dangerous situation.

In case the hoist is near a wall, and the landing is a door on the wall, follow these instructions to assemble the safety landing gate:

- Follow the operations used for its erection described before and follow the same warnings.

- In order to fix the safety landing gate assemble a structure made of two lateral tubes of 48 mm I fixed to the wall through nogs able to support the transmitted loads. The tube size is specified in the picture here. blocking gate box on the other tube and check the correct position.

Respect the hoist position as specified in the picture.

42

3- BUILDING MEASURES

1- Building measures of the blocking gate mechanism

2- Building measures of the unblocking lever

COPY

The unblocking lever is assembled on the outer side of the chassis of the front closing.

The assembly is made by using the blocking plate fixed through suitable screws.

Use the lever putting the shaped cam inside the box. Hold the unblocking lever with its handle. Keep the unblocking lever connected with the chain to the transport drum is always compulsory. It does not allow the drum to rotate when the unblocking lever is inserted and the gate is open.

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4- EMPLOYMENT

The mechanism which blocks the gates block the rotation of the drum of the rack and pinion hoist when the safety landing gate is open (in vertical position).

The operator who uses the hoist must follow these instructions:

After having loaded the hoist and closet the loading ramps, makes the hoist go upwards till the landing floor, where a safety landing gate is present, by using the pendant control at the ground level;

The safety gate must compulsory be assembled whenever a landing at a certain floor is needed;

The operator who is at the landing floor must not open the safety landing gate before having rotated the transport drum. However the opening of the safety gate is blocked by the gate block which till the drum has not been rotated;

The operator must lift the lever of the drum rotation and rotate it by nearing it to the safety landing gate;

After the complete rotation of the drum, unfasten the unblocking lever from the drum and put it on the blocking box, unblocking the safety landing gate;

The operator can open the safety landing gate (making it rotate on its left pivot) bringing it in vertical position;

After the loading and unloading operations of the transport drum the operator must close the safety landing gate before making the drum rotate. The drum can rotate only when the safety gate is closed (otherwise the drum will block and will not rotate);

The gate must be completely closed (in horizontal position) in such a way has to make the blocking mechanism spring;

The operator can remove the unblocking lever from the block box and hang it to the support on the drum after having closed the safety landing gate.

Unblock the drum rotation mechanism and bring it upwards or downwards by acting on the proper lever.

After the drum rotation it is impossible to open the safety landing gate since it has been blocked by the block gate.

After the complete rotation of the drum the operator can do the uphill or the descent of the drum to go on working. COPY

44

Position of the rack and pinion hoist during uphill and descent operations

When the transport drum is in this position it is not possible opening the safety landing gate.

When the safety landing gate is closed the drum can be rotated.

COPY

When the transport drum is not rotated and the unblocking lever is not inside the box the inner mechanism is in the same position of the above picture, thanks to its spring. In the section C-C it is impossible opening the safety landing gate because it has been blocked by the slit of the inner plate.

45

Position of the rack and pinion hoist during loading and unloading operations

When the transport drum is rotated as in the picture near here the opening of the safety landing gate is possible and the opening of the unloading ramp, too.

The opening of the gate automatically blocks the rotation of the transport drum.

Closing the safety landing gate is a compulsory operation to rotate the transport drum.

Remember to put the unblocking lever inside the blocking gate box for the rotation of the transport drum. This operation makes spring

COPY gate

When the safety landing gate is open the mobile lever, connected to the drum with a chain, blocks the rotation of the transport drum.

Anyway if someone tries to rotate the transport drum when the safety landing gate is open (see the picture above) it will be blocked by the inner lever of the blocking box that works as a stop.

Only when the safety landing gate is closed it is

46

possible to rotate the drum since the mobile lever can be taken out of the blocking box.

5- SAFETY WARNINGS

Against the fall from the landing when the gate is closed

The gate has an upper and an intermediate batten and a stop band at the base.

Follow the minimum height of the upper batten and the sizes between the battens.

The stop band at the base is of a minimum height of mm 150.

Against accidental movements (scaffolding)

The closed gate is always fixed to its two ends in such a way as to work as a scaffolding.

Against any accidental opening of the gate

The gate cannot open accidentally since it has a special lateral mechanical closing.

The bayonet movement of the gate makes it always closed thanks to its weight.

Therefore it is not allowed opening the gate accidentally.

Against the voluntary opening of the gate if the drum is not present.

The gate cannot be opened accidentally when the drum is not present thanks to the mechanical blocking system. The system allows the opening of the gate only if the drum is present since it unblocks the stop and allows the movement of the gate.

Against the hoist movement while the gate is open.

When the gate is open the drum will be blocked to the standard of the gate through the proper system of levers since the open gate does not allow any movement of the gate.

The drum movement depends on the gate closing that does not allow the uphill and descent of the drum. protection.

Against the protection dismantling and that of the opening and closing systems of the

The gate is properly fixed to the structures of the building site.

The dismantling of the protection can occur only voluntarily and by using proper working instruments.

COPY

47

DISEGNI TECNICI

TECHNICAL DRAWINGS

DESSINS TECHNIQUES

TECHNISCHE ZEICHNUNGEN

COPY

48

COPY

49

COPY

50

COPY

51

COPY

52