Herkules Hebetechnik GmbH K1200-HLS-64, K1200-HLS-61, K1200-HLS-66 Operating Manual And Test Record

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Operating manual and test record

for

service lift

Machine type

Article No.

Serial No.

K1200-HLS-61

HLS 1200-61

K1200-HLS-64

HLS 1200-64

K1200-HLS-66

HLS 1200-66

HLS1200-61-64-66_2012.06_760-070_2.0_EN

Herkules Hebetechnik GmbH Falderbaumstraße 34 D - 34123 Kassel Tel.: +49 (0)561 58907-0 Fax: +49 (0)561 58907-34 E-mail: info@herkules.de Internet: www.herkules.de

OPERATION AND SAFETY INSPECTION

Table of contents

1 Operation and Safety Inspection ................................................................................... 5

2 General information ....................................................................................................... 6

2.1 Hazard warnings .................................................................................................... 6

2.2 Limitation of liability ................................................................................................ 6

2.3 Copyright ................................................................................................................ 7

2.4 Terms of guarantee ................................................................................................ 7

2.5 Customer service ................................................................................................... 7

3 Master data sheet.......................................................................................................... 8

4 Product description ........................................................................................................ 9

4.1 Intended use .......................................................................................................... 9

4.2 Product structure .................................................................................................. 10

4.3 Technical data ................................................................ ................................ ...... 11

4.4 Product designation ............................................................................................. 11

5 EC Declaration of Conformity ...................................................................................... 12

6 General safety instructions .......................................................................................... 13

6.1 Operator’s duty of care ......................................................................................... 13

6.2 Operator’s duties .................................................................................................. 13

6.3 Basic safety measures ......................................................................................... 14

6.4 Requirements of operating personnel .................................................................. 15

7 Transport and preparation ........................................................................................... 16

7.1 Transport inspection ............................................................................................. 16

7.2 Disposal of the packaging materials..................................................................... 16

8 Installation and Assembly ............................................................................................ 17

8.1 Environmental conditions for assembly ................................................................ 17

8.2 Assembly instruction HLS1200-61 ....................................................................... 18

8.3 Assembly instruction HLS1200-64 / 66 ................................................................ 21

8.4 Grounding, electrostatic charge ........................................................................... 24

9 Operation .................................................................................................................... 25

9.1 Description of Control Elements ........................................................................... 25

9.2 Commissioning ..................................................................................................... 26

9.3 Description of safety catch ................................................................................... 26

OPERATION AND SAFETY INSPECTION

9.4 Loading ramps ..................................................................................................... 27

9.5 Function interim drive over ramp (HLS1200-61) .................................................. 27

9.6 Function protective flaps (HLS1200-64) ............................................................... 27

9.7 Function CE-Stop (HLS1200-66) ......................................................................... 27

9.8 Operating ............................................................................................................. 28

9.8.1 Use of the lifting platform: ............................................................................ 28

9.8.2 Lifting the platform: ...................................................................................... 28

9.8.3 Lowering the lift platform: ............................................................................ 28

9.8.4 Exiting the service platform .......................................................................... 28

9.9 Working on the lifted vehicle ................................................................................ 29

9.10 End of work .......................................................................................................... 29

10 Troubleshooting........................................................................................................... 30

10.1 Possible problems and their resolutions............................................................... 30

11 Maintenance ................................................................................................................ 31

11.1 Air bags characteristics and durability .................................................................. 32

11.2 Notice about filter regulator and air line................................................................ 32

11.3 Notice about the sliding area of the scissors ........................................................ 32

11.4 Lubrication and test points ................................................................................... 33

12 Safety Inspection ......................................................................................................... 34

12.1 Regular safety check ............................................................................................ 35

13 Disassembly and Disposal .......................................................................................... 36

13.1 Disassembly ......................................................................................................... 36

13.2 Disposal ............................................................................................................... 36

14 Additional information .................................................................................................. 37

OPERATION AND SAFETY INSPECTION

1 Operation and Safety Inspection

Carried out by the manufacturer to check the following details:

Following plates present:

 Nameplate  Operating instructions (abbreviated)  Lifting capacity  Bar mains pressure  Raise "up",- lower "down"  Company logo  CE marking

Operation and safety checked:  Safety valve set to 3.5 bar operating pressure

Inspected:

 Unladen function test  Safety catch function  The control valve automatically goes into the 0 position  No damage to the surface of the air bags  Secure fit of all supporting screws  Safeguard of the scissor pins  Condition of the pneumatic lines (proper position and do not leak)  Function loading ramps  Function Roll-off protection  Function folding ramp

Serial No.: See cover sheet

Date: ____________________

Name: ____________________

Herkules Hebetechnik GmbH Falderbaumstraße 34 D - 34123 Kassel Tel.: +49 (0) 561/58907-0 Fax: +49 (0) 561/58907-34

GENERAL INFORMATION

2 General information

The operating instructions (and test log book) contain important information concerning the installation, and ensure safe, proper, and economical operation as well as preservation of operational safety. Observance of these operating instructions will help you to avoid danger, reduce repair costs and downtime as well as to increase the life of your service lift.

As evidence of regular safety checks this test log book contains a form. This should be used to provide documented details of tests. (It is advisable to make a copy of the form before starting to fill it out.)

Installation and testing Safety-related work and safety inspections may only be performed by suitably trained personnel. In this

documentation, personnel are designated as expert and qualified persons.

2.1 Hazard warnings

To identify hazardous areas and important information, the following symbols with the described definitions are used. Please pay special attention to text sections marked with these symbols.

Signifies danger for life and limb, meaning improper execution of the process

referred to by the symbol may be fatal!

Signifies a notification of a key function or an important notice!

2.2 Limitation of liability

All details and indications in this operating manual were compiled taking into account the applicable standards and regulations, and the latest technology as well as our many years of insight and experience. The manufacturer accepts no liability for any damage caused by:

 Failure to adhere to the operating manual  Improper use  The intervention of non-qualified staff  Arbitrary alterations  Neglecting maintenance

GENERAL INFORMATION

2.3 Copyright

These operating instructions are to be treated as confidential and are solely intended for personnel working with the machinery. Transfer of the operating manual to third parties without the written consent of the manufacturer is prohibited.

Text, drawings, images and other illustrations are copyrighted and intellectual property rights apply.

2.4 Terms of guarantee

The terms of guarantee are included as a separate document in the sales brochures.

2.5 Customer service

For technical information, please contact our customer service centre as follows:

Customer service:

Herkules Hebetechnik GmbH Falderbaumstraße 34 D - 34123 Kassel Tel.: +49 (0)561 58907-0 Fax: +49 (0)561 58907-34 E-mail: info@herkules.de

MASTER DATA SHEET

3 Master data sheet

Name; Type: ..................................................

Serial No.: See cover sheet

Manufacturer: HERKULES Hebetechnik GmbH Falderbaumstr. 34 D-34123 Kassel

Intended use:

The lift with air bag and scissor system is a lifting machine for lifting vehicles with a permissible load capacity (see technical data) of a maximum load distribution of 3:2 in the driving direction or 2:3 against the driving direction.

Any construction-related modifications as well as basic repairs are to be recorded on

this master sheet!

Changes to the construction, testing by experts, re-commissioning

(Date, type of change, expert signature)

....................................................................................................................................................................

Name Address of assessor

....................................................................................................................................................................

Location Date Signature of assessor

PRODUCT DESCRIPTION

4 Product description

4.1 Intended use

The lift is exclusively intended for lifting vehicles (passenger cars) with a maximum nominal load (see chapter on Technical data).

Lifting individuals and other objects is prohibited. Working under a lifted vehicle and during the lifting and lowering movement is not permitted. Operation may only be performed by persons who have read and understood the operations manual and

who are more than 18 years of age. Vehicles may only be lifted at the desgined lifting points (at framework or on the wheels). It is only allowed

to lift vehicles as stated in the operating instructions. The products described in these operating instructions can be used in explosion hazardous areas and are

subject to the Directive 94/9/EC. Measures to protect against explosion hazards are required. See Chapter

"general safety information" and Chapter "Installation” for further information.

The marking of the equipment is Ex II 3G c IIA T4

The lifting platform is part of the machinery group II, category 3; used in general industry in Area 2 for gases of explosion group IIA c = constructional safety T4 = up to 135 ° C surface temperature

Version as a category 2 is available upon request The scope of intended use also includes the reading of the current operating manual as well as compliance

with all the indications included in the same – particularly safety instructions. The scope also extends to ensuring that all inspection and maintenance operations are implemented within

the prescribed time periods. If the vehicle lift system is not used according to its intended use, safe operation of the system cannot be

guaranteed. In the event of any accident resulting in personal injury or damage to property resulting from improper use,

the operator of the lifting system shall be responsible and not the manufacturer!

PRODUCT DESCRIPTION

4.2 Product structure

The vehicle lift consists of a pneumatically operated platform main body on one hand and of a cantilever set on the other hand lifting the vehicle directly by the wheels.

The air bag performs an axial stroke movement that is carried out laterally by the scissors. The scissors also restrict the lift height of the service lift. A safety catch prevents the service lift from sinking in the case of deflation.

The operation of the service lift ensues with an operating unit that is connected to the lift via two pneumatic tubes (air bags / safety catch).

Technical data about the service lift is available in the Technical data Chapter. You will find reference to professional assembly in the Mounting Chapter.

Diagram 1: Product HLS1200-61

Diagram 2: Product HLS1200-64/-66

PRODUCT DESCRIPTION

4.3 Technical data

Technical changes

reserved.

HLS 1200-61

HLS 1200-64

HLS 1200-66

Lifting capacity of the service lift

2500 kg

Empty weight of the service lift

750 kg

Maximum load distribution

3:2 in or against the driving direction

Lifting time of the service lift

approx. 15 sec.

Lowering time of the service lift

approx. 20 sec.

Effective stroke of the service lift

825 mm

Height of the service lift

930 mm

825 mm

Insertion height minimum/ overhead height

105+5 mm

Length of the base body

1597 mm

Width of the base body

1126 mm

Total length

3545 mm

3550 mm

Total width

1955 mm

Gear

pneumatic (2 air bags)

Operating pressure for the safety valve

3.5 bar

Pneumatic connection to supply system P

max

8 bar (provided by the customer)

Noise pollution under

70 dB(A)

Dimension sheet

K 1208-IND-002-3

K 1208-IND-004-3

K 1208-IND-006-3

Assembly plan

K 1208-HLS-003-3 K 1208-HLS-005-3

Fitting frame for grids Fitting frame for foundation

K 1208-HLS-034-3 K 1208-HLS-035-3

Pneumatic circuit diagram

K 1208-008-4

K 1208-HLS-042-3 K 1200-HLS-012-3

Pneumatics spare parts

K 1208-008-4

K 1208-HLS-042-3 K 1200-HLS-012-3

Spare parts lifting platform

K 1208-IND-002-3

K 1208-IND-004-3

K 1208-IND-006-3

Safety devices

Anti-drop safety device

Yes

Safety valve

Yes

Roll-off safety device (vehicle)

Yes

Safety equipment mechanical

Yes

Protective frame

Safety equipment pneumatical CE stop with aucoustics signal

Yes

Stop of lifting

platform 120mm

before stroke end

4.4 Product designation

The details of the lifting platform are stated on the type shield on the machine frame as well as in the EC Declaration of conformity.

Article No.

Year of construction

Machine type

Operating pressure

Serial No.

Vers.

Lifting capacity

Empty weight

Details Nameplate

EC DECLARATION OF CONFORMITY

5 EC Declaration of Conformity

set out in Annex II A of the EC Machinery Directive (2006/42/EC)

The manufacturer

Herkules Hebetechnik GmbH Falderbaumstraße 34 D - 34123 Kassel

Herkules Hebetechnik GmbH

is responsible for the documentation and declares that the following machine described,

the service lift

machine type K 1200-HLS-61 K 1200-HLS-64 K 1200-HLS-66

Art.- No. HLS 1200-61 HLS 1200-64 HLS 1200-66

Serial No.: See cover sheet See cover sheet

complies with the Health and Safety requirements of the following EC directives:

Machinery Directive 2006/42/EG Directive 94/9/EG Ex II 3G c IIA T4

Applicable harmonised standards:

EN 1493 EN 292; EN 294; EN 349 EN 1127-1

Vehicle lifting platform Safety of machinery; safety distances Potentially explosive atmospheres

EC type examination

Test certificate no.

K1200-HLS-61 K1200-HLS-64 K1200-HLS-66

44 205 10377 991-006 44 205 10377 991-006 44 205 10377 991-006

Testing laboratory

TÜV Nord Cert GmbH

Any construction-related modifications, which affect the technical data specified in the operating instructions and thus significantly alter the intended use of the machine, shall render this declaration of conformity null and void!

Kassel, 15.07.2010

Location, Date René Bartsch, executive direct

GENERAL SAFETY INSTRUCTIONS

6 General safety instructions

6.1 Operator’s duty of care

The lifting platform was designed and built taking a hazard assessment into account and following careful selection of the harmonised standards to be met, as well as additional technical specifications. It thus corresponds to the state of the art and guarantees the utmost level of safety.

However, this safety level can only be reached during practical operation, when all measures required have been implemented. The Due diligence is required on the part of the operator of the lifting platform, to plan these measures and ensure their implementation.

The operator must, in particular, ensure that

 The lifting platform is only used as intended (see chapter on Product description).  The service lift only be used in a fully functional and fault-free state and will be checked regularly for

operational functionality with special attention to safety equipment.

 The placement of the service lift is located and designed so that the operator is able to observe all

movements of the load as well as have an overview of the area under the lift and its load. The operator is responsible for supplying adequate lighting.

 Access to the danger area (area under the lifting platform and under the load) by individuals is forbidden.

Operations in the danger area are prohibited. Maintenance operations are excluded, (see Chapter on Maintenance).

 The operating instructions are to remain fully readable and available in the area in which the lifting

platform is used.

 The lifting platform is only used by individuals having read and understood the operating instructions.  Personnel are to be regularly instructed of all relevant information regarding work safety and

environmental protection and familiar with the operating instructions and the safety notices therein.

 Only qualified individuals and experts may repair the lifting platform.  None of the safety and warning notices linked to the lifting platform are to be removed and must remain

readable.

 No interference with the service lift (for example, repairs) should take place without adhering adequately

to protective measures (safeguard the base from sinking with a service support).

6.2 Operator’s duties

The operating safety ordinances are intended for the operators of work equipment used in vulnerable areas. The operator must take a risk assessment of the area where the work equipment (service lift) will be used.

The dangers that arise during the use of the work equipment related to the substances and working environment should be detected and taken into account.

The operator shall take the measures necessary and choose operating equipment suitable for the conditions prevailing at the workplace and assure the safety and health of employees.

For the execution of risk assessment and decision on suitable equipment, the operator must apply countryspecific guidelines and standards.

GENERAL SAFETY INSTRUCTIONS

6.3 Basic safety measures

When operating the service lift, the statutory accident prevention regulations in accordance with BGV A1 (General requirements) apply. Regulations BGR 500 (operators of work equipment) can be used for information purposes.

The operator is to monitor the vehicle during lowering and lifting.

Service lift parts such as air bags or air bags must be protected while working with high temperatures (welding, grinding, etc.) and from mechanical and chemical damage.

Compliance with the following points is particularly emphasised:

 The service lift is only is only to be used for lifting passenger cars.  The total weight of the lifted car may not exceed the stipulated lifting capacity, whereby a maximum

load distribution of 3:2 in the driving direction or 2:3 against the driving direction is permitted.

 While operating the service lift, instructions in the operator's manual are to be complied with.  Only persons who are 18 years old or older and instructed in the use of the service lift are permitted

to use it.

 During lifting and lowering movements, no person other than the operator may stand in the way of the

area of movement for loading and service lift.

 The transport of passengers on the service lift or in the car being lifted is prohibited.  Climbing on the service lift or in the car being lifted is prohibited.  Following any modifications to the construction and repairs to load-bearing parts, the service lift must

be inspected by an expert. Changes and repairs must be recorded on the master data sheet.

 In the event of modifications (i.e. repairs) appropriate safety measures must be met. (Safeguard the

base from sinking with a service support.)

 Sufficient clearance between low lying vehicle parts and the service lift should be ensured before

lifting begins.

Not complying with the safety regulations can cause serious injuries as well as damage to the lifted vehicle.

Make sure that the front wheels are in the straight-ahead position. Before lifting, prevent the vehicle from rolling away. Pull the hand brake and shift the car into reverse or first gear. For vehicles with automatic transmission shift the car into the P position.

GENERAL SAFETY INSTRUCTIONS

6.4 Requirements of operating personnel

The lifting platform must only be used by individuals who have been suitably trained, instructed and authorised. These persons must be familiar with the operating manual and proceed in accordance with the same. The respective authorisations of the operating personnel are to be clarified.

Moreover, for the following activities, specific qualifications are required:

Operation

Execution

Installation