FREEWAY S180 Mobile Service Manual Download

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995367 – Revision A

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7.0 – Spare Parts List

The parts listed below are all the spare parts a service engineer requires to perform a service on a
Freeway S180 Mobile Hoist.

Part Code

Description

360901

Leg Actuator Cover

123082

Leg Actuator Lead (1250mm)

123100

4 Way Handset (Battery & Service LED)

123106

4 Way Control Box (LCD & Data Logging)

360902

LH Leg Assembly

360903

RH Leg Assembly

360904

Leg Actuator Kit

360905

Lift Actuator Kit

360906

Mast Fixing Kit

360907

Front Castor Kit (Pair)

360908

Rear Castor Kit (Pair)

360909

Freeway S180 Base Assembly

360910

Freeway S180 Boom Assembly

360911

Freeway S180 Carry Bar Assembly

360912

Freeway S180 Mast Assembly

510005

Battery Pack (2.9 Ah Lead Acid)

510091

Mains Snap Lead

510092

Charger Lead (UK Plug)

520034

Lift Actuator Lead (700mm)

999004

Freeway S180 User Manual

992004

Freeway S180 Spare Parts Manual

Summary of Contents for S180 Mobile

Page 1: ...Doc No 995004 Revision of document A Rev Date 07 05 2021 S180 Mobile Hoist Service Manual ...

Page 2: ...oist E Stop button not working 11 8 7 Hoist Leg Actuator is not responding 12 8 8 Hoist has Power but does not respond to Handset commands 12 8 9 Hoist doesn t respond to the correct Handset commands 13 8 10 Troubleshooting Hoist Safety Mechanisms 13 9 0 Servicing Removal and Replacement 14 9 1 Battery 14 9 2 Cables 15 9 2 1 Cables Handset 15 9 2 2 Cable Lift Actuator 16 9 2 3 Cable Leg Actuator 1...

Page 3: ...ervice for the end user 2 0 Safety Precautions Read and understand this manual in its entirety before servicing the Freeway S180 Hoist Freeway authorised personnel must complete the Full Service of the Freeway S180 Hoist The Hoist must not be in use by the user during any form of servicing Ensure that the all servicing procedures are followed correctly as instructed in this Manual All listed tools...

Page 4: ...Check all pivot points for wear Ensure all Hand Knobs are functioning as intended and without damaged thread Ensure Handgrips are attached and or in an acceptable state Control Box and Battery Inspect the components for damage that may affect the function and safety of the product Check Emergency Stop Function is working Ensure the Hoist is capable of charging Check that the LED and LCD when appli...

Page 5: ...from any obstacles 2 Using the handset raise the Carry Bar to the upper limit Listen for unusual noise 3 Lower the Carry Bar to bottom limit and ensure that the actuator lowers smoothly without resistance 4 Using the handset open the legs to their widest position 5 Apply the brake to the rear castors 6 Using a calibrated 180Kg weight stack Position it perpendicularly under that Carry Bar 7 Attach ...

Page 6: ...llen Key 4mm Allen Key x2 5mm Allen Key 8mm Spanner 13mm Spanner Small Flat Head Screwdriver Circlip Pliers Long Nose Pliers Equipment Required Marker Pen Cloth Lint Free Cloth Test Weights 180Kg Weight Trolley Lifting Straps x2 Attach Weight to Carry Bar Vernier Calliper Sundries Required Loctite 243 Morris Grease K42EP or equivalent New tech lubes ltd Silicon Grease FS SILL Tech or equivalent ...

Page 7: ...l within the community the device is being used within If there is any uncertainty of the below guidelines contact your local authorities to determine the proper method of disposal of potentially biohazardous parts and accessories The relevant components utilised in the manufacture of the device that can be recycled at the end of the device life are Fully recyclables Consideration when Recycling S...

Page 8: ...x LCD Data Logging 360902 LH Leg Assembly 360903 RH Leg Assembly 360904 Leg Actuator Kit 360905 Lift Actuator Kit 360906 Mast Fixing Kit 360907 Front Castor Kit Pair 360908 Rear Castor Kit Pair 360909 Freeway S180 Base Assembly 360910 Freeway S180 Boom Assembly 360911 Freeway S180 Carry Bar Assembly 360912 Freeway S180 Mast Assembly 510005 Battery Pack 2 9 Ah Lead Acid 510091 Mains Snap Lead 51009...

Page 9: ...d 2 Check the Handset is correctly connected to the correct control box port 3 Check the Handset lead is not damaged e g cuts and breaks 4 Check to see if hoist battery is out of charge and requires charging 5 Check the Battery is located correctly on top of the control box 6 Check for any damage to the battery terminals e g burns and breaks 7 Perform a visual check on the Control box for any dama...

Page 10: ...ble Attachment 4 Connect the Battery correctly to the Control Box as shown in section 9 2 4 5 Replace the Battery see section 9 1 6 Replace the Control Box see section 9 3 7 See section 9 2 4 on Charger Lead replacement 8 See section 9 1 on Battery replacement 9 See section 9 3 on Control Box replacement 8 3 Hoist doesn t lift Attempt to raise lower hoist with handset but hoist is not responding T...

Page 11: ...n Lift Actuator replacement 2 See section 9 3 for guidance on Control Box replacement 8 5 Hoist is functioning but LCD and or LED is inactive Attempt to raise lower hoist with handset the Hoist does perform commands but the LCD Display does not respond or LED light has no colour Follow the Troubleshooting Guide below Troubleshooting Guide 1 Check LCD Display or LED externally for any impact damage...

Page 12: ...mmissioning 6 See section 9 6 for guidance on Leg Actuator replacement 7 See section 9 3 for guidance on Control Box replacement 8 8 Hoist has Power but does not respond to Handset commands Attempt to raise lower Carry Bar and Open Close Legs with the handset but hoist does not respond There is Power as the LED indicates when the Hoist charges Troubleshooting Guide 1 Check that the E Stop button h...

Page 13: ...cables are connected to the correct port in the Control Box Action Guide 1 Re route the power cables to the correct ports in the Control Box See section 9 2 for correct Cable Routing 8 10 Troubleshooting Hoist Safety Mechanisms Hoist doesn t not lower while Hoist is in use When this occurs the Manual E Lower can be used to safely lower the patient The manual E Lower mechanism is situated at the to...

Page 14: ... Hoists remember to remove the charger lead and remove any external power source Prior to any servicing the Emergency Stop Button on the Control Box must be activated to remove any power to the product 9 1 Battery This section will instruct the correct procedure on how to remove and replace the Battery Removal Step 1 Grab the Battery in the same fashion as shown in the image below Step 2 Press the...

Page 15: ...fitting the Cables for servicing procedures or replacement 9 2 1 Cables Handset Removal Step 1 Remove the Handset connecter from the Control Box by pulling downward out of the Port Step 2 Unhook the Handset from the Hoist Refitting Replacement Step 3 Refitting is a reversal of the removal process noting the following points A Align the Handset connecter as shown in the image with the locator facin...

Page 16: ...able which ports the Control Box by pulling downward This is the middle Control Box Port as shown in the image Step 2 Release the cable from the Actuator by lifting the locking device upward it is recommended a flat head screwdriver is used Step 3 Pull the cable outward away from the Actuator to remove ...

Page 17: ...rsal of the removal process noting the following points A When fitting the Cable into the Actuator port ensure the locator is facing away from the Actuator 9 2 3 Cable Leg Actuator Removal Step 1 Remove the Jack End of the Cable which ports the Control Box by pulling downward This is the port on the right hand side of the Control Box as shown in the image ...

Page 18: ...emoval for correct refitting and replacement 9 2 4 Cable Charger Removal Step 1 Where Applicable turn the charger off at the wall plug and remove Step 2 Detach the Charger lead from the Snap Lead by pulling them apart as shown Step 3 Detach the Snap Lead from its latch circled in the image below and pull the lead connecter from the Control Box as arrowed Step 4 If the Plug has not already been rem...

Page 19: ...s or replacement Removal Step 1 Remove the Battery from the Hoist Refer to section 9 1 Step 2 Remove all the Cabling leads from the Control Box Refer to section 9 2 Step 3 Use a 3mm Allen Key to remove the Screw fixing the Control Box to the Bracket Step 4 Lift the Control Box from its positioning on the Bracket to remove Refitting Replacement Step 5 Refitting is a reversal of the removal process ...

Page 20: ... replacement Removal Step 1 Remove the Battery refer to section 9 1 Step 2 Remove the Cables Leads from the Control Box refer to section 9 2 Step 3 Remove the Control Box refer to section 9 3 Step 4 Using a 3mm Allen Key and an 8mm Spanner remove the three circled screws and nuts to release the Attachment Bracket Refitting Replacement Step 5 Refitting is a reversal of the removal process ...

Page 21: ...1 Remove the Lift Actuator Cable See section 9 2 2 Step 2 Remove the Four Black Caps from the Actuator fixing points Step 3 Using two 5mm Allen Keys remove a screw and washer from one end of the Actuators top fixing point as shown Step 4 Pull the Pin out from the top fixing to release the top end of the Actuator Once this pin has been removed the boom will need manual support to disallow it from f...

Page 22: ...e Hoist Refitting Replacement Step 7 Refitting is a reversal of the removal process noting the following point A Ensure the Actuator is fitted in the correct orientation With the LIANK Specification label facing towards the rear castors of the Hoist B Ensure the Nuts are tight and secure the Actuator do not over tighten as this will bend the framework and will affect the functioning of the Actuato...

Page 23: ... to section 9 2 3 Step 2 Follow steps 1 4 from section 9 12 Base Removal to detach the Mast and Base correctly Step 3 Remove the Leg Actuator Cover Refer to section 9 8 Step 4 Place the Base on its side for easier service access Step 5 Using Long Nose Pliers bend the two retaining ends of the retaining clip forward to straighten them to allow removal Step 6 Grab the retaining clip from the looped ...

Page 24: ...clip from both pins securing the actuator to both legs Step 8 Place the Base upside down to allow for easier servicing of the Leg Actuator Step 9 Slide the pin out to release the Actuator Repeat for the second fixing point Step 10 Use a 10mm Spanner to remove the Bolt shown ...

Page 25: ... of 39 Step 11 Use a positive head screwdriver and remove the two screws retaining the metal bracket Step 12 Using two 10mm Spanners remove the bolt and nut shown Step 13 The Actuator will slide out of its fixing point as shown ...

Page 26: ...Ensure that the two leg fixing points are aligned correctly and that the actuator slides into position on the centre bracket of the base C When fixing the bolt below ensure that the two washers and nut are used in the correct order bolt washer base washer and nut D When fixing the Actuator and Pins to the Leg fixing points ensure to use brand new retaining clips to secure the Actuator DO NOT reuse...

Page 27: ...installing the Carry Bar for servicing procedures or replacement Removal Step 1 Remove the two Black Caps from the Carry Bar Bumper Cover Step 2 Using circlip pliers remove the circlip from one end of the Carry Bar retaining pin Ensure to grab the nylon washer Step 3 Pull the Pin out from the Boom to release the Carry Bar ...

Page 28: ...tite 243 to the thread of the Pin 9 8 Leg Actuator Cover Within this section it will explain the correct procedure on removing and reinstalling the Leg Actuator Cover for servicing procedures or replacement Removal Step 1 Follow steps 1 4 from section 9 12 Base Removal to detach the Mast and Base correctly Step 2 Place the Base on its side for easier service Gently rest the Base on its side to avo...

Page 29: ...s securing the plastic cover on the Actuator Step 7 Detach the Leg Actuator Cable from the connectors The Brown from the Red and the Blue from the Green Step 8 Refit the small plastic cover back to the Actuator when finished Unless a new cable is being fitted immediately If so continue through these steps and refit the cover during the fitting of the new cable ...

Page 30: ...f the removal process noting the following point A Pull the Leg Actuator Cable through the Leg Actuator Cover and place the connectors through the black nut Secure the Cable by threading the nut onto the white plastic thread that is placed on the cable B When attaching the fixing the cables Ensure the Red and Brown are connected together and the Green and Blue DO NOT circuit these cables incorrect...

Page 31: ...ce a 5mm Allen Key into the countersunk bolt and use a 13mm Spanner on the underside of the Castor as shown and loosen Step 3 Remove the nut and washer from the securing bolt as shown Remove the castor from the bolt Refitting Replacement Step 4 Refitting is a reversal of the removal process noting the following point A Attach the Castor in the correct order as shown Bolt Hoist Leg bumper castor wa...

Page 32: ...e a 5mm Allen Key into the countersunk bolt and use a 13mm Spanner on the underside of the Castor as shown and loosen Step 3 Remove the nut and washer from the securing bolt as shown Remove the castor from the bolt Refitting Replacement Step 4 Refitting is a reversal of the removal process noting the following point A Attach the Castor in the correct order as shown Bolt Hoist Leg bumper castor was...

Page 33: ...d Base correctly Step 3 Remove the Leg Actuator Cover Refer to section 9 8 Step 4 Remove the Leg Actuator Refer to section 9 6 Step 5 Remove the Front Castors Refer to section 9 9 Step 6 Remove the Rear Castors Refer to section 9 10 Step 7 Remove the Bolt from the Leg as shown in the image with a 5mm Allen Key Step 8 On the inside of the leg align the frame hole with the hole of the internal boss ...

Page 34: ...g from the Base Refitting Replacement Step 11 Refitting is a reversal of the removal process noting the following points A Ensure the boss remains within the leg when attaching to the base B Apply a suitable amount of Loctite 243 to the bolts when fixing ...

Page 35: ...e Base for servicing procedures or replacement Removal Step 1 Unplug the Leg Actuator Cable from the Control Box Step 2 Remove the Mast Base connector Bolt by twisting the Star Knob anti clockwise until the bolt detaches Step 3 Remove the Star Knob from the Base Step 4 Raise the Mast of from the Base by lifting it vertically upward ...

Page 36: ...emoval process noting the following point A Ensure the Star Knob is fully tightened to disallow any play between the Mast and Base of the Hoist 9 13 Boom Within this section it will explain the correct procedure on removing and reinstalling the Boom for servicing procedures or replacement Removal Step 1 Remove the Lift Actuator Cable See section 9 2 2 Step 2 Remove the Lift Actuator See section 9 ...

Page 37: ...3mm Allen Key into the hole at the back of the boom to lock the inner threaded boss This will allow the screws to be removed Step 6 Using a 6mm Spanner remove a bolt from the Boom as shown Step 7 Using a 6mm Spanner remove the second bolt from the Boom to release ...

Page 38: ...ing procedures or replacement Removal Step 1 Remove Battery from the Hoist Refer to section 9 1 Step 2 Remove all the Cabling leads from the Control Box Refer to section 9 2 Step 3 Remove the Control Box from the Hoist Refer to section 9 3 Step 4 Remove the Lift Actuator from the Hoist Refer to section 9 5 Step 5 Remove the Boom from the Hoist Refer to section 9 13 The Carry Bar will not need to b...

Page 39: ... contained in this assembly and installation manual no liability can be accepted by Freeway for any errors or omissions Freeway operates a policy of continuous improvement Specifications and other data are subject to change without notice Unit 1 Tir Llwyd Industrial Estate St Asaph Avenue Kinmel Bay Conwy LL18 5JZ ...

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