Herkules Hebetechnik GmbH K1200-HLS-61 Operating Manual And Test Record Download Page 1

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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: [email protected]
Internet: www.herkules.de

Summary of Contents for K1200-HLS-61

Page 1: ...erial 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 ...

Page 2: ...2 ...

Page 3: ... 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 ...

Page 4: ...xiting 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 Regula...

Page 5: ... 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 __...

Page 6: ... 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...

Page 7: ...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 Te...

Page 8: ...ting 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 Loca...

Page 9: ...e 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 scop...

Page 10: ...ssors 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 prof...

Page 11: ...08 IND 004 3 K 1208 IND 006 3 Assembly plan K 1208 HLS 003 3 K 1208 HLS 005 3 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 K 1208 HLS 034 3 K 1208 HLS 035 3 Pneumatic circuit diagram K 1208 008 4 K 1208 008 4 K 1208 HLS 042 3 K 1200 HLS 012 3 Pneumatics spare parts K 1208 008 4 K 1208 008 4 K 1208 HLS 042 3 K 1200 HLS 012 ...

Page 12: ... 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...

Page 13: ...enance 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...

Page 14: ...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 t...

Page 15: ...ng Herkules service assemblyman qualified person Fault clearance Herkules service assemblyman qualified person Servicing Herkules service assemblyman qualified person Maintenance Herkules service assemblyman qualified person Repairs Herkules service assemblyman Disassembly Herkules service assemblyman qualified person Operating individuals in training should only operate the lifting platform when ...

Page 16: ...not attempt to use the product Immediately contact Herkules customer service 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 Do not send back damaged goods before receiving confirmation from the customer service centre 7 2 Disposal of the packaging materials The packaging material must be disposed of i...

Page 17: ...s solely responsible for the selection of the installation location The service lift must only be used within a temperature range of 5 C to 65 C During the selection of the assembly location bear in mind the measurements of the service lift that are outlined in the chapter on Technical data as well as the chapter on Additional information take note of the measurements with a lifted vehicle as well...

Page 18: ...ing content Detailed assembly see chapter additional information 3 Screw in hose barb 1x Hose barb 1 2 4 Connect platform sided hose line 1x Rubber hose 16mm 1x Rubber hose 8mm 1x Hose connector 6mm 2x Hose clamp 10 16 1x Hose clamp 16 25 5 Connect platform sided hose line Connect pneumatic line provided by the customer 1x Operator control module 1x Hose clamp 10 16 1x Hose clamp 16 25 ...

Page 19: ...tion on 8 Screw together cantilever with the platform main body 6x Hexagon screw M12x40 6x Nut M12 12x Ring washer 13mm Important Put in the screws by yourself 9 Install roll off protection stop side Notice running direction 2x Plate roll off protection 4xHexagon screw M10x30 4x Nut M10 8x Ring washer 10 5mm 10 Ramps holder running side Notice running direction 2x Plate roll off protection 4xHexag...

Page 20: ... Interim drive over ramps Tilt up interim drive over ramp 2x Folding ramp 13 Adjust lifting platform Mount lifting platform Boreholes 16mm 4xHexagon screw 12x100 4x Ring washer 13mm 4x Dowel S16 14 Install hose lines Shorten in case it is necessary Install operator control module Mounting material Provided by the customer ...

Page 21: ...kaging content Detailed assembly see chapter additional information 3 Screw in hose barb 1x Hose barb 1 2 4 Connect platform sided hose line 1x Rubber hose 16mm 1x Rubber hose 8mm 1x Hose connector 6mm 2x Hose clamp 10 16 1x Hose clamp 16 25 5 Connect platform sided hose line Connect pneumatic line provided by the customer 1x Operator control module 1x Hose clamp 10 16 1x Hose clamp 16 25 ...

Page 22: ...l module Open stopcock hand operated lever in the switch position on 8 Picture Screw together cantilever with the platform main body 6x Hexagon screw M12x40 6x Nut M12 12x Ring washer 13mm Important Put in the screws by yourself 10 Picture Install operator control module 4x Plate roll off protection 8xHexagon screw M10x30 8x Nut M10 16x Ring washer 10 5mm 11 Picture Mount drive on ramps 4x Drive o...

Page 23: ... Insert grids 4x Grid 367x887mm 2x Grid 490x920mm 13 Adjust lifting platform adjust on substructure Provided by the customer Mount lifting platform Boreholes 16mm 4xHexagon screw 12x100 4x Ring washer 13mm 4x Dowel S16 14 Install hose lines Shorten in case it is necessary Mount operator control module Mounting material Provided by the customer ...

Page 24: ... layers Optional accessories grounding item number see chapter additional information Hints for grounding All grids are reliable with the help of the optional accessories components attached to the main body cantilever and connected with each other The grounding line of the installed grids for ground connection on the main body must be properly connected metallic contact Pneumatic lines from the l...

Page 25: ...e familiar with the operating instructions 9 1 Description of Control Elements The service lift is actuated with either the hand lever valve or the foot pedal The control valve has three settings with relevant markings lift 0 position and lower A stable framework protects the control valve The pressure gauge shows the amount of pressure in the air bags No Description Additional information 1 hand ...

Page 26: ... the operating instructions for the respective work places on the service lift Only the operating personnel may stand in the vicinity of the service lift while in use Also read the Chapter General Safety Instructions 9 3 Description of safety catch During lifting the safety catch is swivelled down The catches of the safety catch slide on both sides of the detents of the inner scissoring After the ...

Page 27: ...must be raised see picture interim drive over ramp in normal position Picture 7 8 Interim drive over ramp in the basic position interim drive over ramp is folded down 9 6 Function protective flaps HLS1200 64 The protective flaps on the cantilever of the lifting platform satisfy an important safety feature You prevent the retraction of lifting platform in the pit grid russeting of accidental clampi...

Page 28: ...l and lifting ceases Lifting automatically stops once the maximal lift height is achieved Care must be taken during lifting that the safety catch is securely engaged in the gear teeth on each side after each lifting movement especially between movements smaller than the lift max This is noticeable through a clearly audible clicking sound 9 8 3 Lowering the lift platform Areas subject to danger mus...

Page 29: ... when install or dismantle heavy parts Thereby the vehicle can tilt over the lifting platform 9 10 End of work After completing work with the service lift the following points should be adhered to The service platform must be in the lower end limit Close the main tap of the operating control unit Guard the main tap from unauthorized use with a padlock not included in delivery Diagram 9 Operating u...

Page 30: ...re 1 bar above allowable pressure of the safety valve Make sure there is a mains pressure of Pmax 8 bar Open the shut off valve Check the hose lines and if necessary replace them with new ones Check the safety valve for contamination and replace if necessary Malfunction while lowering Lift platform is resting on top of an obstacle Safety catch engaged Raise the lift platform remove the obstacle an...

Page 31: ...ments Monthly All moveable parts such as pivot bolts sliding pads and sliding surfaces should be check for wear and tear cleaned and lubricated Check air bags and air tubes for any damages Visually inspect and check for leaks Examine the surface of the air bags for impurities then clean and maintain Inspect valves for functionality and check for leaks Check that the dowels are properly fixed If ne...

Page 32: ...eplaced Only original parts from the manufacturer are permitted to be used 11 2 Notice about filter regulator and air line The filter regulator is not included in the scope of delivery of the lift platform A filter regulator must be installed in the mains connection provided by the customer Only dehumidified non lubricated compressed air should be used Follow maintenance and cleaning of the filter...

Page 33: ...earing pins below right and left Check the safety washers from both of the bearing pins for proper fit lubricate bearing pin 5 sliding pads and guide rails above right and left Check sliding pads for damage and wear Lubricate sliding pads and guide rails 6 bearing pin safety catch right and left Check the safety washers from both of the bearing pins for proper fit lubricate bearing pin 7 air bags ...

Page 34: ...operation and safety inspection After the first commissioning check at regular intervals in accordance to 10 2 BetrSichV German Plant Health and Safety Regulations The use of which can be found under the section regular safety check Chapter regular safety check Document the condition of the service lift in a separate copy and attach it to the operating instructions and inspection log Regular safet...

Page 35: ...emark Nameplate Sign with lifting capacity Sign with bar mains pressure Operating instructions abbreviated Designation lift lower Secure fit of all supporting screws Safeguard of the scissor pins condition of the pneumatic lines safety valve set to 3 5 bar operating pressure Pressure gauge bar mains pressure Pmax 8 bar Control lever returns automatically to the 0 position when released Safety catc...

Page 36: ...steps in the assembly instructions found in Chapter Assembly instructions in the reverse order The safety regulations in Chapter General Safety Instructions must be observed when disassembling the system 13 2 Disposal The service lift must be disposed of in accordance with the current environmental and disposal guidelines ...

Page 37: ...0 socket ISO 3547 18 x 20 x 15mm 690 147 830 181 5 Middle bolt K1208 Set of pins complete with socket and grease nipple 3000 0012 6 Thrust bearing bolt below K1200 socket ISO 3547 18 x 20 x 15mm 690 139 830 181 7 Double air bag K1208 15733 8 Sliding piece 695 000 9 Safety valve set up on 3 5 bar 700 171 10 Anti drop safety device K1200 K1208 DUO 15362 11 Pneumatic cylinder drop safety 710 124 12 A...

Page 38: ...protection nut M12 DIN985 600 114 6 10 Ring washer 13 DIN125 650 113 12 11 Hexagon screw M10x30 DIN933 500 099 8 12 Hexagon protection nut M10 DIN985 600 110 8 13 Ring washer 10 5 670 112 16 14 Hexagon screw 12x100 DIN571 505 125 4 15 Ring washer 13 DIN9021 660 113 4 16 Dowel S16 810 155 4 17 Hose connector for rubber hose 6mm 730 318 1 18 Hose barb 1 2 a x 16mm 730 048 1 19 Hose clamp 10 16x9 720...

Page 39: ...IN933 500 177 6 10 Hexagon protection nut M12 DIN985 600 114 6 11 Ring washer 13 DIN125 650 113 12 12 Hexagon screw M10x30 DIN933 500 099 8 13 Hexagon protection nut M10 DIN985 600 110 8 14 Ring washer 10 5 670 112 16 15 Hexagon screw 12x100 DIN571 505 125 4 16 Ring washer 13 DIN9021 660 113 4 17 Dowel S16 810 155 4 18 Hose connector for rubber hose 6mm 730 318 1 19 Hose barb 1 2 a x 16mm 730 048 ...

Page 40: ...1 Air sleeve double lift 15773 1 2 Safety valve set up on 3 5 bar 700 171 1 3 Pneumatic cylinder drop safety 710 124 1 4 Hose package incl Mounting materials 3000 0003 1 5 Operator control module manual operation Optional foot operation 300 249 1 6 Maintenance unit provided by the customer 6 5 3 1 2 5 ...

Page 41: ...ir sleeve double lift 15773 1 2 CE control Pneumatic plate 300 293 1 3 Safety valve set up on 3 5 bar 700 171 1 4 Pneumatic cylinder drop safety 710 124 1 5 Roll switch with retaining tab 15875 1 6 Operator control module manual operation CE stop version 300 341 1 7 Maintenance unit provided by the customer 1 2 5 4 6 7 3 ...

Page 42: ...ADDITIONAL INFORMATION 42 Dimensions installation pit HLS1200 64 66 ...

Page 43: ...ADDITIONAL INFORMATION 43 Dimensions substructure HLS1200 64 66 ...

Page 44: ...ADDITIONAL INFORMATION 44 Schematic diagram installation HLS1200 64 66 ...

Page 45: ...ADDITIONAL INFORMATION 45 Dimension sheet HLS 1200 61 ...

Page 46: ...ADDITIONAL INFORMATION 46 Dimension sheet HLS 1200 64 66 ...

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