Professional Documents
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HAPP 35
Two Post
Hydraulic Lift
HAPP 35
Table of Contents
Introduction ................................................................................................................. 5
Hoist operation ........................................................................................................... 6
Safety Warning Signals ........................................................................................... 6
Use of the hoist ....................................................................................................... 7
Expected Rated Load Distribution ........................................................................... 7
Safety Notice Points ................................................................................................ 8
Workplace Health and Safety (WH&S) Design registration and operation.......... Error!
Bookmark not defined.
Operation .................................................................................................................... 9
Hoist Operating Procedures ....................................................................................... 9
Pre operation checks .............................................................................................. 9
Operation .............................................................................................................. 10
Maintenance ......................................................................................................... 10
Defects - Malfunctions............................................................................................ 11
............................................................................................................................... 11
Specification ............................................................................................................. 12
Example hoist operation ........................................................................................... 14
Arm Restraint ........................................................................................................ 14
Vehicle in Raised Position ..................................................................................... 15
Set on Locks ...................................................................................................... 15
Lowering ............................................................................................................... 15
Maintenance ............................................................................................................. 16
Maintenance Schedule ...................................................................................... 16
Annual Inspection .............................................................................................. 16
Maintenance by the Operator ............................................................................ 16
Troubleshooting ........................................................................................................ 18
Disposal .................................................................................................................... 19
Installation ................................................................................................................ 20
Space required ...................................................................................................... 20
INSTALLATION ..................................................................................................... 22
Hydraulic Drawing..................................................................................................... 23
Exploded drawing ..................................................................................................... 24
Controls .................................................................................................................... 27
Power unit ............................................................................................................. 27
Electrical system .......................................................... Error! Bookmark not defined.
Limit switch wiring (optional) .................................... Error! Bookmark not defined.
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HAPP 35
Electrical wiring – AS3000 ........................................ Error! Bookmark not defined.
HAPP hoist summary ............................................................................................... 31
Australian and CE Standards ................................................................................... 32
Site inspection and preparation .............................................................................. 33
Installation............................................................................................................... 35
Installation Procedure ......................................................................................... 35
Hoist operation ........................................................................................................ 42
HAPP Installation Frequently asked question (FAQ) .............................................. 45
What oil do I use? ................................................................................................. 45
What is the easiest way to add oil? ...................................................................... 45
How much oil do I need ? ..................................................................................... 45
How do I install anchor bolts?.............................................................................. 45
What are the top tips for installing my hoist? ......................................................... 46
The balance cables don’t fit, one side seems shorter than the other ? ............ 46
The fittings on the pump assembly are loose. .................................................. 47
The hose does not reach the fitting on the pump assembly. ............................ 47
The hose fitting supplied is different to the one on the pump assembly. ........ 47
My carriage won’t come down when I first lift the hoist? ................................ 48
Some customer customizations ................................................................................ 49
Make use of the power and column position ............ Error! Bookmark not defined.
Custom door protection ......................................................................................... 49
Custom vehicle connectors ................................................................................... 49
Be happy and enjoy your HAPP hoist ................................................................... 50
To Our Customers..................................................................................................... 51
Safe operating procedures and installation ............................................................... 51
Introduction
In this manual, contents about safety should be paid special attention. Here are
some signals used in this manual.
The figure appearing before passage shows that it is not allowed to operate according
to the passage, or the potential risk will develop into big casualty and heavy damage
to the lift.
The passage besides this signal lists the notice points and security
●Though we have taken the safety into consideration during designation and
produce, some training is required before operating the hoist. Without reading this
manual, do not operate or maintain the lift.
●Read the requirement for power source and electric current on the nameplate of
motor, and make sure that the power is connected by a specialized electrician.
●The manufacturer is not responsible for giving notice of any further change on
partial structure of the lift after selling the lift.
● This hoist is rated at 4 T capacity any vehicle whose weight is above 4000kg is not
allowed to be raised on this machine.
ⅱ. Operators should be familiar with all functions and operating methods of the lift.
ⅳ. If there is any abnormal sound during rising and lowering, stop using the lift.
ⅴ. Never use the lift to raise a vehicle whose weight is above 4ton.
• After raising the vehicle briefly, stop and check adapters for secure contact.
• Once the disk adapters contact the lift points, operators should check arm
restraints for engagement.
• Make sure the vehicle doors are closed during raising and lowering cycles
Ensure you have read and understood all manuals and safety procedures.
Ensure any maintenance and repairs have been completed and signed off.
Equipment:
Check:
Continually check for balance and rigidity of vehicle on hoist before lifting to operating height.
Raise:
Lower:
Maintenance
Follow the HAPP user guides for regular planned maintenance. Ensure checks by competent persons
are performed at regular intervals or in the event of any accidental damage.
Hydraulic oil:
ISO grade 46 grade hydraulic oil is recommended for this hoist.
Environment:
This hoist is not designed to be operated for outside, steam cleaning or high moisture or harsh
environments. Vehicle hoists installed in such environments are not covered by HAPP warranty.
Only HAPP hoists that are registered with HAPP and Workplace Health and Safety are to be used in
business premises. In these locations the HAPP registration label will be affixed to the hoist and
supporting documentation is to be held on the business premises.
This document does not relieve the owner / operator of its legal responsibilities in accordance with
the Workplace Health and Safety Act 2011.
Unloading Handle
HAPP 35
Height overall 2722 mm
Raising / Lowering time Approx. 50s
Lifting height max. 1800 mm
Lifting height min. 110 mm
Support arm reach 695…920 mm
Support arm reach 795…1120 mm
Inside columns 2728 mm
Drive-through clearance 2480 mm
max.
Load capacity 4000 kg
Net weight 547kg
Anchoring M20 Tru bolt
Motor power 2.2kW
Rated current 14.6A
Power supply 240V or 415V
50Hz
Once the disk adapters contact the lift points, operators should check arm restraints
for engagement. If necessary, slightly move the arm until the gear segments mesh.
Never unlatch the arm restraints when the lift is under load.
Each support arm is provided with an automatic arm restraint which unlatches
automatically when the lift is in bottom position. When the carriages are in a raised
position, the arm restraint can be disengaged by pulling the Pull Handle.
Pull Handle
1. Fully lower the lift and swing arms to full drive- through position.
2. Slowly position vehicle midway between adapters. Apply the parking brake.
3. Swing and telescope arms as required to position adapters to manufacturer's
recommended lift point.
4. Turn the disk adapters that they evenly contact all four lift points.
5. Leave vehicle and remain clear of lift.
During raising and lowering cycles: Closely watch the vehicle and the lift, do not allow
anyone to enter or stay at lift area and make sure the vehicle doors are closed. Once
the disk adaptors contact the lift points, operators should check arm restraints for
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engagement. After raising the lift briefly, stop and check the adaptors for secure
contact.
1. Push and hold GREEN button until lift reach desired height.
Lift stops once button is released
5. Fasten the vehicle to the support arms using lashing straps when removing or
installing heavy components
Set on Locks
Use the Unloading Handle to set the lift on the mechanical locks.
In this way the vehicle can be securely fixed when the vehicle is in a raised position.
Lowering
Raising and lowering cycles: Closely watching the vehicle and the lift, do not allow
anyone to stay in lift area and make sure the vehicle doors are closed
• Remove tools, stands or other objects from lift bay.
• Lift is ready for operation
• If the safety plate is in the engaged position, briefly raising the lift before
lowering.
• Pull the unlocking steel wire on both columns
• Press the Unloading Handle until lift reaches desired height
• Lift stops once Relief Handle is released or downward travel limit is
reached. During lowering cycles the support arm automatically stop at a
height of 110mm.
• To lower the arm completely, please release the Unloading Handle.
Swing arms to full drive-through position and drive the Vehicle off the lift
In case of motor defect or power failure the lift can be lowered manually.
Authorized personnel only! Do not restart the lift before the error has been remedied.
If the lift load lies fully on the safety plates, manual lowering is not possible.
Maintenance Schedule
Establish a periodic preventive maintenance procedure to ensure trouble free
operation and long service life.
Annual Inspection
We recommend that the lift should be inspected by qualified service personnel every
12 months.
Hydraulic System
1 Once a year check the fluid level (see below) with the lift fully lowered and
add fluid as required
2 Visually check all hydraulic hoses for tightness.
The hydraulic fluid must be replaced periodically depending on aging, soiling and
water absorption. It is recommended to replace the pressure hoses as required, but
after six years at the latest
Checking the Fluid Level
The fluid level can be read through the transparent reservoir at the power unit.
With the lift fully lowered, the fluid level must reach above the min level.
Greasing Points
Sliding Tracks
The slide tracks inside the columns should be greased every six months (or more
frequently in case of noise generation).
Slightly grease the slide tracks and the whole length using a brush
Arm Extensions
The arm extensions should be greased every six months (or more frequently in case
of sticky arms.
If arms are stuck, sometimes weld slag can be caught in the arm, the arm should be
removed inverted (upside down) and worked in and out till free.
Arm Restraints
Weekly check the arm restraints for secure
engagement.
Lift Stability
1 Every six month check the nuts of all anchor bolts for correct installation torque
2 Retighten them as requirement
Installation Torque
HAPP 35 80Nm
Cleaning
Do not use high pressure / steam jet cleaners or caustic cleaning agents.
1 Periodically wash off aggressive substances and treat the lift with oil or wax
spray.
2 Repair damage to the paintwork immediately to prevent corrosion. The RAL
number is available through the manufacturer.
Space required
The lift must be installed on a level concrete floor, detailed data of which as shown in
the following drawing
.
The lift installation concrete surface must be perfectly smooth.
hoist.Make sure you measure the size of your dyna bolts before
selecting your drill bit. Typically HAPP hoist shipments are 20mm in
size (M20). These diagrams show 18mm (M18) bolts, these can be
supplied as options if required.
Note: M20 – 20mm tru bolts are supplied with HAPP hoists.
Power unit
Control unit
Some HAPP motors are supplied with an additional connector that bridges the A2
connector as shown below.
This white connector is used to attach an limit switch to the hoist. In cases where this
connector is not required, bridge(connect) these two wires to disable the connector.
Important:
The limit switch is wired to the top crossbar on HAPP 40.
Ensure the hoses are pulled to the top of the column and that the limit switch wires
are not held in the hydraulic line clamps. If they are remove them and attach to hose
with cable ties.
Motor
Connect to: 3/L2 5/L3
Chassis
Each HAPP hoist uses dual hydraulic rams (one in each column) to lift the carriage
which has the lifting arms connect to them. The ram lifts by pushing a heavy duty
chain connected to the column on one side to the carriage on the other side. Each
hoist has dual safety interlocks (one on each column) which engage independently
as the hoist lifts.
There are three basic styles of 2 post hoists available from HAPP. Floor plate,
Hydraulic and Clear floor styles.
o The floor plate style (Happ30, 35, 70 and 80) connects the columns
with balance cables that balance the load across the hoist carriages
and hydraulic hoses for lifting across the floor protected by a checker
plate cover between the columns. This plate is approximately 50mm in
height and has an angled surface on each side to enable easy drive
through with vehicles.
The column height of these hoists range from 2.72m to 2.85m
depending on model. The column widths of these hoists range from
3.26m to 3.41m depending on model.
o The typical clear floor style (Happ40 and 60) connects the columns
with balance cables that balance the load across the hoist carriages
and hydraulic hoses for lifting protected by a section of U shaped bar
across between the columns at the top of the hoist. The connection
at the top of the column enables the floor to remain clear but introduces
a height restriction. The connecting bar also provides a load sharing
function as each column now has a strut connecting them at the top as
well as the floor via concrete.
The column height of these hoists are 3.68m. The column widths of
these hoists are 3.44m
o The hydraulic hoist style (HAPP 90) uses a hydraulic control valve to
balance the load between the columns by managing the pressure
supplied to the hydraulics. It is a clear floor style hoist also.
The column height of the HAPP 80 is 2.02m with variable column
width.
The HAPP 90 uses loxon fitting bolts (anchor bolts can be used). The
loxon bolts act like a nut rather than a bolt. Whilst the actual bolt in a
loxon is 16mm in diameter the hole size required is 24mm to allow for
the nut size.
4. Height of enclosure. Your shed should allow enough room for the top of the
hoist to clear the roof by 100mm when installing. This will allow for the removal
of the hoist after it is bolted to the floor (otherwise you will not be able to lift the
column off the mounting bolts).
5. Confirm vehicle clearance. Locate the position of the hoist intended for
installation. Draw a template on the ground with marking chalk and confirm the
height for clearance to the roof, and horizontal distance for clearance at each
end of the vehicle. Vehicles are lifted from the central point of gravity which is
typically around the middle of the driver’s door (between A and B pillars of
car). This will impact the clearance at the front and rear of the vehicle.
Measure the distance from the midpoint of the door to front and rear of floor
and confirm clearance at ground level and at maximum lift height.
6. Confirm the maximum lift height clearance for vehicle by measuring the
distance from the lift position to the ground. HAPP pads are typically around
110-120mm from ground level when in the lowered position. If your lift position
is 200mm then your total possible lift height will be higher by 80mm than
specified. This is not normally an issue however in some cases when you
have a high vehicle and a clear floor model you may need to allow for this. In
this case if you vehicle is a van with 2 meters in height for example, the clear
floor hoist has a cut out sensor bar that will stop any vehicle hitting the cross
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bar. Its height is normally 3.68m, but in this case the maximum lift height of
the hoist will be less than the maximum possible height.
7. Confirm Ground clearance for vehicle. HAPP pads will typically install at
around 110-120mm clearance. Whist they can be modified to fit under lower
cars this is typically not the best approach as the pads and lift arms take the
weight of the vehicle and should not be modified. (HAPP considered the
engineering of slimmer arms in this area and decided that it is better to have to
raise some cars rather than compromise standards.) Most customers either
make or purchase vehicle ramps which will raise the vehicle the minimal
amount required to clear the hoist. This is a very simple approach which works
well.
Installation
You will need the following items for hoist installation:
ISO grade 46 hydraulic oil Shell Telus 46 or equivalent
18 mm -20mm concrete drill bit depending on model (24mm for happ90
loxons). We recommend a trade quality bit, not the cheap brand. Note,
always measure your supplied anchor bolts before purchasing a concrete bit.
The bit should be the size measured allowing the bolt to neatly fit into the
hole.
Specialized hammer drill (not a standard hand drill with hammer setting)
Socket for anchor bolts / loxon (depending on your model sockets are
typically 24 - 26 24mm)
Builders level (for column alignment)
Assorted open end spanners for nuts on pump assembly, balance cables,
release cables (single point release models), hose fittings.
Read over the installation procedure below before you start to familiarize
yourself with the process.
Installation Procedure
1. Unpack the hoist. The hoists are packed head to tail held in a steel shipping
frame. The components to assemble the hoist are mostly pre-assembled,
however some of the parts for assembly are placed inside the columns such
as arms, pads, anchor bolts and hoses. Unpack the contents of the hoist that
can be easily removed, often the arms can be lifted out of the column reducing
the weight of the column for subsequent steps.
2. Remove the frames. Support the hoist top that is connected to the top of the
frame (remember the hoist is packed head to tail). Then remove the bolts
holding the frame. Do the same for the other end. Failure to support the
column puts weight on the frame which will likely lead to scratching the hoist
as you remove the frame.
3. Move the columns apart and remove the remaining loose pieces from inside
the column.
4. Stand the columns up near the installation point. To stand up the column it is
best to get three capable people and slowly walk the column up to the upright
position.
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Note: The columns can be moved by fork lift, trolley before standing up or
walked after standing up by carefully edging the corners to the column toward
the desired location.
5. Mount the slave column that does not contain the pump / motor unit in place
with two anchor bolts. Anchor bolt holes should be drilled through the hole in
the base plate to ensure correct alignment. Drilling from markings on a floor
often leads to subtle misalignment which will prevent the anchor bolt from
being inserted. Make sure you install the anchor bolts using the process
below. A anchor bolt should be fully inserted before tightening, measure the
depth of the hole with a bolt and drill further if necessary. Sometimes it is
difficult to get the cement dust out of the hole. Loosening the dust with a screw
driver, blowing or vacuuming often helps. The bolts will be driven in with the
nut on using a solid sledge hammer. The bolts must be tight in the hole and
will tighten up quickly during the tightening step. Do not use a ratchet gun in
this step.
6. Tighten the anchor bolts in place and verify the column is plum or slightly
angled outwards as shown below. Use shims to get the correct alignment if
necessary.
Fixed
clip
Hydraulic
hose
Power Hydraulic
unit Cylinder hose
T-fitting
Elbow
Hydraulic fitting
hose
Elbow
fitting
12. Fit the safety release cables (single point release models only). The safety
release cable are connected via a small cable that is routed from the release
lever across to each safety location. A number of these are assembled during
Figure: Single point release cable routing for HAPP 70 floor plate hoist
13. Lay out and connect the balance cables (wire rope) (not required for HAPP
90). The balance cables are designed to align the levels of the carriage and
distribute the load so the carriages lift evenly. Do not tighten the balance
cables fully at this stage.
Lift each carriage up until both safety latches engage about 400-800mm or
onto two blocks of equal height to enable the cable to be routed more easily.
The cables are installed so that one side pulls the other side if it is not aligned.
The pulley systems for both clear floor and floor plate models route the cable
from the bottom of one carriage through pulleys to attach from the top to the
other carriage. As the carriage is raised if the other carriage is not raising at
the same rate the cable will pull the other carriage up. The cable attached from
the bottom will be doing the pulling as the hoist lifts.
Conversely as the carriage is lowered if one carriage is lowering faster than
the other it will pull down on the cable attached from the top, pulling the other
carriage down by the other end of the cable which is attached from below the
carriage. These points are important when fine tuning the carriages to lift and
lower at the same time using the adjustment nuts. Once balance cables are
connected the safety latches can be released or blocks can be removed and
the carriages lowered to the floor.
Cylinder Nut
14. Install the floor plate. (Floor plate versions only. The floor plate will likely fit
exactly into position which confirms the correct location of the main column
from the slave column.
15. Install the main column anchor bolts. Drill and install anchor bolts for the
main column in the same manner as described previously.
16. Finish installation of slave column. Drill and install remaining anchor bolts
for the slave column in the same manner as described previously.
17. Assemble the arms: Attach each arm to the carriages. For hoists with smaller
arms or angled (asymmetrical arms) they are placed on the end of the hoist
that will lift the engine side of the vehicle. Remove the circlip from the base of
the pin, apply some grease to the carriage, arms and pin and knock the pin in
with a hammer. (the pins are often tight fitting)
18. Assemble the lock out pins. These pins are inserted behind the arm locating
pins on the carriage. They will lock into position once the carriage is lifted and
will be in operational when the carriage is in the lowered position so you can
move the arms underneath the vehicle.
19. Install the pump / power unit. Locate the pump assembly onto the main
column with four bolts and connect the hydraulic line from the pump to the ram
on that side. A qualified electrician will connect the power to the single or
three phase connection depending on the choice made. Some models have a
an extra white connector extending from the motor switch; these two wires in
the plug are connected to the lock out sensor which routes from the top bar on
the clear floor hoists. On floor plate hoists these two wires are bridged
(connected) to allow the pump to operate.
20. Lubrication: apply grease to chain and cables, particularly where they contact
the wheels. Apply grease and oil/ WD 40 lubricant to the inside of the column
where the carriage will ride.
21. Check all oil fittings for a tight seal. There should be no oil leakage from
joints.
22. Fill the oil container with 10L of ISO grade 46 oil. Shell Telus 46 or an
equivalent 46 grade oil should be used.
Hoist operation
The hoist is now fully installed and ready for its first test operation. This is where we
fine tune the installation and fix any problems.
These tests should be repeated monthly.
1. Pump - Motor operation:
a. Check all fittings to pump assembly are tight (they are typically loose as
fittings may need to be swapped from side to side for some hoists and
other hoists have different fittings to standard.)
b. The qualified electrician will check that the wiring to the pump is
correct
Adjusting the balance cables to synchronize the lifting and lowering allows the
safety latches to engage at the same time.
Test:
o The carriages are not rising evenly; one carriage is slow, it is behind the
other fast carriage.
Loosen the lowering cable and tighten the lifting cable on the fast carriage.
Re check tension of cables as before
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o The carriages are not lowering evenly, one carriage is slow it is behind the
other fast carriage
Loosen the lowering cable and tighten the lifting cable on the slow carriage
Re check tension of cables as before
6. Column mounting
e. Lift different weights on hoist starting with light increasing to normal load
weight
Test:
f. Check that anchor bolts are at correct tension
Re tension anchor bolts
g. Check surrounding concrete for any cracks or deterioration.
Stop all tests, footings are not sufficient for the hoist.
h. Check column level is the same as installed
i. Check location are correct. If columns are shifting at all stop all tests and
check footings / anchor bolts are stable.
j. Continue to recheck the bolts for sound fixing and tight location of nuts with
vehicles loaded for the first week and at regular intervals during operation
of hoist.
The bolts must be a firm fit into the hole, it may require a solid firm hit with a
decent hammer to drive them through, make sure you put the nut and washers on
before hitting them thru, in case you mis hit and damage the thread.
Do not drill pilot holes in cement, measure the bolt size and use the appropriate
bit. Some of the bolts have the size stamped on them, but they are hard to find.
Note : Do not use sleeve anchor type bolts with automotive hoists.
Floor plate hoist, what is the white connector on motor for, or my motor is wired up
but will not start?
Clear floor hoists use this limit switch connector provided on the motor (the white
connector), it should be disabled on other models. Whilst this is specified in the
manuals, electricians can miss this. To disable the connector the wires need to be
closed (joined / bridged) which then enables motor operation. Connect the two
wires and pull them inside the cover, if you decide to add a limit switch, use this
cable.
Floor plate hoists do not need the limit switch connector provided on the motor
(the white connector), disable the connector by bridging (Connecting the two
wires , pull them inside the cover), if you decide to add a limit switch, use this
cable.
Drill your anchor bolt holes right through the cement if possible, the anchor bolts
can then be removed by hitting them through into the underlying soil
The balance cables don’t fit, one side seems shorter than the other ?
Typically the cause of this is that the cables are not routed correctly. Check the
pulleys and cables to locate where the cable may not be fitted correctly.
The hose does not reach the fitting on the pump assembly.
As pumps are fitted to different models the hose fitting can be on the wrong side.
The hose fitting can be located on either side of the pump assembly. To swap the
sides, swap the hose outlet with the plug outlet on the opposite side.
The hose fitting supplied is different to the one on the pump assembly.
As pumps are used on different models the fittings can be different. In these
cases the fitting is supplied in the parts supplied with the hoist, remove the black
fitting on the pump assembly and replace with the fitting supplied in the parts.
To Our Customers
We try our best to provide customers with specific
information for installation, operation and maintenance to
ensure that you can use the machine without mistakes. If
you have any questions during installation and
operation, we’ll be glad to help you.
This document does not relieve the owner / operator of its legal
responsibilities in accordance with the Workplace Health and
Safety Act 2011.