FREEWAY S180 Mobile Service Manual
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FREEWAY S180 Mobile Service Manual

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S180 Mobile
Hoist
Service Manual
Doc No. 995004
Revision of document: A
Rev Date: 07.05.2021

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Summary of Contents for FREEWAY S180 Mobile

  • Page 1 S180 Mobile Hoist Service Manual Doc No. 995004 Revision of document: A Rev Date: 07.05.2021...

  • Page 2: Table Of Contents

    Contents 1.0 – Introduction ..................................3 2.0 – Safety Precautions ................................3 3.0 – Annual Servicing ................................4 4.0 – Test Procedure .................................. 5 5.0 – Tools, Equipment and Lubricants Required for Servicing....................6 6.0 – Decommissioning ................................7 7.0 – Spare Parts List .................................. 8 8.0 –...

  • Page 3: Introduction

    This Manual will explain how to carry out interim servicing and parts replacement on the Freeway S180 Mobile Hoist safely and effectively. This document is divided into sections to help a Service Engineer find the correct information. Each section will show in a step by step fashion the correct way to disassemble and assemble the Hoist.

  • Page 4: Annual Servicing

    3.0 – Servicing To be completed by Approved Service Engineer Maintenance should be completed by an approved service engineer every 6 months to ensure the products required standard is maintained. The service history of the product should be documented each service. When Servicing the Hoist, ensure to fill out the Service Log which is located in the back of the User Manual.

  • Page 5: Test Procedure

    Carry Bar: Check that the Carry Bar is able to swivel 360 degrees with ease. This should be done with and without load. Inspect the functionality of the Spring Clips, ensure they return to position once operated, they should be touching the inside of the Carry Bar.

  • Page 6: Tools, Equipment And Lubricants Required For Servicing

    5.0 – Tools, Equipment and Lubricants Required for Servicing When carrying out work on the Freeway S180 Mobile Hoist you will require the following: Tools Required 3mm Allen Key 4mm Allen Key x2 5mm Allen Key 8mm Spanner 13mm Spanner...

  • Page 7: Decommissioning

    6.0 – Decommissioning When the Hoist has completed its life cycle and can no longer perform to its intended use safely the Hoist must be decommissioned by an approved Service Engineer. The following specifies the importance of correct disposal procedure including local laws and being environmentally friendly. Please observe the local laws on recycling and respect the current laws for disposal within the community the device is being used within.

  • Page 8: Spare Parts List

    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 &...

  • Page 9: Troubleshooting

    For guidance on how to dismantle the hoist to perform troubleshooting actions, see section 9.0 – Servicing. If the fault is not found and/or the solutions do not correct the problem, contact your local Freeway authorized dealer immediately – contact details are provided on the last page of this manual.

  • Page 10: Hoist Doesn't Charge

    8.2 - Hoist doesn’t charge Connect the Hoist charging lead from the Hoist to the Wall Socket. (Ensuring that the lead is connected properly) to determine if the Hoist charges. If the control box LED does not illuminate a steady orange, follow the Troubleshooting Guide below. Troubleshooting Guide 1.

  • Page 11: Hoist Doesn't Lift Load Correctly - Stop/Start Action

    Action Guide 1. Remove the Hoist from charge. 2. Connect the Lift Actuator Cable correctly. See section 9.2.2 for guidance. 3. Replace the Cable. See Section 9.2.2 for guidance. 4. Replace the Lift Actuator. See Section 9.5 for guidance. 5. Replace the Control Box. See section 9.3 for guidance 6.

  • Page 12: Hoist Leg Actuator Is Not Responding

    8.7 - Hoist Leg Actuator is not responding Using the Handset the Hoist Lifting/Lowering function is working but the Powered Leg does not respond to commands. Follow the Troubleshooting Guide below. Troubleshooting Guide 1. Check Cable between the Control Box and the Leg Actuator is connected correctly. 2.

  • Page 13: Hoist Doesn't Respond To The Correct Handset Commands

    6. Replace the Control Box. See section 9.3 for guidance. 7. See section 9.2.1 for guidance on Handset attachment. Note: Bear in mind this error could be to a specific button on the handset while the other buttons still function. Follow the same procedure. 8.9 –...

  • Page 14: Servicing - Removal And Replacement

    Hoist. The step by step process is to be followed in sequence to perform a successful service on the Hoist. Unless stated otherwise, all images refer to a Freeway S180. NOTE: Before carrying out any work on a Freeway S180 Hoists, remember to remove the charger lead and remove any external power source.

  • Page 15: Cables

    A) Reposition the Battery above the Control Box – Push the Battery inward and the Battery will “click” into place. 9.2 – Cables In this section it will explain the correct procedure on removing/ refitting the Cables for servicing procedures or replacement. 9.2.1 –...

  • Page 16: Cable - Lift Actuator

    9.2.2 – Cable – Lift Actuator Removal Step 1 – Remove the Jack End of the Cable 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.

  • Page 17: Cable - Leg Actuator

    Step 4 - Remove the cable from any clips that are routing it along the Hoist. Refitting / Replacement Step 5 - Refitting is a reversal 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.

  • Page 18: Cable - Charger

    Step 2 – To detach the Leg Actuator Cable from the Base. See section 9.8 (Leg Actuator Cover Removal). These guidelines will also instruct on the Cable removal. As they are removed through the same process. Refitting / Replacement Step 5 - Refitting is a reversal of the removal process noting the following points: A) See section 9.8 (Leg Actuator Cover Removal) for correct refitting and replacement.

  • Page 19: Control Box

    A) Ensure that the Snap Lead is refitted in the correct orientation in the Control Box port, and that the Snap Lead is securely fastened to its latch and will not easily displace. 9.3 – Control Box In this section it will explain the correct procedure on removing and reinstalling the Control Box for servicing procedures or replacement.

  • Page 20: Attachment Bracket

    9.4 – Attachment Bracket In this section it will explain the correct procedure on removing and reinstalling the Attachment Bracket for servicing procedures or 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 –...

  • Page 21: Lift Actuator

    9.5 – Lift Actuator In this section it will explain the correct procedure on removing and reinstalling the Lift Actuator for servicing procedures or replacement. Removal Step 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 –...
  • Page 22 Step 5 – Using two 5mm Allen Keys, remove a screw and washer from one end of the Actuators bottom fixing point as shown. Step 6 – Pull the Pin out from the bottom fixing to release the top end of the Actuator. The Actuator can then be removed from the Hoist.

  • Page 23: Leg Actuator

    9.6 – Leg Actuator Within this section it will explain the correct procedure on removing and reinstalling the Leg Actuator for servicing procedures or replacement. Removal Step 1 – Remove the Leg Actuator Cable. (Refer to section 9.2.3) Step 2 – Follow steps 1-4 from section 9.12 (Base Removal) to detach the Mast and Base correctly.
  • Page 24 Step 7 – Repeat step 5 and 6 to remove the 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 –...
  • Page 25 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. 995367 –...
  • Page 26 Refitting / Replacement Step 14 - Refitting is a reversal of the removal process noting the following points: A) When placing the Actuator back onto the Base, ensure it is the correct orientation. (Use image below for reference) B) Ensure that the two leg fixing points are aligned correctly and that the actuator slides into position on the centre bracket of the base.

  • Page 27: Carry Bar

    9.7 – Carry Bar Within this section it will explain the correct procedure on removing and reinstalling the Carry Bar for servicing procedures or replacement. Removal Step 1 – Remove the two Black Caps from the Carry Bar Bumper Cover. Step 2 –...

  • Page 28: Leg Actuator Cover

    Refitting / Replacement Step 4 - Refitting is a reversal of the removal process noting the following point: A) Ensure the Nuts are tight and secure the Carry Bar, do not over tighten as this will bend the framework and will affect the pivoting function of the Carry Bar. B) Ensure the Circlips are fitted correctly into the Pins grove and that a nylon washer is placed either side.
  • Page 29 Step 5 – Raise the Cover from the Base and place in front as shown. Step 6 – Use a positive head screwdriver to remove the four screws 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.
  • Page 30 Step 9 - From the Leg Actuator Cover, remove the plastic nut on the inside that secures the cable to allow the Cable to pass through the hole. A 16mm Spanner may be required to assist. Step 10 – Pull the Cable through to fully remove detach the Leg Actuator Cable and the Leg Actuator Cover from the Hoist.

  • Page 31: Front Castor

    9.9 – Front Castor Within this section it will explain the correct procedure on removing and reinstalling the Front Castor for servicing procedures or replacement. Removal Step 1 - Place the Hoist on its side for easier service – Gently rest the Hoist on its side to avoid damage such as paint scratching.

  • Page 32: Rear Castor

    9.10 – Rear Castor Within this section it will explain the correct procedure on removing and reinstalling the Rear Castor for servicing procedures or replacement. Removal Step 1 - Place the Hoist on its side for easier service – Gently rest the Hoist on its side to avoid damage such as paint scratching.

  • Page 33: Leg - (Lh Leg And Rh Leg)

    9.11 – Leg – (LH Leg and RH Leg) Within this section it will explain the correct procedure on removing and reinstalling the Legs of the hoist, images refer to one Leg only but same process applies to both. Removal Step 1 –...
  • Page 34 Step 10 – Remove the Leg 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: Base

    9.12 – Base Within this section it will explain the correct procedure on removing and reinstalling the 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.

  • Page 36: Boom

    Step 5 – Remove the Leg Actuator Cover from the Base. (Refer to section 9.8) Step 6 - Remove the Leg Actuator (Refer to section 9.6) Step 7 – Remove the LH Leg and the RH Leg from the Base. (Refer to section 9.11) – The Castors are not required to be removed.
  • Page 37 Step 5 – Place a tool such as a 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 –...

  • Page 38: Mast

    Step 8 – The Boom can be removed from the Mast. Refitting / Replacement Step 9 - Refitting is a reversal of the removal process noting the following point: A) Ensure when tightening the Boom to the Mast the Boom is able to move freely along with no to little play between the two mating parts.
  • Page 39 While every effort has been made to ensure the accuracy of information 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.

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