FREEWAY S180 Mobile User manual

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

995367 –Revision A Page 2of 39
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 –Troubleshooting................................................................................................................................................................9
8.1 - Hoist doesn’t turn on ....................................................................................................................................................9
8.2 - Hoist doesn’t charge ...................................................................................................................................................10
8.3 - Hoist doesn’t lift..........................................................................................................................................................10
8.4 - Hoist doesn’t Lift Load Correctly – Stop/Start Action .................................................................................................11
8.5 - Hoist is functioning but LCD and/or LED is inactive ....................................................................................................11
8.6 - Hoist 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 ..........................................................................................................................................17
9.2.4 –Cable –Charger ..................................................................................................................................................18
9.3 –Control Box.................................................................................................................................................................19
9.4 –Attachment Bracket ...................................................................................................................................................20
9.5 –Lift Actuator ...............................................................................................................................................................21
9.6 –Leg Actuator ...............................................................................................................................................................23
9.7 –Carry Bar.....................................................................................................................................................................27
9.8 –Leg Actuator Cover.....................................................................................................................................................28
9.9 –Front Castor ...............................................................................................................................................................31
9.10 –Rear Castor...............................................................................................................................................................32
9.11 –Leg –(LH Leg and RH Leg) ........................................................................................................................................33
9.12 –Base..........................................................................................................................................................................35
9.13 –Boom........................................................................................................................................................................36
9.14 –Mast .........................................................................................................................................................................38

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1.0 –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. The aim of the manual is to help and assist you, so that
you can provide a successful service 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 and equipment stated in this Manual must be used to safely service this Hoist.
Ensure you have assessed all risks for your environment and any persons within that
environment before commencing work.
Ensure you have all PPE available to carry out the work before commencing.

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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. When doing so, ensure the Serial Number of the Product and the User Manual match up.
Each Hoist has its designated User Manual which is supplied to the User during commissioning.
Component
Service/Inspection required
Generic:
Visual inspection of the externals of the Mobile Hoist.
Significant damage that may affect the function of the Mobile
Hoist along with a clear safety hazard is unacceptable.
Check the Labelling on the hoist to ensure they are all still
legible, this includes the Serial Number and other important
markings.
Clean the Hoist at the end of each service. See User Manual for
cleaning details.
Check all main nuts and bolts to see if they are loose, if so
tighten accordingly.
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 applicable) are working
correctly.
View LCD Display functions and ensure they correspond
correctly. (LCD Versions only)
Lift and Leg Actuators:
Inspect the components for damage that may affect the
function and safety of the product.
Listen for any unusual sounds when operating the Actuators.
Fully open and close the Actuators to ensure they are working
correctly –this includes ensuring they reach the open and
closed limits as well inspecting for damage along the stroke.
Both actuators should actuate smoothly at a consistent
velocity.
Ensure the Manual Emergency Lowering Device is performing.
Ensure the Actuator Cable Retaining Clips are in place.
Handset and Cables:
Inspect the components for damage that may affect the
function and safety of the product.
Ensure all Cables are fitted to the Control Box correctly.
Verify all Handset functions are in working order.
Ensure LED’s are working correctly.

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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. (If fitted)
Legs:
Ensure Legs are perpendicular to the Base when closed.
Brakes:
Ensure the Brakes function when activated
Ensure the Hoist can move freely when the Brakes are
deactivated. (Ensure they aren’t rubbing on the Wheels)
Castors and Wheels
Examine the products Wheels and Castors for signs of damage
or wear, ensure they run freely and are not cracked.
Check to see all casters are flat on the floor and hoist is
stable.
Ensure the product is able to rotate freely with ease.
4.0 –Test Procedure
Below is the full testing procedure required to complete an Annual Hoist Service.
The SWL (180Kg) is an essential load for the testing of the Hoist and a mode of transportation to
transport the weights to the Hoist is required.
1. Position the Floor Hoist on a flat and level surface and away 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 the weight stack to the Carry Bar using lift straps.
8. Raise the Weight to the Upper Limit. Be aware of any unusual noises while raising the SWL
(Safe Working Load).
9. Deactivate the brakes and close the legs using the handset.
10. Drive the Hoist forward and backwards one metre. Make sure that the castors rotate and
role correctly.
11. Activate the rear castors brakes.
12. Using the handset begin to lower the weight. Before reaching the floor press the E-STOP
button on the Control Box to check the safety device is working correctly.
13. Begin to twist the Red manual E-lower device positioned at the top of the actuator until
weight has reached the floor.
14. Detach the weight from the Carry Bar.
15. Twist the E-STOP Button in a clockwise motion until it returns to its natural position.
16. Once weight is removed continue lowing the Carry Bar down to the bottom limit.
17. Test Complete.

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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
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)

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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. 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:
Steel frame (Mast, Boom, Base, Legs)
Carry Bar Cover
Castors
Leg Actuator
Initial packaging of the device (cardboard)
Lift Actuator
Metallic fixing –screws etc.
Handset + Cables
Carry Bar
Control Box
Leg Actuator Plastic Cover
Battery

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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

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8.0 –Troubleshooting
Should a problem arise with the use of the Hoist, this section offers guidance to all known faults
revolving the product. The list of faults below offers the correct actions in sequence to resolve the
issue.
For each step per scenario, if the step does not determine the issue, continue to the following step
in sequence until the fault is found. Once the fault is found, refer to the action guide with the
corresponding number to resolve the issue. After following the correct action, check that the hoist is
now functioning correctly, and perform a simple test. See Section 4.0 for correct test procedure.
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.
8.1 - Hoist doesn’t turn on
Operate the handset to determine if the hoist powers up. If it does not –Follow the Troubleshooting
guide below.
Troubleshooting Guide
1. Check the E-Stop button on the control box has not been activated.
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 damage.
8. Replace current Control Box.
Action Guide
1. Twist the E –Stop button in a clockwise direction to reset.
2. Re-attach the Handset to the correct control box port –See Section 9.2.1 on Handset
attachment.
3. Remove the Handset from the Hoist and Replace –See Section 9.2.1 on Handset attachment.
4. Plug the charging lead into a wall socket see if the Hoist begins to Charge. The hoist control
box should show a steady orange LED to indicate the hoist is now charging. If unsuccessful,
continue Troubleshooting Guide and refer to the section on “Hoist doesn’t Charge” as this
is likely the guide to resolve the issue. If Hoist turns on, allow the Hoist to charge before
testing. If Hoist does show signs of charging but does not turn on, continue this
Troubleshooting Guide.
5. Re-attach the Battery in the correct fashion shown in section 9.1.
6. Remove the Battery and Replace as shown in section 9.1
7. Replace the Control Box –See section 9.3
8. See section 9.3 on Control Box replacement.

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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. Check the Charger plug is turned on at the power supply.
2. Check that the Charger Lead is connected correctly to the Control Box
3. Check charging lead for damage, e.g. cuts and breaks.
4. Check that the Battery is connected properly with the Control Box.
5. Inspect the Battery terminals for any damage, e.g. burns and breaks.
6. Inspect the Control Box terminals for any damage, e.g. burns and breaks
7. Replace the charging lead.
8. Replace the Battery
9. Replace the Control Box
Action Guide
1. Turn the Plug Switch at the wall on.
2. Reattach the Charger Lead to the Control Box –See section 9.2.4 on Charger Cable
Attachment.
3. Replace charging lead –See section 9.2.4 on Charger Cable 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. (The LCD displays the “up”
“down” function, LCD version only), For Hoists without the LCD, a response noise from the Control
Box should be noticeable. Follow the Troubleshooting Guide below.
Troubleshooting Guide
1. Check if the Hoist is plugged into Charge. (Hoist will not raise and lower while on charge)
2. Check that the Lift Actuator to Control Box cable is connected properly between the two
ports.
3. Check the Lift Actuator to Control Box cable for damage, e.g. cuts and breaks.
4. Inspect the Lift Actuator for any signs of damage which could affect its function, including
the Port. E.g. Large Cracks and breaks, electrical burns.
5. Inspect the Control Box Port for any damage. E.g. electrical burns, breaks.
6. Replace the Lift Actuator to Control Box cable.
7. Replace the Control Box.
8. Replace the Lift Actuator.

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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. See guidance in section 9.2.2 on Cable replacement.
7. See guidance in section 9.3 on Control Box replacement.
8. See guidance in section 9.5 on Lift Actuator replacement.
8.4 - Hoist doesn’t Lift Load Correctly – Stop/Start Action
Attempt to raise/lower hoist with handset, the actuator begins to raise the load but cuts out and
performs stop/start motion to handset commands. Follow the Troubleshooting Guide below.
Troubleshooting Guide
1. Lift Actuator is broken
2. Control Box is broken
Action Guide
1. See section 9.5 for guidance on 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, e.g. cracks or breaks.
2. Control Box/handset is damaged
Action Guide
1. Replace the Control Box/and or Handset depending on which has the LED damage. See
Section 9.3 for Control Box Replacement. See Section 9.2.1 for Handset attachment.
2. Replace the Control Box/and or Handset depending on which has the LED damage. See
Section 9.3 for Control Box Replacement. See Section 9.2.1 for Handset commissioning.
8.6 - Hoist E-Stop button not working
Attempt to E-Stop the Hoist but function is inactive. Follow troubleshooting guide below:
Troubleshooting Guide
1. Control Box is damaged
Action Guide
1. See section 9.3 for guidance on Control Box replacement.

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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. Check for Cable damage between the Control Box and Leg Actuator cable.
3. Inspect the Leg Actuator for any damage, including the cable port. E.g. large cracks and
electrical burns.
4. Inspect the Control Box Leg Actuator Cable Port for any damage. E.g. cracks and electrical
burns.
5. If there is no indication of any power while commanding the Powered Legs, Handset buttons
could be damaged.
6. Replace the Leg Actuator.
7. Replace the Control Box.
Action Guide
1. Connect the Cable between the two components. See section 9.2.3 for Leg Actuator Cable
fitting.
2. Replace the Control Box to Leg Actuator cable. See section 9.2.3 for guidance.
3. Replace the Leg Actuator. See section 9.6 for guidance.
4. Replace the Control Box. See section 9.3 for guidance.
5. Replace the Handset. See section 9.2.1 for Handset commissioning.
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 has not been activated.
2. Check the Handset is correctly connected to the Control Box.
3. Check that the Lift Actuator and Leg Actuator Cables are both connected to the Control Box.
4. Check the Handset cable is not damaged, e.g. cuts and breaks.
5. Check the Lift Actuator and Leg Actuator Cables for damage, e.g. cuts and breaks
6. Check the Control Box Handset Port for any damage. E.g. cracks and electrical burns.
7. Replace the Handset
Action Guide
1. Reset the E-Stop button by twisting in a clockwise motion. The Button should release.
2. Re-attach the Handset to the Control Box –See Section 9.2.1 on Handset attachment.
3. Re-attach the Lift Actuator and Leg Actuator Cables to the Control Box. See section 9.2.2 and
9.2.3 for guidance.
4. Remove the Handset from the Hoist and Replace –See Section 9.2.1 on Handset
attachment.
5. Remove the Lift Actuator and Leg Actuator from the Hoist and Replace –See section 9.2.2
and 9.2.3 for guidance.

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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 –Hoist doesn’t respond to the correct Handset commands
Troubleshooting Guide
1. Check the Lift Actuator and Leg Actuator power 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 top end of the Actuator and is coloured red. For use, the mechanism is
turned in a clockwise motion manually. This will slowly lower the Actuator. Continue turning the
Mechanism until the Patient can be safely removed.

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9.0 –Servicing –Removal and Replacement
This section will cover the details of how to remove, refit and replace all serviceable parts to the
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.
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 leaver on the battery at the top end of the battery and lift away from its
location.
Refitting / Replacement
Step 3 –Refitting is a reversal of the removal process noting the following points:

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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 –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 facing away from
the Hoist

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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.
Step 3 –Pull the cable outward away from the Actuator to remove.

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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.
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)

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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.
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 removed from the wall socket, detach the plug
from its fixing to the Hoist.
Refitting / Replacement
Step 5 - Refitting is a reversal of the removal process noting the following points:

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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.
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 noting the following points:
A) Ensure that the Control Box slides into position correctly and vertically straight onto
the Bracket for correct fitting.

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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 –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.