FREEWAY SA180C User manual

Doc No. 995066 Revision of document: A
Rev Date: 26.04.21
SA180C Stand Aid
Service Manual

995066 - Revision A Page 2of 41
Contents
1.0 –Introduction..............................................................................................................................................................................................3
2.0 –Safety Precautions ....................................................................................................................................................................................3
3.0 –Servicing ...................................................................................................................................................................................................4
4.0 –Test Procedure .........................................................................................................................................................................................6
5.0 –Tools, Equipment and Lubricants Required for Servicing .........................................................................................................................7
6.0 –Decommissioning .....................................................................................................................................................................................8
7.0 –Spare Parts List .........................................................................................................................................................................................8
8.0 –Troubleshooting .......................................................................................................................................................................................9
8.1 –Stand Aid doesn’t turn on ...................................................................................................................................................................9
8.2 –Stand Aid doesn’t charge ..................................................................................................................................................................10
8.3 –Stand Aid doesn’t lift.........................................................................................................................................................................10
8.4 –Stand Aid doesn’t Lift Load Correctly – Stop/Start Action.................................................................................................................11
8.5 –Stand Aid is functioning but LCD and/or LED is inactive....................................................................................................................11
8.6 –Stand Aid E-Stop button not working................................................................................................................................................11
8.7 –Stand Aid Leg Actuator is not responding .........................................................................................................................................12
8.8 –Stand Aid has Power but does not respond to Handset commands .................................................................................................12
8.9 –Stand Aid doesn’t respond to the correct Handset commands.........................................................................................................13
8.10 –Troubleshooting –Stand Aid 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.........................................................................................................................................................................19
9.3 –Control Box .......................................................................................................................................................................................20
9.4 –Attachment Bracket ..........................................................................................................................................................................21
9.5 –Lift Actuator ......................................................................................................................................................................................22
9.6 –Leg Actuator......................................................................................................................................................................................24
9.7 –Upper Assembly ................................................................................................................................................................................25
9.7.1 –Upper Handle Assembly............................................................................................................................................................25
9.7.2 –Stainless Steel Assembly ...........................................................................................................................................................27
9.8 –Leg Rod Assembly .............................................................................................................................................................................28
9.9 –Front Castor ......................................................................................................................................................................................29
9.10 –Rear Castor......................................................................................................................................................................................30
9.11 –Leg –(LH Leg and RH Leg) ...............................................................................................................................................................32
9.12 –Leg Bearing Assembly......................................................................................................................................................................33
9.13 –Foot Tray .........................................................................................................................................................................................34
9.14 –Knee Pad .........................................................................................................................................................................................35
9.15 –Control Bracket ...............................................................................................................................................................................39
9.16 –Frame..............................................................................................................................................................................................40

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1.0 –Introduction
This Manual will explain how to carry out interim servicing and parts replacement on the Freeway
SA180C Stand Aid 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 SA180C Stand Aid
Freeway authorised personnel must complete the Full and Interim services of the Freeway
SA180C Stand Aid
The Stand Aid 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 Stand
Aid.
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 Stand Aid, 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 Stand Aid 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 Stand Aid. Significant
damage that may affect the function of the Stand Aid along
with a clear safety hazard is unacceptable.
Check the Labelling on the Stand Aid to ensure they are all still
legible, this includes the Serial Number and other important
markings.
Clean the Stand Aid 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 Stand Aid 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.

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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.
Upper Assembly:
Ensure that the Stainless Steel Assembly is adjustable within
the Upper Assembly.
Knee Pad:
Inspect the Knee Pad for damage including cuts and breaks.
Inspect the Knee Pad is functioning as intended, the Knee Pad
should hold its current position and not lower due to gravity.
Ensure the Knee Pad Height and Length adjustment functions
correctly.
Foot Tray:
Ensure the Foot Grips are still applied and undamaged.
Inspect the Foot Tray for any permanent deformation or
fatigue.
Ensure no cracks are present and the Foot Tray is attached
correctly.
Ensure Foot Tray is fitted correctly.
Legs:
Ensure Legs are perpendicular to the Base when closed.
Leg Bearings:
Inspect the condition of the Bearings, significant wear will
require replacement.
Brakes:
Ensure the Brakes function when activated
Ensure the Stand Aid 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 castors are flat on the floor and the Stand Aid
is stable.
Ensure the product is able to rotate freely with ease.

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4.0 –Test Procedure
Below is the full testing procedure required to complete an Annual Stand Aid Service.
The SWL (180Kg) is an essential load for the testing of the Stand Aid and a mode of transportation to
transport the weights to the hoist is required.
1. Position the Stand Aid on a flat and level surface and away from any obstacles.
2. Using the handset raise the Upper Handle Assembly to the upper limit. Listen for unusual
noise.
3. Lower the Upper Handle Assembly to the 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 weights. Position it perpendicularly under the Upper Assembly.
7. Attach the weight stack to the Upper Assembly using lift straps.
8. Raise the Weight 2/3 the lifting range. Be vigilant for unusual noises while raising the weight.
9. Deactivate the brakes and close the legs using the handset.
10. Drive the Stand Aid forward and backwards one metre. Make sure that the castors rotate
and roll 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 reach the floor.
14. Detach the weight from the Upper Handle Assembly.
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 Upper Handle Assembly down to the bottom
limit.
17. Apply 45kg of weight directly to the Foot Tray to test the Foot Tray is still rigid and does not
bend significantly under load.
18. Test Complete.

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5.0 –Tools, Equipment and Lubricants Required for
Servicing
When carrying out work on the Freeway SA180C Stand Aid you will require the following:
Tools Required
3mm Allen Key
4mm Allen Key x2
5mm Allen Key x2
6mm Allen Key
5mm Spanner
8mm Spanner
13mm Spanner
13mm Ratchet Spanner
17mm Spanner
19mm Spanner
24mm Spanner
Flat Head Screwdriver
Equipment Required
Marker Pen
Cloth
Lint Free Cloth
Test Weights –180kg
Weight Trolley
Lifting Straps x2 (Attach weight to Upper Assembly)
Sundries Required
Loctite 243
New tech lubes ltd Silicon Grease –FS SILL-Tech (or equivalent)

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6.0 –Decommissioning
When the Stand Aid has completed its life cycle and can no longer perform to its intended use safely
the Stand Aid 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 (Frame, Upper Assembly, Legs)
Knee Pad
Castors
Leg Actuator
Initial packaging of the device (cardboard)
Lift Actuator
Metallic fixing –screws etc.
Handset + Cables
Foot Tray
Control Box
Battery
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 SA180C Stand Aid.
Part Code
Description
520034
Lift Actuator Lead (700mm)
123082
Leg Actuator Lead (1250mm)
123102
4 Way Handset (Battery & Service LED)
123106
4 Way Control Box (LCD & Data Logging)
119900
Freeway SA180C LH Leg Assembly
119901
Freeway SA180C RH Leg Assembly
119902
Foot Tray Assembly
119903
Rear Castor Assembly
119911
Front Castor Assembly
119904
Freeway SA180C Frame Assembly
119905
Control Bracket Assembly
119906
Upper Handle Assembly
119907
SA180C Knee Pad Assembly
119001
Lift Actuator Assembly
119107
Leg Actuator Assembly
119910
Leg Rod Assembly
510005
Battery Pack (2.9 Ah Lead Acid)
510091
Mains Snap Lead
510092
Charger Lead (UK Plug)
999066
Freeway SA180C User Manual
992066
Freeway SA180C Spare Parts Manual

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8.0 –Troubleshooting
Should a problem arise with the use of the Stand Aid, 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 Stand
Aid is now functioning correctly, and perform a simple test. See Section 4.0 for correct test
procedure.
For guidance on how to dismantle the Stand Aid 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 –Stand Aid doesn’t turn on
Operate the handset to determine if the Stand Aid 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 the Stand Aid 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 Stand Aid and Replace –See Section 9.2.1 on Handset
attachment.
4. Plug the charging lead into a wall socket see if the Stand Aid begins to Charge. The control
box should show a steady orange LED to indicate the Stand Aid is now charging. If
unsuccessful, continue Troubleshooting Guide and refer to the section on “Stand Aid
doesn’t Charge” as this is likely the guide to resolve the issue. If Stand Aid turns on, allow
the Stand Aid to charge before testing. If the Stand Aid 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 –Stand Aid doesn’t charge
Connect the Stand Aid charging lead from the Stand Aid to the Wall Socket. (Ensuring that the lead is
connected properly) to determine if the Stand Aid 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 –Stand Aid doesn’t lift
Attempt to raise/lower the Stand Aid with handset, but it is not responding. (The LCD displays the
“up” “down” function, LCD version only), For Stand Aids without the LCD, a response noise from the
Control Box should be noticeable. Follow the Troubleshooting Guide below.
Troubleshooting Guide
1. Check if the Stand Aid is plugged into Charge. (Stand Aid 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.