Happ Happ25 User manual

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Version 7.0 ©HAPP Australia Pty Ltd Page 2
Contents
@!7-+A(B!*3'(%$C(*#3!-3D!-((A3(*#3'!............................................................................................................!4!
1.1!;-$(*#3'!E*(1!E#%D'!......................................................................................................................!4!
1.2!7-+A(B!C-$(*#3!'*43-)!.....................................................................................................................!5!
1.4!FG&AC(AD!9-(AD!?*+(AD!>''*43HA3(!.............................................................................................!7!
1.5!>((A3(*#3'!........................................................................................................................................!7!
1.6!Operating!instructions!......................................................................................................................!9!
Operation!.....................................................................................................................................................!9!
Hoist,Operating,Procedures!.....................................................................................................................!9!
Pre,operation,checks!.......................................................................................................................!10!
Operation!...........................................................................................................................................!11!
Maintenance!......................................................................................................................................!11!
Defects,7,Malfunctions!.....................................................................................................................!12!
3.!=-*3!&-%-HA(A%'!#+!(1A!AI$*&HA3(!.....................................................................................................!12!
3.1!<$('*DA!J*HA3'*#3!K*C($%A!.................................................................................................................!12!
3.2!?*+(!&-%-HA(A%!C1-%(!.....................................................................................................................!13!
4!53'(-))-(*#3!#+!(1A!AI$*&HA3(!.................................................................................................................!13!
4.1!Brief!Installation!Steps!............................................................................................................................!14!
Remove!hoist!from!the!delivery!vehicle!...............................................................................................!14!
Unpack!all!loose!fitting!items!...............................................................................................................!15!
Remove!runways!..................................................................................................................................!15!
Construct!and!attach!end!frames!.........................................................................................................!16!
Connect!the!cables!...............................................................................................................................!17!
Install!the!pump!assembly!....................................................................................................................!18!
Securing!with!anchor!bolts!...................................................................................................................!19!
Initial!Testing!of!the!lift!.........................................................................................................................!20!
Connect!the!safety!release!mechanism!................................................................................................!20!
Final!testing!of!the!lift!..........................................................................................................................!21!
5.!;1AC2!K#*3('!LA+#%A!:'*34!...................................................................................................................!22!
6.!K-C2*34M!(%-3'&#%(!-3D!'(#%-4A!............................................................................................................!23!
7.!Trouble!Shooting!......................................................................................................................................!24!
9.!Electrical!system!.......................................................................................................................................!27!
Limit!switch!wiring!................................................................................................................................!28!
Limit!switch!wiring!................................................................................................................................!29!
Electrical!wiring!–!AS3000!....................................................................................................................!29!
10!Power!unit!–!pump!assembly!..................................................................................................................!30!
Exploded!view!of!pump!assembly.!...............................................................................................................!31!
11!Detailed!hoist!installation!Instructions!....................................................................................................!31!
Unpacking!.............................................................................................................................................!31!
Unpack!all!loose!fitting!items!...............................................................................................................!31!
Remove!runways!..................................................................................................................................!31!
Column!location!...................................................................................................................................!32!
Column!assembly!.................................................................................................................................!33!
Final!testing.!.................................................................................................................................................!40!
Entrance!ramp!installation!...........................................................................................................................!41!
Moveable!hoist!configuration!......................................................................................................................!41!

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Version 7.0 ©HAPP Australia Pty Ltd Page 3
Final notes on the HAPP 25 --- Read Me---
Column location
Do not pre drill holes for this hoist, setup the hoist as instructed and drill the holes based on
the columns being in the exact location that enables cross beams to raise and lower freely.
Anchor bolt selection
he HAPP 25 can be moved, this hoist is shipped with anchor bolts to fix the hoist in position.
Customers can purchase Loxon bolts from HAPP or other suppliers to present a flat surface to
the hoist legs. This makes it easier to move the hoist.
Installation
A separate document with pictures describing the installation of the hoist should be reviewed
before installing. Generally extend hydraulic cylinder before laying it on cross beams that
have the columns fitted and crossbeam blocked to a height of approx. 300mm
Safety mechanism
Make sure the two levers located at each end of the hoist are aligned (e.g: both at 2pm….)
This makes the safety mechanism easier to tune later on.
Extra strap under main runway
In some HAPP 25’s an extra strap is in place under the main runway, if the cable connection
plate on the hydraulic ram extends at an angle it can catch this plate. It is acceptable to
remove this strap or modify it ensure the plate clears.
Raincoat studs
There are some mushroom shaped studs on the edge of the runway, we have never supplied
the ‘raincoat’ that is available to be hung of these mounts. Sometimes these studs are broken
in transport. If you see these studs they can be removed as they serve no purpose. Or if there
are damage studs, they can be safely removed also.
Pump Assembly
Read the notes in this manual on pump assembly connection, it describes mains power and
limit switch connections
Cable adjustment
Make sure you have even lifting on all four cables, small differences in adjustment may cause
the plate connecting cables to cylinder rod to not be horizontal. Check this plate when
adjusting the cables.
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Safety first - ALWAYS
You are responsible for installation, maintenance and safe operation of the hoist and any
workplace health and safety obligations. Make sure you follow all safety tips in this manual
and from referenced sources with particular focus on:
•!Keep clear of the hoist and vehicle when raising and lowering.
•!Hydraulics are for lifting / lowering only, never work on a raised vehicle unless all
safety latches are engaged
•!Ensure you have a regular maintenance program in place.
•!Ensure you check and maintain all lift components and understand operating
procedures before operation.
•!Ensure operators read this manual before operation and review it on a regular basis.

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Version 7.0 ©HAPP Australia Pty Ltd Page 4
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Version 7.0 ©HAPP Australia Pty Ltd Page 5
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Version 7.0 ©HAPP Australia Pty Ltd Page 8
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1.6#Operating#instructions#
Operation,
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Hoist,Operating,Procedures,
#This!product!is!designed!to!raise!vehicles!only!for!the!purpose!of!examination,!repairs!and!
maintenance.!

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Version 7.0 ©HAPP Australia Pty Ltd Page 10
Pre,operation,checks,
Operator:# #
Ensure!you!have!read!and!understood!all!manuals!and!safety!procedures.!
Ensure!any!maintenance!and!repairs!have!been!completed!and!signed!off.!
Equipment:# #
Check:!
•!All#fittings!for!tightness!
•!Anchor!bolts!are!tight!
•!Foundations!are!visibly!sound!
•!Safety!release!mechanisms!are!functional!
•!Cables!are!sound,!tensioned!and!not!frayed,!rusted!
•!Electrical!cords!are!sound!
•!Pads!are!not!damaged!
•!Arm!locks!are!functional!
•!For!visible!structural!defects!
#
!,

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Version 7.0 ©HAPP Australia Pty Ltd Page 11
Operation,
Ensure!all!vehicles!are!loaded!with!lift!fully!down.!Carefully!align!pads!with!correct!mounting!locations!on!
vehicle.!
Continually!check!for!balance!and!rigidity!of!vehicle!on!hoist!before!lifting!to!operating!height.!
Raise:#
•!Ensure!all!personnel!are!clear!of!hoist!
•!Push!green!button!to!raise!
•!Push!hydraulic!release!lever!to!lower!until#safety#latches#engage!before#commencing#work!
!
Lower:#
•!Ensure!all!personnel!are!clear!of!hoist!
•!Push!green!button!to!raise!slightly!
•!Disengage!safety!latches!on!each!column!per!operators!manual!
•!Push!hydraulic!release!lever!to!lower!
Before!working!at!any!position!ensure!the!raise!procedure!is!followed!and!safety!latches!are!engaged!on!
all!columns.!
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.! !
Isolate!electrical!circuits!before!performing!maintenance!procedures.!
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.!
!,

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Version 7.0 ©HAPP Australia Pty Ltd Page 12
Defects,7,Malfunctions,
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Version 7.0 ©HAPP Australia Pty Ltd Page 13
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4.1#Brief#Installation#Steps#
The following represents the basic steps for installation of the HAPP 25, these steps may vary depending on
your installation environment. We have provided multiple descriptions of installation to ensure you are able to
review the steps and learn what is required before attempting the installation.
A second more detailed description with pictures is provided in section 11 ( The first few sections are similar so
don’t give up, review all of the sections) . It is recommended you read both sections which will give you two
descriptions of installation which should then reinforce the steps required to install and setup the hoist.
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Remove#hoist#from#the#delivery#vehicle#
If you have arranged for the delivery via a tilt tray it is generally a good idea to have the truck to unload as close
to the install location as possible. If this is not possible you may wish to construct the hoist in another area
and used the dolly wheels to move the hoist into the desired location. The hoist can be moved easily when on
the dolly wheels however you need to allow for the clearance of the posts to ground with is approximately
AHH<#!,&./>>&*0&0!

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15
40mm. If you have collected the hoist on a trailer, you may want to unpack before any movement.
Unpack#all#loose#fitting#items#
The hoist is packed with the runways and end frames forming the package frame. Carefully remove the items
within the package being careful that items do not fall as you remove them. It is recommended to put some
cardboard or similar material down next to the package to protect items should they fall out.
Remove#runways# #
At this stage the contents of the package have been removed, you now have the end frames and runways left.
The runways are removed with a lifting device or fork lift after unbolting the end frames.
Tip:
From this point on there are some installation points on the main runway ( the one with they clinder) that you
will want to perform. As the main runway is accessible during this step it is a good time to fit and check some
items.) Whilst these items can be addressed at a later stage they are likely easier during this stage.
•!Hydraulic line connection
Check the hydraulic line from the cylinder to the outside edge of runway. If the fittings have not been
attached and you have easy access during this stage you can fit them now. If you do not want to do this
now you can delay this process and connect the hose directly from the pump to the cylinder without
going through the hole in the runway and fit it after you have raised the runway and located it on the
safety latch.
Figure: hose fitting which may need to be fitted.
•!Lubricate all pulleys with Wurth dry lube (use the high pressure dry lube product)
Removing the pulleys is not recommended, the cables can be difficult to reroute.
•!Cylinder preparation
The cylinder as supplied is in the fully raised position (ram tube inside the cylinder). When you
assemble and attach the steel cable you will need to extend the ram tube to provide enough length of
cable to thread into the hoist. The cylinder is most easily extended by using a ratchet strap to pull the
cylinder out. Do this at a time when the cables will not cause an issue but before you lower the runways
down where the cylinder will be hard to access.
•!Cable preparation
When you extend the cables using a brush remove any excess debris that may have collected on the
cables and recoat with Wurth dry lube or equivalent.
•!Secure safety rods
Tape the safety rods on the cross beams so they do not get damaged when moving them around.
The runways once removed should be placed on wooden blocks that will enable the end frames to be slotted
into them. Typically use blocks of 150mm or more in height. Place both runways in a location similar to where
they will be after the unit is installed. You will be able to move the unit using the dolly wheels if the unit is not
in the exact position.

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16
Construct#and#attach#end#frames#
•!The end frames consist of the columns and cross beam.
•!Lay each column down with a support under the top of column that will enable the top end of the
column to be slightly higher than the base.
•!Both sides need to be at approximately the same angle and at the width required to fit the cross beam.
•!Lubricate both column internals, pulleys and nylon runners with Wurth dry lube.
•!Slide the cross beam into the columns, and lower to bottom whilst holding the safety latch in the
release position.
•!Install the column cap assembly.
•!Move the end frames to the ends of the hoist.
•!Using the bolts provided connect the cross beam to the runway. There are two larger end plates to stop
the car from over running the hoist that go onto the end of the hoist furthest from the entry end and two
smaller plates that are used at the entrance end as shown below.
•!Ensure that the head of the bolt is on the inside of the cross beam (where the cables run). Failure
to do so may cause the cables to hit the thread of the bolt. You m a y n e ed t o t r i m th e b o lt thread
on the outside with a 100mm angle grinder to avoid contact with the safety release mechanism.
There are two forms of safety latch available for the HAPP 25, internal and external latches. The internal latch
mechanism is typically used in workshop focused environments, the external in storage focused environments.
External latch
Figure: End frame assemblies external locking mechanism.
Note the following in relation to bottom two pictures:
•!Left picture A – Cap assembly bolted to column.
•!Left picture B – Pulley cover
•!Left picture C and Right picture B – correct threading representation on connecting bolts
•!Left picture C and Right picture A – difference in entre spacer plate ( C ) and end of ramp plate
( A ).
•!Left picture D – Lock out pin for extended storage protection

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17
•!Left picture E – Dual nut and washer fitting for cable
Internal latch
The internal latch uses the same end frame but contains the latches inside the cross beam as shown below.
Figure: End frame assemblies for internal locking mechanism
With the end frames installed the internal safety ladder is installed and cap assembly bolted to the top of column.
When the safety ladder passes through the cross beam the latches will engage. (This photo would not be visible
to an installer as it occurs inside the column)
Figure: safety ladder installed into the cross beam. Note the safety latches extending past the ladder. The cross
beam my need to be raised if the latches are to be moved for cable adjustment.
Connect#the#cables#
The cables have already been extended, and should now be able to be routed through the pulleys and up into the
cap assembly.
External lock.
The cable routes up to the top plate on the column.
You wil l put a washe r then two nuts on each thread as shown below. Cable lengths can vary from time to time.
Spacers are available from HAPP if the thread does enable enough adjustment.
Figure: Correct orientation of bolts ( item B) , with thread to outside, trim off excess with cut of wheel if
desired.
The cable setup on the internal locking mechanism is similar to the external locking mechanism. With the
addition of the routing of the cable past the second safety release pulley as shown below. The cross beam may
need to be supported to allow the second safety pulley to be moved inwards allowing the cable to route in its
normal route (from pulley to top of column). A small wedge can be used to hold this pulley in preventing it
from impacting the cable route. If a wedge is used ensure it is removed before operation of the hoist.

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Figure: Routing of cable in internal lock mechanism
Figure: Safety ladder installed into cross beam (column would normally hide this).
With all of the cables installed install the cable covers that cover the pulleys on the crossbeam.
Install#the#pump#assembly#
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