Heiniger BACKEASE 600 User manual

F0169 Backease Hoist Manual Page 1 of 9 28/05/2014
Rev:03
BACKEASE 600
Operators Manual
Installation, Safety, Operation, Maintenance, Guarantee.
Read these instructions fully before installing or operating
the BACKEASE 600.
Manufactured by
Heiniger Australia
5A Tayet Link
Bibra Lake, WA 6163
Tel: [phone] Fax: [phone]
Email: [e-mail]

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Important Notice:
As the installation and operation of this crane is beyond the control of the manufacturer and/or
it's agents, the manufacturer and/or its agent's shall in no circumstances be liable for any loss,
damage or injury of any kind whatsoever and howsoever caused or occasioned to property or
persons resulting from the installation or use of this crane.
The following components are supplied
1 Hoist Boom Post
1 Hoist Base
1 Lifting Hook
1 Power Pack Bracket
1 O.5m Earth Cable (black)
1 3.5m Battery Cable (red)
1 2.5m Hydraulic Hose + Nipple
1 Hoist Boom + pins and R clips
1 Hoist Cylinder with pins, clips, Breather, Elbow fitting and Hose Burst Valve
6 ½" X 2" bolts, flat & spring washers & nuts
1 Boom Storage Bracket inc Mounting Plate
2 ⅜" X 1" B & N + spring washer + flat washer
1 ⅜" X 2½" B & N + spring washer + flat washer
2 10mm x 20mm bolt + spring washer + flat washer
3 Hoist Support Leg Bracket
1 ⅜" X 3" bolt + nyloc nut
1 Hoist Support Leg
1 Power Pack inc fittings
1 Remote Hand Control
6 Cable Ties
Tool Requirements:
Electric hand drill 7/16" and 9/16" HSS drill bits
Marking pen Open ended spanners and shifting spanner
Hack saw Funnel
3.5 litres of hydraulic oil Castrol Hyspin AWS32 (approximate)
Installation Instructions: Installation takes 2 to 3 hours.
1. Position the hoist base on the corner of the tray with the sides against the cabguard and
along the tray edge. Fit the Hoist Boom Post to the base, check that the base does not
foul the tray dropsides or that the cab guard does not interfere with the rotation of the
boom post.
2. For maximum strength the base must be bolted to the tray frame or bearers.
Steel trays are usually fully welded to the frame and the base can be bolted to the tray
floor adjacent to the frame. With aluminium tray, or steel framed timber-floored tray, the
base should be bolted to the frame or bearers. Alternatively, use lengths of 50 mm x
10mm flat steel bar or similar (not supplied) drilling to suit and installed under the tray
floor as a spreader. This will ensure that the loaded crane will not pull bolts through the
floor.
3. With the base in position, mark the tray through each of the six boltholes.
4. At each marked point, drill a 9/16” hole through the tray and / or frame or bearers.

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5. Bolt the base to the tray using the six ½" x 2" bolts, flat and spring washers and nuts.
6. Position the boom lugs on the closed end of the boom either side of the top of the boom
post on the same side as the ram mounting lug and insert the pin.
7. Position the lugs of the ram on either side of the lug on the boom post and insert the 1”
pin. Push the retaining clip home. Position the rod end clevis of the cylinder to the boom
in the same way. The ram ports should be on the topside of the ram.
8. Secure the lifting hook to the boom with the pin. Push the retaining clip home.
9. The power unit is the best installed under the tray so that load space is not reduced and
the unit is protected from damage. On most vehicles the unit is installed under the front
end of the tray on the same side as the base.
In choosing a position these points should be observed:
a) The reservoir end of the unit extends further from its mounting bracket than does its
motor. When space is limited, rotating the unit and bracket may improve installation.
b) The unit and bracket should clear any extreme movement of the vehicle drive shaft
and suspension.
c) The unit should be level and accessible for servicing (i.e. oil top-up). Some access
difficulty is to be expected.
d) The position should not require excessively long lengths of hydraulic hose or power
cable.
e) The mounting bracket can be adjusted by light bending to suit different spacings
between tray bearers.
10. With the mounting bracket in position mark the tray bearers through each of the end
four holes.
11. At each of the marked points drill a 7/16” hole through the bearer.
12. Do steps 13 to 19 before installing the bracket under the tray
13. To prevent unauthorised use of the crane the handset control should be located inside
the vehicle cab. Locate a suitable rubber grommet in the cab wall behind the driver's
seat and pass the control cable through the grommet. Route the control cable from the
cab to where the power unit is to be installed ensuring that the control cable is protected
from damage.
14. Remove the plastic plug from the power unit pump and screw in the hydraulic nipple
fitting. Connect the elbow end of the hydraulic hose and check connections for
tightness.
15. Bolt the power unit to the mounting bracket with the two 10mm bolts, flat & spring
washers. Through the bottom of the bracket into the base of the pump.
16. Fill the oil reservoir with 2.2 litres of hydraulic oil.
Important: For steps 17 and 20 study illustration 1.
17. For 12 Volt and 24 Volt power units:
(a) Remove the large nut and washer from the terminal on the side of the Start Solenoid,
attach both the red wire from the Remote Hand Control and one end of the red 3.5
metre power cable, replace the washer and nut.
(b) Attach the black wire from the Remote Hand Control to red wire coming from the
lowering solenoid using connector supplied.
(c) Attach the green wire from the Remote Hand Control to the small terminal on the Start
Solenoid.
18. Bolt the mounting bracket to the bearers or some suitable position.
19. Route the power cable from the power unit, forward under the tray, along a suitable
path under the cab and up to the vehicle battery, ensuring that it is protected from any
damage (e.g. chaffing burning on engine manifolds). Use cable ties to retain as
required.
20. Attach the earth strap to the negative post on DC motor, as in illustration 1. Attach the
other end of the earth strap to the vehicle chassis. The pump must be earthed to the

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vehicle chassis through good metal to metal contact. The vehicle chassis must be
earthed to the vehicle battery. If the chassis is not earthed to the battery the power pack
will try to earth through the vehicle wiring, causing damage to that wiring.
21. Route the hydraulic hose from power pack unit, forward under the tray and up between
the cab and cabguard to the hydraulic ram.
Important: Ensure that the routing of the hose is such that when the crane is rotated and/or the
boom is raised and lowered to its extremes the hose is neither kinked, stressed nor fouled by
the tray, the cab, the cabguard or any of the crane components. To prevent chaffing or damage,
surplus hose should be secured with cable ties (or similar) where possible.
22. To fit the Boom Storage Bracket. See illustration 3.
First position the boom, (height and extension) against the cab guard in the position it is
to be stored in. The mounting plate should be attached to the cab guard vertically with
the centre of the plate lining up with the pin retaining the hook on the end of the boom.
The height of the mounting plate should be such that the storage bracket can be bolted
to it with the boom resting in the storage bracket. Ensure that the pin on the boom rests
in the centre of the vee, the hook should slide between the mounting plate and the
storage bracket. The boom storage bracket must be used in conjunction with the slew
lock pin to keep the boom secure during transport.
23. Adjusting the support leg. See illustration 4.
With the vehicle on level ground place the support leg against the bracket. Mark leg with
a pencil at the hole level. Add 25mm above that mark and drill a ⅜" hole through the
leg, parallel to the footplate. Cut as illustrated. Bolt the leg to the bracket.
24. When satisfied that the crane has been installed in accordance with these instructions
and diagrams, ensure all bolts are tensioned, and all electrical and hydraulic
connections are correct and sound.
25. Connect the power cable to the positive (+) terminal on the battery.
Read Safety Instructions before Operating
Safety instructions:
Lifting more than the SWL (Illustration 2) may result in serious personal injury and
permanent damage to the crane.
Always use the Support leg when lifting loads.
Always use the Slew Lock when lifting loads.
Use the crane only when the vehicle is on level ground. Use of the crane when the
vehicle is not level may cause the suspended load to slew dangerously out of control.
When practical and safe to do so, steady suspended load with one hand, whilst holding
the remote toggle in the other hand. Never stand under suspended load or raised boom.
Do not move the vehicle with the boom raised or the load suspended.
Secure the load to the vehicle. Do not rely on the lifting hook or the lowered boom to
retain loads on a moving vehicle.
When the vehicle is left unattended, lock the remote toggle inside vehicle cab to prevent
unauthorised use.
Do not allow minors to operate the crane.
Inspect crane components (hydraulic hose in particular) and installation regularly to
check for wear, loosening of bolts etc. or damage. Replace any worn or damaged parts
immediately.
Always store boom securely using the Slew Lock and the Boom Storage Bracket and
store the Support Leg in the vehicle when not in use.

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Operating:
The boom can be raised and lowered by using the Remote Hand Control. The boom is raised by
the pump generating hydraulic pressure and is lowered by the activation of the lowering
solenoid allowing the weight of the boom and load to force oil out of the ram and back to the
reservoir at a regulated rate.
It is normal for the initial crane action to be "spongy". This is due to trapped air introduced into
the system by the hose, fittings and ram. The sponginess will disappear after several raising
and lowering actions. When sponginess has disappeared check oil level.
Maintenance Instructions: Maintenance recommended at least every time the vehicle is
serviced.
1. Never operate crane with insufficient or unsuitable oil. Check oil level when the boom is
lowered. Overfilling of the reservoir is unlikely to cause damage but will lead to loss of
excess oil. Check quality of oil.
2. Check integrity of all electrical connections. Check routing of and condition of control cable,
power and earthing cables. Ensure there is no chafing or rubbing through on any cables as
damaged cables can cause serious damage and even uncontrolled lifting of boom.
3. Check routing of and condition of hydraulic hose.
4. Check condition of lifting hook and lifting hook pin and retaining clip regularly.
5. Grease collar at top of crane base unit. Boom post can be lifted right out to grease if
required.
6. Check all mounting bolts are securely tightened.
7. Small squirt of oil into cylinder breather to lubricate dry end of cylinder.
Trouble Shooting:
If the crane has been installed in accordance with these instructions and illustrations then it will
provide many years of satisfactory service. If the crane does not function
correctly check the following points.
Symptom: Crane will not operate.
Cause no oil
Remedy fill reservoir with hydraulic oil.
Cause faulty electrical connections.
Remedy check electrical connections to battery.
check that power unit/tray is earthed to chassis
check electrical connections to the power unit.
rectify faulty connections.
Symptom: Crane will not lower after being partially raised.
Cause Lowering solenoid not operating correctly.
Remedy Check wiring to lowering solenoid. If okay, listen for a click from the
solenoid as you press and release toggle switch to down position.
If there is no click then the solenoid may not be operating. Contact
manufacturer.
Symptom: Crane lowers from partially raised position but will not lower from fully
raised position i.e. - jams at top.
Cause The Hose Burst Valve has locked shut due to back pressure in the
hydraulic circuit. Given time it will release. If the problem reoccurs contact the
manufacturer.
Symptom: Crane ceases to operate. Vehicle taillights cease to function.
Cause Power unit is not separately earthed to chassis. (Temporary earthing
was possibly achieved through tail light wiring).
Remedy Earth power unit to chassis with earthing cable supplied.
Check taillight wiring for damage. Replace lighting fuse if blown.
Guarantee:

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1. Subject to and in accordance with the provisions of this Guarantee Heiniger Australia (the
"Company") warrants the crane against defects in materials and manufacture for a period
for twelve (12) months from the date of purchase.
2. In the event of a defect occurring within the Guarantee period which prevents the
designed or safe use of the crane the Company or its nominated representative (its
"Agent") will repair or make good the defect or, at the Company's option, replace same
free of charge, provided the defective component is delivered to the Company or at the
direction of the Company to its Agent, freight to your account and prepaid both ways by
you.
3. This Guarantee shall only apply where the crane has been installed, operated and
maintained in accordance with the instructions and diagrams provided by the Company.
4. This Guarantee does not extend to or cover any part of the crane which in the opinion of
the Company is worn by fair wear and tear or has been damaged or rendered defective
by wilful act, abuse, misuse, negligence, inadequate or improper care or the reliability or
condition of which has been affected by any alteration or repair carried out other than by
the company or at the direction of the Company by its Agent.
5. No employee or Agent of the Company shall have the authority to add to or alter any of
the provisions of this Guarantee.
6. This Guarantee is issued only to the initial retail purchaser of the crane and is not
transferable or assignable.
7. This Guarantee shall be read and construed as being subject to the provisions of any
applicable Federal and/or State Consumer Protection Legislation from time to time, with
the intent and purpose that the provisions hereof shall be read and construed in such a
manner and will be modified to such extend as may be necessary to ensure the
provisions hereof do not breach any such legislation as aforesaid.
8. Save as aforesaid the Company, its employees or Agents shall in no circumstances be
liable for any loss damage or injury of any kind whatsoever caused or occasioned to
property or persons. In no event shall the liability of the Company, its employees or
Agents ever exceed in total the amount of the purchase price of the crane paid by you.

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illustration 2

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illustration 3
illustration 4