Herkules Hebetechnik GmbH K1200-HLS-11 User manual

Operating Manual and Test Record
for
Service Lift
Machine Type
Article No.
Serial No.
K1200-HLS-11
HLS 1200-11
K1200-HLS-14
HLS 1200-14
K1200-HLS-16
HLS 1200-16
Translation of German Original
“760-066_HLS1200-11-14-16_2015.02_2.2_DE”
760-066_HLS1200-11-14-16_2017.04_2.2_EN
Herkules Hebetechnik GmbH
Falderbaumstraße 34
D - 34123 Kassel
Tel.: [phone]
Fax: [phone]
E-mail: [email protected]
Internet: www.herkules.de

2
Table of contents
1Operation and Safety Inspection...................................................................................4
2General Information ......................................................................................................5
2.1 Hazard Warnings ................................................................................................... 5
2.2 Limitation of Liability............................................................................................... 5
2.3 Copyright................................................................................................................6
2.4 Terms of Guarantee............................................................................................... 6
2.5 Customer Service................................................................................................... 6
3Product Description.......................................................................................................7
3.1 Intended Use.......................................................................................................... 7
3.2 Product Structure................................................................................................... 8
3.3 Technical Data....................................................................................................... 9
3.4 Product Designation............................................................................................... 9
4EC Declaration of Conformity......................................................................................10
5General Safety Instructions.........................................................................................11
5.1 Operator’s Duty of Care .......................................................................................11
5.2 Operator’s Duties ................................................................................................. 11
5.3 Basic Safety Measures ........................................................................................ 12
5.4 Requirements of Operating Personnel................................................................. 13
6Transport and Preparation ..........................................................................................14
6.1 Transport Inspection ............................................................................................ 14
6.2 Disposal of the Packaging Materials.................................................................... 14
7Installation and Assembly............................................................................................15
7.1 Environmental Conditions for Assembly............................................................... 15
8.2 Assembly Instruction HLS1200-11....................................................................... 16
8.3 Assembly Instruction HLS1200-14 / -16............................................................... 19
8.4 Grounding, Electrostatic Charge..........................................................................22
8Operation ....................................................................................................................23
8.1 Description of Control Elements...........................................................................23
8.2 Commissioning.....................................................................................................24
8.3 Description of Anti-Drop Safety Device................................................................ 24

3
9.4 Loading Ramps.................................................................................................... 25
9.5 Function Interim Drive Over Ramp (HLS1200-11) ............................................... 25
9.6 Function Protective Flaps (HLS1200-14)............................................................. 25
9.7 Function CE-Stop (HLS1200-16) ......................................................................... 25
9.8 Operating .............................................................................................................26
9.8.1 Use of the Lifting Platform: ............................................................................26
9.8.2 Lifting the Platform:........................................................................................26
9.8.3 Lowering the Platform:...................................................................................26
9.8.4 Exiting the Platform .......................................................................................26
9.9 Working on the Lifted Vehicle ..............................................................................27
9.10 End of Work.........................................................................................................27
9Troubleshooting...........................................................................................................28
9.1 Possible Problems and their Solutions................................................................. 28
10 Maintenance................................................................................................................29
10.1 Air Bellow Characteristics and Durability.............................................................. 30
10.2 Notice about Filter Regulator and Air Line ........................................................... 30
10.3 Notice about the Sliding Area of the Scissors......................................................30
10.4 Lubrication and Test Points..................................................................................31
11 Safety Inspection.........................................................................................................32
11.1 Regular Safety Check .......................................................................................... 33
12 Disassembly and Disposal ..........................................................................................34
12.1 Disassembly......................................................................................................... 34
12.2 Disposal ............................................................................................................... 34
14 Additional Information .................................................................................................35

OPERATION AND SAFETY INSPECTION
4
1 Operation and Safety Inspection
Carried out by the manufacturer to check the following details:
Following plates present:
Nameplate
Operating instructions (abbreviated)
Lifting capacity
Bar mains pressure
Raise "up",- lower "down"
Company logo
CE marking
Operation and safety checked:
Safety valve set to 3.5 bar operating pressure
Inspected:
Unladen function test
Safety catch function
The control valve automatically goes into the 0 position
No damage to the surface of the air bags
Secure fit of all supporting screws
Safeguard of the scissor pins
Condition of the pneumatic lines (proper position and do not leak)
Function loading ramps
Function Roll-off protection
Function folding ramp
Serial No.: See cover sheet
Date: ____________________
Name: ____________________
Herkules Hebetechnik GmbH
Falderbaumstraße 34
D - 34123 Kassel
Tel.: [phone]
Fax: [phone]

GENERAL INFORMATION
5
2 General Information
The operating instructions (and test log book) contain important information concerning the installation, and
ensure safe, proper, and economical operation as well as preservation of operational safety.
Observance of these operating instructions will help you to avoid danger, reduce repair costs and downtime
as well as to increase the life of your service lift.
As evidence of regular safety checks this test log book contains a form. This should be used to provide
documented details of tests. (It is advisable to make a copy of the form before starting to fill it out.)
Installation and testing
Safety-related work and safety inspections may only be performed by suitably trained personnel. In this
documentation, personnel are designated as expert and qualified persons.
2.1 Hazard Warnings
To identify hazardous areas and important information, the following symbols with the described definitions
are used. Please pay special attention to text sections marked with these symbols.
Signifies danger for life and limb, meaning improper execution of the process
referred to by the symbol may be fatal!
Signifies a notification of a key function or an important notice!
2.2 Limitation of Liability
All details and indications in this operating manual were compiled taking into account the applicable
standards and regulations, and the latest technology as well as our many years of insight and experience.
The manufacturer accepts no liability for any damage caused by:
Failure to adhere to the operating manual
Improper use
The intervention of non-qualified staff
Arbitrary alterations
Neglecting maintenance

GENERAL INFORMATION
6
2.3 Copyright
These operating instructions are to be treated as confidential and are solely intended for personnel working
with the machinery. Transfer of the operating manual to third parties without the written consent of the
manufacturer is prohibited.
Text, drawings, images and other illustrations are copyrighted and intellectual
property rights apply.
2.4 Terms of Guarantee
The terms of guarantee are included as a separate document in the sales brochures.
2.5 Customer Service
For technical information, please contact our customer service centre as follows:
Customer
service:
Herkules Hebetechnik GmbH
Falderbaumstraße 34
D - 34123 Kassel
Tel.: [phone]
Fax: [phone]
E-mail: [email protected]

PRODUCT DESCRIPTION
7
3 Product Description
3.1 Intended Use
The lift is exclusively intended for lifting vehicles (passenger cars) with a maximum nominal load (see
chapter “Technical data”).
Lifting individuals and other objects is prohibited.
Working under a lifted vehicle and during the lifting and lowering movement is not permitted.
Operation may only be performed by persons who have read and understood the operations manual and
who are more than 18 years of age.
Vehicles may only be lifted at the designed lifting points (at framework or on the wheels). It is only allowed
to lift vehicles as stated in the operating instructions.
The products described in these operating instructions can be used in explosion hazardous areas and are
subject to the Directive 2014/34/EU. Measures to protect against explosion hazards are required. See
Chapter "General Safety Information" and Chapter "Installation” for further information.
The marking of the equipment is Ex II 3G c IIA T4
The lifting platform is part of the machinery group II, category 3; used in general industry in Area 2 for gases
of explosion group IIA
c = constructional safety
T4 = up to 135 ° C surface temperature
Version as a category 2 is available upon request
The scope of intended use also includes the reading of the current operating manual as well as compliance
with all the indications included in the same –particularly safety instructions.
The scope also extends to ensuring that all inspection and maintenance operations are implemented within
the prescribed time periods.
If the vehicle lift system is not used according to its intended use, safe operation of the system cannot be
guaranteed.
In the event of any accident resulting in personal injury or damage to property resulting from improper use,
the operator of the lifting system shall be responsible and not the manufacturer!

PRODUCT DESCRIPTION
8
3.2 Product Structure
The vehicle lift consists of a pneumatically operated platform main body on one hand and of a cantilever set
on the other hand lifting the vehicle directly by the wheels.
The air bag performs an axial stroke movement that is carried out laterally by the scissors. The scissors
also restrict the lift height of the service lift. A safety catch prevents the service lift from sinking in the case
of deflation.
The operation of the service lift ensues with an operating unit that is connected to the lift via two pneumatic
tubes (air bags / safety catch).
Technical data about the service lift is available in the “Technical Data”Chapter.
You will find reference to professional assembly in the “Mounting”Chapter.
Diagram 1: Product HLS1200-11
Diagram 2: Product HLS1200-14/-16

PRODUCT DESCRIPTION
9
3.3 Technical Data
Technical changes
reserved.
HLS 1200-11
HLS 1200-14
HLS 1200-16
Lifting capacity of the service lift
2500 kg
Empty weight of the service lift
750 kg
Maximum load distribution
3:2 in or against the driving direction
Lifting time of the service lift
approx. 15 sec.
Lowering time of the service lift
approx. 20 sec.
Effective stroke of the service lift
825 mm
Height of the service lift
930 mm
825 mm
825 mm
Insertion height minimum/ overhead
height
105+5 mm
No
No
Length of the base body
1597 mm
Width of the base body
1126 mm
Total length
3545 mm
3550 mm
3550 mm
Total width
1955 mm
Gear
pneumatic (2 air bags)
Operating pressure for the safety
valve
3.5 bar
Pneumatic connection to supply
system Pmax
8 bar (provided by the customer)
Noise pollution under
70 dB(A)
Dimension sheet
K 1208-HLS-002-3
K 1208-HLS-004-3
K 1208-HLS-006-3
Assembly plan
K 1208-HLS-003-3
K 1208-HLS-005-3
K 1208-HLS-003-3
K 1208-HLS-005-3
Fitting frame for grids
Fitting frame for foundation
K 1208-HLS-034-3
K 1208-HLS-035-3
K 1208-HLS-034-3
K 1208-HLS-035-3
Pneumatic circuit diagram
K 1208-008-4
K 1208-008-4
K 1208-HLS-042-3
K 1200-HLS-012-3
Pneumatics spare parts
K 1208-008-4
K 1208-008-4
K 1208-HLS-042-3
K 1200-HLS-012-3
Spare parts lifting platform
K 1208-HLS-002-3
K 1208-HLS-004-3
K 1208-HLS-006-3
Safety devices
Anti-drop safety device
Yes
Safety valve
Yes
Roll-off safety device (vehicle)
Yes
Safety equipment mechanical
No
Yes
Protective frame
No
Safety equipment pneumatical
CE stop with acoustic signal
No
No
Yes
Stop of lifting
platform 120mm
before stroke end
3.4 Product Designation
The details of the lifting platform are stated on the type shield on the machine frame as well as in the
EC Declaration of conformity.
Article No.
Year of construction
Machine type
Operating pressure
Serial No.
Vers.
Lifting capacity
Empty weight
Details
Nameplate

EC DECLARATION OF CONFORMITY
10
4 EC Declaration of Conformity
set out in Annex II A of the EC Machinery Directive
(2006/42/EC)
The manufacturer
Herkules Hebetechnik GmbH
Falderbaumstraße 34
D - 34123 Kassel
Herkules Hebetechnik GmbH
is responsible for the
documentation and declares
that the following machine
described,
Service Lift
Machine Type
K 1200-HLS-11
K 1200-HLS-14
K 1200-HLS-16
Art.- No.
HLS 1200-11
HLS 1200-14
HLS 1200-16
Serial No.:
See cover sheet
See cover sheet
complies with the Health
and Safety requirements
of the following
EC directives:
Machinery Directive 2006/42/EG
Directive 2014/34/EG
Ex II 3G c IIA T4
Applicable harmonised standards:
EN 1493
EN 292; EN 294; EN 349
EN 1127-1
Vehicle lifting platform
Safety of machinery; safety distances
Potentially explosive atmospheres
EC type examination
Test certificate no.
K1200-HLS-11
K1200-HLS-14
K1200-HLS-16
44 205 10377 983-004
44 205 10377 983-004
44 205 10377 983-004
Testing laboratory
TÜV Nord Cert GmbH
Kassel, 25.04.2017
Location, Date Dirk Meinzer, Managing Director

GENERAL SAFETY INSTRUCTIONS
11
5 General Safety Instructions
5.1 Operator’s Duty of Care
The lifting platform was designed and built taking a hazard assessment into account and following careful
selection of the harmonised standards to be met, as well as additional technical specifications. It thus
corresponds to the state of the art and guarantees the utmost level of safety.
However, this safety level can only be reached during practical operation, when all measures required have
been implemented. The Due diligence is required on the part of the operator of the lifting platform, to plan
these measures and ensure their implementation.
The operator must, in particular, ensure that
The lifting platform is only used as intended (see chapter “Product Description”).
The service lift only be used in a fully functional and fault-free state and will be checked regularly for
operational functionality with special attention to safety equipment.
The placement of the service lift is located and designed so that the operator is able to observe all
movements of the load as well as have an overview of the area under the lift and its load. The operator is
responsible for supplying adequate lighting.
Access to the danger area (area under the lifting platform and under the load) by individuals is forbidden.
Operations in the danger area are prohibited. Maintenance operations are excluded, (see Chapter
“Maintenance”).
The operating instructions are to remain fully readable and available in the area in which the lifting
platform is used.
The lifting platform is only used by individuals having read and understood the operating instructions.
Personnel are to be regularly instructed of all relevant information regarding work safety and
environmental protection and familiar with the operating instructions and the safety notices therein.
Only qualified individuals and experts may repair the lifting platform.
None of the safety and warning notices linked to the lifting platform are to be removed and must remain
readable.
No interference with the service lift (for example, repairs) should take place without adhering adequately
to protective measures (safeguard the base from sinking with a service support).
5.2 Operator’s Duties
The operating safety ordinances are intended for the operators of work equipment used in vulnerable areas.
The operator must take a risk assessment of the area where the work equipment (service lift) will be used.
The dangers that arise during the use of the work equipment related to the substances and working
environment should be detected and taken into account.
The operator shall take the measures necessary and choose operating equipment suitable for the conditions
prevailing at the workplace and assure the safety and health of employees.
For the execution of risk assessment and decision on suitable equipment, the operator must apply country-
specific guidelines and standards.

GENERAL SAFETY INSTRUCTIONS
12
5.3 Basic Safety Measures
When operating the service lift, the statutory accident prevention regulations in
accordance with BGV A1 (General requirements) apply. Regulations BGR 500
(operators of work equipment) can be used for information purposes.
The operator is to monitor the vehicle during lowering and lifting.
Service lift parts such as air bags or air bags must be protected while working with
high temperatures (welding, grinding, etc.) and from mechanical and chemical damage.
Compliance with the following points is particularly emphasised:
The service lift is only to be used for lifting passenger cars.
The total weight of the lifted car may not exceed the stipulated lifting capacity, whereby a maximum
load distribution of 3:2 in the driving direction or 2:3 against the driving direction is permitted.
While operating the service lift, instructions in the operator's manual are to be complied with.
Only persons who are 18 years old or older and instructed in the use of the service lift are permitted
to use it.
During lifting and lowering movements, no person other than the operator may stand in the way of the
area of movement for loading and service lift.
The transport of passengers on the service lift or in the car being lifted is prohibited.
Climbing on the service lift or in the car being lifted is prohibited.
Following any modifications to the construction and repairs to load-bearing parts, the service lift must
be inspected by an expert. Changes and repairs must be recorded on the master data sheet.
In the event of modifications (i.e. repairs) appropriate safety measures must be met. (Safeguard the
base from sinking with a service support.)
Sufficient clearance between low lying vehicle parts and the service lift should be ensured before
lifting begins.
Not complying with the safety regulations can cause serious injuries as well as damage
to the lifted vehicle.
Make sure that the front wheels are in the straight-ahead position. Before lifting,
prevent the vehicle from rolling away. Pull the hand brake and shift the car into reverse
or first gear. For vehicles with automatic transmission shift the car into the P position.

GENERAL SAFETY INSTRUCTIONS
13
5.4 Requirements of Operating Personnel
The lifting platform must only be used by individuals who have been suitably trained, instructed and
authorised. These persons must be familiar with the operating manual and proceed in accordance with the
same. The respective authorisations of the operating personnel are to be clarified.
Moreover, for the following activities, specific qualifications are required:
Operation
Execution
Installation
Herkules service assemblyman / qualified person
Starting up
Herkules service assemblyman / qualified person
Briefing
Herkules service assemblyman / qualified person
Fault clearance
Herkules service assemblyman / qualified person
Servicing
Herkules service assemblyman / qualified person
Maintenance
Herkules service assemblyman / qualified person
Repairs
Herkules service assemblyman
Disassembly
Herkules service assemblyman / qualified person
Operating individuals in training should only operate the lifting platform when supervised by an experienced
person. Evidence of completed and successful training should be confirmed in writing.
All control and safety installations must, only be operated by suitably trained persons.
All individuals engaging in activities involving the lifting platform must read the operating instructions and sign
to confirm that they have understood them.

TRANSPORT AND PREPARATION
14
6 Transport and Preparation
6.1 Transport Inspection
Check the order upon receipt of delivery for damages caused during transport.
If there is identifiable damage, proceed as follows:
Leave the goods and packaging in an unchanged state. Do not attempt to use the product.
Immediately contact Herkules customer service.
Customer service:
Herkules Hebetechnik GmbH
Falderbaumstraße 34
D - 34123 Kassel
Tel.: [phone]
Fax: [phone]
E-mail: [email protected]
Do not send back damaged goods before receiving confirmation from the customer
service centre!
6.2 Disposal of the Packaging Materials
The packaging material must be disposed of in accordance with the current environmental - and disposal
guidelines.

INSTALLATION AND ASSEMBLY
15
7 Installation and Assembly
The following important safety instructions must be observed during the assembly of the service lift. Adhering
to safety instructions helps to avoid life-threatening injuries, personal damages, as well as damage to
machinery.
The installation work must only be performed by suitably-trained persons and with compliance of the
safety instructions during the process.
Before commencing the installation work, the lifting platform must be investigated for damage in
transit.
Always ensure that only authorised persons enter the working space and that no other persons are
exposed to any risk from the installation work.
All machine connections (tubes) are laid out so that there is no risk of stumbling.
Also read the Chapter “General Safety Instructions”.
7.1 Environmental Conditions for Assembly
The service lift is only suitable for use in dry, closed, indoor rooms.
The ground where the car lift is to be assembled should be horizontal and flat (according to DIN 18202), and
the load capacity of the floor must be able to support the total weight of the service lift.
The operator is solely responsible for the selection of the installation location.
The service lift must only be used within a temperature range of 5°C to 65°C. During the selection of the
assembly location bear in mind the measurements of the service lift that are outlined in the chapter
“Technical Data”as well as the chapter “Additional Information”(take note of the measurements with a
lifted vehicle as well).
Adequate ceiling height must be present (at least the total height of the service lift plus the vehicle height).
Care must be taken that the minimum distances specified are adhered to (according to country-specific
regulations and workplace ordinances) with regard to distance between walls and equipment respectively. It
should be noted that the service lift must not block any emergency escape routes. Adequate lighting must be
present at the assembly site (according to country-specific regulations and workplace ordinances).
A compressed air supply R1/2" of 8 bar mains pressure must be available at the service lift assembly
location.
Care must be taken in selecting the assembly location so that the operator has an
unobstructed view of the service lift and the car being lifted.
Only use dehumidified, non lubricated compressed air! A filter regulator must only be
installed in the mains connection (air filter and water separator)!

INSTALLATION AND ASSEMBLY
16
8.2 Assembly Instruction HLS1200-11
No
.
HLS1200-11
Description
Material requirements
1
Packaging units
1x Platform main body
1x Cantilever set
2
Control packaging content
Detailed assembly see
chapter “Additional
Information”
3
Screw in hose barb
1x Hose barb 1/2"
4
Connect
platform-sided hose line
1x Rubber hose 16mm
1x Rubber hose 8mm
1x Hose connector 6mm
2x Hose clamp 10-16
1x Hose clamp 16-25
5
Connect
platform-sided hose line.
Connect pneumatic line
(provided by the
customer)
1x Operator control module
1x Hose clamp 10-16
1x Hose clamp 16-25

INSTALLATION AND ASSEMBLY
17
No
.
HLS1200-11
Description
Material requirements
6
Run in cantilever
2x Cantilever HLS1200-11
7
Run lifting platform in
the upper end position.
(Operator control
module: Open stopcock
/ hand-operated lever in
the switch position „on“).
8
Screw together
cantilever with the
platform main body.
6x Hexagon screw M12x40
6x Nut M12
12x Ring washer 13mm
Important:
Insert screws from the inside!
9
Install roll-off protection /
stop side
(Notice running
direction).
2x Plate roll-off protection
4xHexagon screw M10x30
4x Nut M10
8x Washer 10.5mm
10
Ramps holder /
running side.
(Notice running
direction).
2x Plate roll-off protection
4xHexagon screw M10x30
4x Nut M10
8x Washer 10.5mm

INSTALLATION AND ASSEMBLY
18
No
.
HLS1200-11
Description
Material requirements
11
Mount drive on ramps.
2x Drive on ramps
12
Interim drive over ramps.
Tilt up interim drive over
ramp.
2x Folding ramp
13
Adjust lifting platform
Mount lifting platform
(Boreholes 16mm)
4xHexagon screw 12x100
4x Washer 13mm
4x Dowel S16
14
Install hose lines
(Shorten in case it is
necessary)
Install operator control
module
(Mounting material:
Provided by the
customer)

INSTALLATION AND ASSEMBLY
19
8.3 Assembly Instruction HLS1200-14 / -16
No
.
HLS1200-14 / 16
Description
Material requirements
1
Packaging units
1x Main body
1x Cantilever set
2
Control packaging content
Detailed assembly see
chapter “Additional
Information”
3
Screw in hose barb
1x Hose barb 1/2"
4
Connect platform-sided
hose line
1x Rubber hose 16mm
1x Rubber hose 8mm
1x Hose connector 6mm
2x Hose clamp 10-16
1x Hose clamp 16-25
5
Connect platform-sided
hose line.
Connect pneumatic line
(provided by the
customer)
1x Operator control module
1x Hose clamp 10-16
1x Hose clamp 16-25

INSTALLATION AND ASSEMBLY
20
No
.
HLS1200-14 / 16
Description
Material requirements
6
Run in cantilever
2x Cantilever HLS1200-14
7
Run lifting platform in the
upper end position.
(Operator control module:
Open stopcock / hand-
operated lever in the
switch position „on“).
8
Screw together cantilever
with the platform main
body.
6x Hexagon screw M12x40
6x Nut M12
12x Washer 13mm
Important:
Insert screws from the inside!
10
Install operator control
module
4x Plate roll-off protection
8xHexagon screw M10x30
8x Nut M10
16x Washer 10.5mm
11
Mount drive on ramps.
4x Drive on ramps