HAPP 35 Manual v3 (205684)

Installation and Operation Manual
HAPP 35
Two Post
Dual point safety release
Hydraulic Lift
HAPP 35
Table of Contents
Introduction ................................................................................................................. 5
Hoist operation ........................................................................................................... 6
Safety Warning Signals ........................................................................................... 6
Use of the hoist ....................................................................................................... 7
Expected Rated Load Distribution ........................................................................... 7
Safety Notice Points ................................................................................................ 8
Workplace Health and Safety (WH&S) Design registration and operation.......... Error!
Bookmark not defined.
Operation .................................................................................................................... 9
Hoist Operating Procedures ....................................................................................... 9
Pre operation checks .............................................................................................. 9
Operation .............................................................................................................. 10
Maintenance ......................................................................................................... 10
Defects - Malfunctions............................................................................................ 11
............................................................................................................................... 11
Specification ............................................................................................................. 12
Example hoist operation ........................................................................................... 14
Arm Restraint ........................................................................................................ 14
Vehicle in Raised Position ..................................................................................... 15
Set on Locks ...................................................................................................... 15
Lowering ............................................................................................................... 15
Maintenance ............................................................................................................. 16
Maintenance Schedule ...................................................................................... 16
Annual Inspection .............................................................................................. 16
Maintenance by the Operator ............................................................................ 16
Troubleshooting ........................................................................................................ 18
Disposal .................................................................................................................... 19
Installation ................................................................................................................ 20
Space required ...................................................................................................... 20
INSTALLATION ..................................................................................................... 22
Hydraulic Drawing..................................................................................................... 23
Exploded drawing ..................................................................................................... 24
Controls .................................................................................................................... 27
Power unit ............................................................................................................. 27
Electrical system .......................................................... Error! Bookmark not defined.
Limit switch wiring (optional) .................................... Error! Bookmark not defined.
© 2013 HAPP Australia Pty Ltd Version 2 2|Page
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Electrical wiring – AS3000 ........................................ Error! Bookmark not defined.
HAPP hoist summary ............................................................................................... 31
Australian and CE Standards ................................................................................... 32
Site inspection and preparation .............................................................................. 33
Installation............................................................................................................... 35
Installation Procedure ......................................................................................... 35
Hoist operation ........................................................................................................ 42
HAPP Installation Frequently asked question (FAQ) .............................................. 45
What oil do I use? ................................................................................................. 45
What is the easiest way to add oil? ...................................................................... 45
How much oil do I need ? ..................................................................................... 45
How do I install anchor bolts?.............................................................................. 45
What are the top tips for installing my hoist? ......................................................... 46
The balance cables don’t fit, one side seems shorter than the other ? ............ 46
The fittings on the pump assembly are loose. .................................................. 47
The hose does not reach the fitting on the pump assembly. ............................ 47
The hose fitting supplied is different to the one on the pump assembly. ........ 47
My carriage won’t come down when I first lift the hoist? ................................ 48
Some customer customizations ................................................................................ 49
Make use of the power and column position ............ Error! Bookmark not defined.
Custom door protection ......................................................................................... 49
Custom vehicle connectors ................................................................................... 49
Be happy and enjoy your HAPP hoist ................................................................... 50
To Our Customers..................................................................................................... 51
Safe operating procedures and installation ............................................................... 51

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Final notes on HAPP 35 -----READ ME FIRST-----

Electrical wiring
Follow electrical wiring notes in this manual
Oil grade
The hoist will need 10 litres of ISO grade 46 oil, this is available from most
Automotive shop.
Anchor bolts
Use a high quality masonry bit ( the quad tip style not the flat blade style) that
matches the size in the kit, you should have M20 bolts which would take a 20mm bit.
Check this before purchasing your bit and do a test hole to confirm it is a neat fit.
Bunnings sell good drills and bits at the price of hiring similar.
Limit switch wiring
The pump assembly can be used with a limit switch as an option, it has a connector
for this similar to the one shown below. The electrical wiring notes tell you to disable
this by connecting (bridging) these two wires. The pump will not run unless these
wires are joined. If you want to add a connector later that is removable the following
connector is available from HAPP.
Connector available from HAPP
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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Introduction
In this manual, contents about safety should be paid special attention. Here are
some signals used in this manual.
If there is this signal before any passage, it means that

operation like this is wrong and will lead to big casualty or
heavy damage to the device.
The figure appearing before passage shows that it is not allowed to operate according
to the passage, or the potential risk will develop into big casualty and heavy damage
to the lift.
The passage besides this signal lists the notice points and security
●Though we have taken the safety into consideration during designation and
produce, some training is required before operating the hoist. Without reading this
manual, do not operate or maintain the lift.
●Read the requirement for power source and electric current on the nameplate of
motor, and make sure that the power is connected by a specialized electrician.
●The manufacturer is not responsible for giving notice of any further change on
partial structure of the lift after selling the lift.
● This hoist is rated at 4 T capacity any vehicle whose weight is above 4000kg is not
allowed to be raised on this machine.
● Before operation of the hoist,

1. Perform pre operation checks as designated on the hoist
2. Read the warning labels on the equipment carefully.
3. Update any log books required

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Hoist operation
Safety Warning Signals
Please read Safety Signage carefully, understand and remember them.

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Use of the hoist
The lift is used to lift vehicles for inspection, repair and maintenance whose weight 4 Tonne or
less. Other usages are not allowed.
Expected Rated Load Distribution
Rated Load Load Distribution Former part : Latter part

Minimum Maximum
HAPP 35 4000 kg 2:3 3:2
In principle, the lift the design supports double direction

placement of the car. The vehicle weight should be evenly
distributed onto the columns. If the hoist is fitted with shorter arms
on one side, these arms should be swapped with the long arms if
vehicle direction is changed.

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Safety Notice Points
ⅰ. Operators should read the manual carefully to avoid accidents.
ⅱ. Operators should be familiar with all functions and operating methods of the lift.
ⅲ. Check before operating and regular check must be carried out.
ⅳ. If there is any abnormal sound during rising and lowering, stop using the lift.
ⅴ. Never use the lift to raise a vehicle whose weight is above 4ton.

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Operation
• Lift operation by authorized personnel over 18 years only.
• Apply the parking brake after positioning the vehicle on the lift.
• Do not allow anyone to stay in lift area during raising and lowering cycles.
• Closely watch the vehicle and the lift during raising and lowering cycles.
• Observe the rated load capacity and load distribution.
• Do not allow anyone to climb on lift or stay inside vehicle
• After raising the vehicle briefly, stop and check adapters for secure contact.
• Once the disk adapters contact the lift points, operators should check arm
restraints for engagement.
• Make sure the vehicle doors are closed during raising and lowering cycles
Hoist Operating Procedures

This product is designed to raise vehicles only for the purpose of examination, repairs and
maintenance.
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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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.
© 2013 HAPP Australia Pty Ltd Version 2 10 | P a g e

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Defects - Malfunctions
 In case of defects or malfunctions such as jerky lift movement or deformation
of the superstructure, support or lower the lift immediately
 Turn off and padlock the main switch. Contact qualified service personnel
 Once any button is actuated, press the Up button, the lift moves until the
button is released
 When the Up button is released, press the Unloading Handle once to set the
lift on the mechanical locks automatic.
 Press the Up button once first, insure the safety plate is in disengaged
position,
 press the Unloading Handle to lower the lift
Unloading Handle

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Specification
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Height overall 2722 mm
Raising / Lowering time Approx. 50s
Lifting height max. 1800 mm
Lifting height min. 110 mm
Support arm reach 695…920 mm
Support arm reach 795…1120 mm
Inside columns 2728 mm
Drive-through clearance 2480 mm
max.
Load capacity 4000 kg
Net weight 547kg
Anchoring M20 Tru bolt
Motor power 2.2kW
Rated current 14.6A
Power supply 240V or 415V
50Hz

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Example hoist operation
Arm Restraint
Once the disk adapters contact the lift points, operators should check arm restraints
for engagement. If necessary, slightly move the arm until the gear segments mesh.
Never unlatch the arm restraints when the lift is under load.
Each support arm is provided with an automatic arm restraint which unlatches
automatically when the lift is in bottom position. When the carriages are in a raised
position, the arm restraint can be disengaged by pulling the Pull Handle.
Pull Handle
3.3 Arm Operation

3.3.1 Preparation
1. Fully lower the lift and swing arms to full drive- through position.
2. Slowly position vehicle midway between adapters. Apply the parking brake.
3. Swing and telescope arms as required to position adapters to manufacturer's
recommended lift point.
4. Turn the disk adapters that they evenly contact all four lift points.
5. Leave vehicle and remain clear of lift.
During raising and lowering cycles: Closely watch the vehicle and the lift, do not allow
anyone to enter or stay at lift area and make sure the vehicle doors are closed. Once
the disk adaptors contact the lift points, operators should check arm restraints for
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engagement. After raising the lift briefly, stop and check the adaptors for secure
contact.
1. Push and hold GREEN button until lift reach desired height.
Lift stops once button is released
Vehicle in Raised Position

1. Observe all accident prevention regulations.
2. Do not allow unauthorized persons to stay under the raised vehicle.
3. Avoid rocking of vehicle.
4. Keep lift free of tools, parts, etc.
5. Fasten the vehicle to the support arms using lashing straps when removing or
installing heavy components
Set on Locks
Use the Unloading Handle to set the lift on the mechanical locks.
In this way the vehicle can be securely fixed when the vehicle is in a raised position.
Lowering
Raising and lowering cycles: Closely watching the vehicle and the lift, do not allow
anyone to stay in lift area and make sure the vehicle doors are closed
• Remove tools, stands or other objects from lift bay.
• Lift is ready for operation
• If the safety plate is in the engaged position, briefly raising the lift before
lowering.
• Pull the unlocking steel wire on both columns
• Press the Unloading Handle until lift reaches desired height
• Lift stops once Relief Handle is released or downward travel limit is
reached. During lowering cycles the support arm automatically stop at a
height of 110mm.
• To lower the arm completely, please release the Unloading Handle.
Swing arms to full drive-through position and drive the Vehicle off the lift
In case of motor defect or power failure the lift can be lowered manually.
Authorized personnel only! Do not restart the lift before the error has been remedied.
If the lift load lies fully on the safety plates, manual lowering is not possible.
Safety plate in engaged position Safety Plate in disengaged position

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Maintenance
The maintenance intervals indicated below apply to average workshop use.
The lift should be inspected more frequently for severe use applications.
Maintenance Schedule
Establish a periodic preventive maintenance procedure to ensure trouble free
operation and long service life.
Annual Inspection
We recommend that the lift should be inspected by qualified service personnel every
12 months.
Maintenance by the Operator
Hydraulic System
1 Once a year check the fluid level (see below) with the lift fully lowered and
add fluid as required
2 Visually check all hydraulic hoses for tightness.
The hydraulic fluid must be replaced periodically depending on aging, soiling and
water absorption. It is recommended to replace the pressure hoses as required, but
after six years at the latest
Checking the Fluid Level
The fluid level can be read through the transparent reservoir at the power unit.
With the lift fully lowered, the fluid level must reach above the min level.
Greasing Points
Sliding Tracks
The slide tracks inside the columns should be greased every six months (or more
frequently in case of noise generation).
Slightly grease the slide tracks and the whole length using a brush
Arm Extensions
The arm extensions should be greased every six months (or more frequently in case
of sticky arms.
If arms are stuck, sometimes weld slag can be caught in the arm, the arm should be
removed inverted (upside down) and worked in and out till free.

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Operational and Wearing Check
Rubber Pads of Disk Adapters

Weekly check the rubber pads for wear.
Replace them as required.
Arm Restraints
Weekly check the arm restraints for secure
engagement.
Lift Stability
1 Every six month check the nuts of all anchor bolts for correct installation torque
2 Retighten them as requirement
Installation Torque
HAPP 35 80Nm
Cleaning
Do not use high pressure / steam jet cleaners or caustic cleaning agents.
1 Periodically wash off aggressive substances and treat the lift with oil or wax
spray.
2 Repair damage to the paintwork immediately to prevent corrosion. The RAL
number is available through the manufacturer.

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Troubleshooting
Trouble Diagnosis Remedy

Main switch off. Turn on main switch.
Lift does not respond.
Mains fuse defective. Replace mains fuse.
Lowering valve Close lowering screw.
Permanently open
Hydraulic system leakage Contact service.

Motor starts up,
pressure build-up Low fluid level Remove leakage.
insufficient to raise load.
Load on lift too heavy. Check fluid level, add
fluid as required.
Load on lift too heavy. Reduce load, observe
rated load capacity.
Level difference Adjust cables maladjusted. Contact service.
between carriages too
big.
Lift cannot be lowered. Latch release defective. Contact service.

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Disposal
For disposal at end of working life, drain hydraulic fluid and dispose of fluid and
other components through the normal industrial scrap route. No hazardous
materials are used

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Installation
Space required
The lift must be installed on a level concrete floor, detailed data of which as shown in
the following drawing
.
The lift installation concrete surface must be perfectly smooth.
Tru bolt sizes vary depending on the shipment of the
hoist.Make sure you measure the size of your dyna bolts before
selecting your drill bit. Typically HAPP hoist shipments are 20mm in
size (M20). These diagrams show 18mm (M18) bolts, these can be
supplied as options if required.

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Note: M20 – 20mm tru bolts are supplied with HAPP hoists.

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INSTALLATION
STEP ONE: (determine location and marks with chalk on the floor.)
1．Determine which side is the approach side and on which side the
power unit to be mounted.
2. Once the location is selected, use a chalk line to layout a grid for the post
locations and make an outline of the posts on the floor at each location.
3. Before proceeding, double check measurements and make certain that the
bases of each column are square and aligned with the chalk line
STEP TWO: (Mounting two columns)

1. Drill each anchor hole in the concrete using a rotary hammer drill. To assure
full holding power, do not ream the hole or allow drill to wobble
.2 After drilling, remove dust thoroughly from each hole and make certain that
the column remains aligned with the chalk line during this process.
3. If shimming is required, insert the shims as necessary under the base plate
so that when the anchor bolts are tightened, the columns will be plumb.
4. With the shims and anchor bolts in place, tighten by securing the nut to the
base then turning 2 -3 full turns clockwise. DO NOT use an impact wrench
for this procedure.
5. Position the other column at the designated chalk locations and secure to
the floor following the same procedures as outlined in step 1, 2, 3, 4
AFTER ENSURING THAT YOUR CABLES WILL FIT CORRECTLY.
STEP THREE: (Routing the Equalizer cables)

1. Raise and lock each carriage approximately 800mm high above the
ground.
2. Make sure that the safety locks on each column are fully engaged before
attempting to route equalizer cables
Carriages must be equal height from the floor before proceeding.
3. With the carriages in equal position from the floor, operators should route
the equalizer cables as shown below.
4. After the equalizer cables have been routed, adjust each cable so that they
are equal tension.
NOTE: The equalizer cables should be checked weekly for equal

tension. Failure to do this will cause uneven lifting. The cables
should always be adjusted so that they are equal tension when
resting on the safety locks.
STEP FOUR: (Mounting the power unit.)

Attach the power unit to the POWERSIDE COLUMN with supplied tolls and parts.
Fill the reservoir with hydraulic oil. Make sure the funnel used to fill the power
unit is clean. In summer and winter, you should change the oil.
STEP FIVE: (Installing Hydraulic Lines.)

1. Install the hydraulic lines as shown below, paying careful attention to keep the
hoses clean and free of debris.

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Hydraulic Drawing
No. Name No. Name No. Name

1 cylinder 4 overflow valve 7 gear pump
2 one-way throttle 5 unloading valve 8 adjustable throttle valve
valve
3 one-way valve 6 electric motor 9 Filter

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Exploded drawing

HAPP 35

HAPP 35

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Controls
Power unit
Control unit
Controls for operating the lift are:

Connect the power first and push the green button the power unit for up, and press
unloading handle on the power unit to lower the lift.
The small allen key in the center of one side of the unit is used to adjust the lowering
speed. The other flat head adjuster under the plastic cover on other side adjusts the
pressure side of the control valve.

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Electrical system
The figure below illustrates the electrical connections for the control unit on the
electric motor.
Figure: Electrical schematic for HAPP motors.
Some HAPP motors are supplied with an additional connector that bridges the A2
connector as shown below.
Limit switch wiring
Figure: Limit switch wiring inside wiring of single phase motor.

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These wires map out to a white connector as shown below.
Figure: Electrical connection to motor
This white connector is used to attach an limit switch to the hoist. In cases where this
connector is not required, bridge(connect) these two wires to disable the connector.
Important:
The limit switch is wired to the top crossbar on HAPP 40.
Ensure the hoses are pulled to the top of the column and that the limit switch wires
are not held in the hydraulic line clamps. If they are remove them and attach to hose
with cable ties.
Electrical wiring – AS3000

Power wiring will be according to the following Australian standard (AS3000),
Electricians must remove the top cover and verify ground , neutral and phase
connections as well as limit switch connection if required and connect wires
according to the following specification.
Phases Neutral Earth
Australia, New Zealand (AS/NZS

3000:2007 3.8.3)
, ,
Motor
Connect to: 3/L2 5/L3
Chassis

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Wiring of single phase power to motor control unit

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HAPP hoist summary
This information is informative only and is subject to change without notice,
refer to specification sheets for current information. The current range of
products is visible on the happ website. http://happ.com.au/products/
Each HAPP hoist uses dual hydraulic rams (one in each column) to lift the carriage
which has the lifting arms connect to them. The ram lifts by pushing a heavy duty
chain connected to the column on one side to the carriage on the other side. Each
hoist has dual safety interlocks (one on each column) which engage independently
as the hoist lifts.
There are three basic styles of 2 post hoists available from HAPP. Floor plate,
Hydraulic and Clear floor styles.
o The floor plate style (Happ30, 35, 70 and 80) connects the columns
with balance cables that balance the load across the hoist carriages
and hydraulic hoses for lifting across the floor protected by a checker
plate cover between the columns. This plate is approximately 50mm in
height and has an angled surface on each side to enable easy drive
through with vehicles.
The column height of these hoists range from 2.72m to 2.85m
depending on model. The column widths of these hoists range from
3.26m to 3.41m depending on model.
o The typical clear floor style (Happ40 and 60) connects the columns
with balance cables that balance the load across the hoist carriages
and hydraulic hoses for lifting protected by a section of U shaped bar
across between the columns at the top of the hoist. The connection
at the top of the column enables the floor to remain clear but introduces
a height restriction. The connecting bar also provides a load sharing
function as each column now has a strut connecting them at the top as
well as the floor via concrete.
The column height of these hoists are 3.68m. The column widths of
these hoists are 3.44m
o The hydraulic hoist style (HAPP 90) uses a hydraulic control valve to
balance the load between the columns by managing the pressure
supplied to the hydraulics. It is a clear floor style hoist also.
The column height of the HAPP 80 is 2.02m with variable column
width.
The HAPP 90 uses loxon fitting bolts (anchor bolts can be used). The
loxon bolts act like a nut rather than a bolt. Whilst the actual bolt in a
loxon is 16mm in diameter the hole size required is 24mm to allow for
the nut size.
o The HAPP 25 and 27 represent 4 post hoists available from HAPP

o The HAPP 10 is a scissor hoist available from HAPP

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Australian and CE Standards
HAPP hoists 25, 40 and 70 have been assessed for Australian Standards certification
and have passed. These hoists have been registered with Workplace health and
Safety and are able to be used in business workshops.
Australian standards and work cover registration has been performed by a registered
engineer at substantial cost to HAPP. This process is detailed involving many
calculations and structural assessments of hoist operation involving HAPP and the
original manufacturer supplying all hoist design and test details as well as supplier
details. Customers need to be aware that many suppliers of hoists claim Australian
standards certification but actually do not have this. Work cover requires businesses
to have cover by design registration which in turn requires Australian Standards
compliance. The work cover compliance by a business also requires approved
installation and regular assessment. It is a business responsibility to fully research
and understand the details of work cover compliance in their location.
In order for HAPP approved hoists to be used in a business workshop the hoist must
be registered with HAPP and formal documentation indicating the serial numbered
hoist is certified and that the hoist has been registered as a certified hoist will be
supplied. This is required for the hoist to be used in the workplace (as well as
installation and operation by competent persons).
The same design principles and components are used across the HAPP product
range.
All HAPP hoists are compliant with CE certification requirements. HAPP hoists have
been supplied to USA and European markets for many years under this certification.
HAPP hoists are registered with CE certification authority by an external testing
authority CCQS in England.

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Site inspection and preparation
Additional information is available on line in our frequently asked questions page.
Customers are recommended to review this page at. http://happ.com.au/faqinsthoist/.
A copy of this page is included in this document, refer to the website for the most
current version.
1. Depth of concrete is impacted by the underlying soil structure - if you are

installing on top of shale you would require less thickness than an installation
on black clay soil.
Sites should have a depth of concrete of 150mm of 25MPA concrete which on
visual inspection is of solid construction. Sites that expect to have heavy
vehicles being loaded constantly would have a depth of 300mm of concrete.
Options for customers concerned with floor concrete thickness:
o Install footings: Cut out a section of the floor with a concrete saw at a
distance of 800mm x 800mm around the base of the hoist to a depth of
300mm. Use reinforcement rods and 25MPA quality concrete in the
footings. Some customers have drilled reinforcement rods into the
surrounding concrete sometimes bonding with chemset fasteners for
added connectivity. This approach is the most common form of
extension as it is relatively quick to perform.
o Extend the base plate with extension beams: 15mm X 30mm x 100mm
long bars are attached to the rear studs which serve to extend the
mounting point of the hoist out by an extra distance, reducing the
leverage of the loaded hoist. These beams are available from happ
stabilizer bars E1 and E2. http://happ.com.au/miscellaneous/clear-floor-
stabilizer-bar-cfsb/. http://happ.com.au/miscellaneous/floor-plate-
stabiliser-bar-fpsb/
o Use a HAPP big base plate which extends the base plate out to a
distance of 800mm X 800mm which then spreads the load out over a
broader area. These plates are available as HAPP big base plate.
2. Column to column leveling. Both columns should be the same height. This
seems to be obvious however some sites have been up to 25mm difference in
height. To measure this use a builders level to assess height of a level beam
from column to column. Any difference in the level beam height to floor is the
difference in height of the installed columns. The impact of this is that the
lifting carriages and arms will be at different heights which will impact the
function of connecting the car and safety locks. Small differences will be able
to be compensated with the adjustment in the balance cables for the hoist and
the adjustable pads supplied with HAPP hoists.
Options for customers concerned with column to column level:
o In many cases the addition of a spacer plate on the lower side will
address the problem.
o In some cases the floor may require a leveling layer of concrete with the
concrete being etched and then having a level layer of concrete.
Consult a concreter to ensure the concrete will bond to the existing
surface.

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3. Variation in level across the column mounting surface. The surface that
the column is to be mounted to must be level. Measure the level with a
builder’s level across width and length directions of the installed column.
Options for customers concerned with column level:
o Small variations can be managed with shims under the mounting bolts,
this is common approach.
o Larger variations may require steel bars or plate to be used to bring up
the column to level.
o Extreme variations will likely be best addressed with footings as
described in section 3.
4. Height of enclosure. Your shed should allow enough room for the top of the
hoist to clear the roof by 100mm when installing. This will allow for the removal
of the hoist after it is bolted to the floor (otherwise you will not be able to lift the
column off the mounting bolts).
5. Confirm vehicle clearance. Locate the position of the hoist intended for
installation. Draw a template on the ground with marking chalk and confirm the
height for clearance to the roof, and horizontal distance for clearance at each
end of the vehicle. Vehicles are lifted from the central point of gravity which is
typically around the middle of the driver’s door (between A and B pillars of
car). This will impact the clearance at the front and rear of the vehicle.
Measure the distance from the midpoint of the door to front and rear of floor
and confirm clearance at ground level and at maximum lift height.
Figure: Example of column location for lifting at vehicle centre of gravity.
6. Confirm the maximum lift height clearance for vehicle by measuring the
distance from the lift position to the ground. HAPP pads are typically around
110-120mm from ground level when in the lowered position. If your lift position
is 200mm then your total possible lift height will be higher by 80mm than
specified. This is not normally an issue however in some cases when you
have a high vehicle and a clear floor model you may need to allow for this. In
this case if you vehicle is a van with 2 meters in height for example, the clear
floor hoist has a cut out sensor bar that will stop any vehicle hitting the cross
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bar. Its height is normally 3.68m, but in this case the maximum lift height of
the hoist will be less than the maximum possible height.
7. Confirm Ground clearance for vehicle. HAPP pads will typically install at
around 110-120mm clearance. Whist they can be modified to fit under lower
cars this is typically not the best approach as the pads and lift arms take the
weight of the vehicle and should not be modified. (HAPP considered the
engineering of slimmer arms in this area and decided that it is better to have to
raise some cars rather than compromise standards.) Most customers either
make or purchase vehicle ramps which will raise the vehicle the minimal
amount required to clear the hoist. This is a very simple approach which works
well.
Installation
You will need the following items for hoist installation:
 ISO grade 46 hydraulic oil Shell Telus 46 or equivalent
 18 mm -20mm concrete drill bit depending on model (24mm for happ90
loxons). We recommend a trade quality bit, not the cheap brand. Note,
always measure your supplied anchor bolts before purchasing a concrete bit.
The bit should be the size measured allowing the bolt to neatly fit into the
hole.
 Specialized hammer drill (not a standard hand drill with hammer setting)
 Socket for anchor bolts / loxon (depending on your model sockets are
typically 24 - 26 24mm)
 Builders level (for column alignment)
 Assorted open end spanners for nuts on pump assembly, balance cables,
release cables (single point release models), hose fittings.
 Read over the installation procedure below before you start to familiarize
yourself with the process.
Installation Procedure
1. Unpack the hoist. The hoists are packed head to tail held in a steel shipping
frame. The components to assemble the hoist are mostly pre-assembled,
however some of the parts for assembly are placed inside the columns such
as arms, pads, anchor bolts and hoses. Unpack the contents of the hoist that
can be easily removed, often the arms can be lifted out of the column reducing
the weight of the column for subsequent steps.
2. Remove the frames. Support the hoist top that is connected to the top of the
frame (remember the hoist is packed head to tail). Then remove the bolts
holding the frame. Do the same for the other end. Failure to support the
column puts weight on the frame which will likely lead to scratching the hoist
as you remove the frame.
3. Move the columns apart and remove the remaining loose pieces from inside
the column.
4. Stand the columns up near the installation point. To stand up the column it is
best to get three capable people and slowly walk the column up to the upright
position.
HAPP 35
Note: The columns can be moved by fork lift, trolley before standing up or
walked after standing up by carefully edging the corners to the column toward
the desired location.
5. Mount the slave column that does not contain the pump / motor unit in place
with two anchor bolts. Anchor bolt holes should be drilled through the hole in
the base plate to ensure correct alignment. Drilling from markings on a floor
often leads to subtle misalignment which will prevent the anchor bolt from
being inserted. Make sure you install the anchor bolts using the process
below. A anchor bolt should be fully inserted before tightening, measure the
depth of the hole with a bolt and drill further if necessary. Sometimes it is
difficult to get the cement dust out of the hole. Loosening the dust with a screw
driver, blowing or vacuuming often helps. The bolts will be driven in with the
nut on using a solid sledge hammer. The bolts must be tight in the hole and
will tighten up quickly during the tightening step. Do not use a ratchet gun in
this step.
Figure: Anchor bolt installation process. Torque to 85 ft lb or 115.2Nm
6. Tighten the anchor bolts in place and verify the column is plum or slightly
angled outwards as shown below. Use shims to get the correct alignment if
necessary.
Figure 1. Plum line for column installation.

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7. Stand the other post into position but DO NOT fix it in place, this way the
column can be moved to enable hoses and cables to be fixed more easily.
8. Check the ram (cylinder) position. The ram should be located onto a pin at
the bottom of the column and be cantered within the carriage. If it has shifted
during transport relocate the ram onto the pin.
9. Check the chain alignment. The chain should be laid over the lifting pulley
evenly and centered.
10. If you have a clear floor hoist, connect the top cross bar. If there is concern
at the column moving you may elect to place some stabilizing weights onto the
base plate to hold in in place or put in two anchor bolts after measuring correct
distances apart for cross bar and confirming the column is plum.
11. Lay out and connect the hoses connecting the two rams together.
Direct Cutting Cutting Metal

fitting sleeve sleeve nut pipe
Fixed
clip
Hydraulic
hose
Power Hydraulic
unit Cylinder hose
T-fitting
Elbow
Hydraulic fitting
hose
Elbow
fitting

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Figure: Typical hose routing for clear floor hoist.
Figure: Typical hose (tubing) routing for floor plate hoist
12. Fit the safety release cables (single point release models only). The safety
release cable are connected via a small cable that is routed from the release
lever across to each safety location. A number of these are assembled during

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manufacture. The cable that connects the two columns will need to be
connected.
Take a moment to inspect the safety release mechanism; you will see
that a lever pulls the catch in so that it does not catch on the lugs on the
carriage when being lowered. It is important that the safety lug be pulled
in just enough to clear the lugs. Later on when testing you will hear the
safety locks clicking over the lugs as the hoist is raised. If you do not
hear this it is likely that you have this cable too tight and the safety is
being pulled on all of the time.
Remove the cover to the single point release lever.
Route the cable from the column that does not have the release lever through
the pulleys at floor level for floor plate hoists or top of the hoist for clear floor
hoist across to the main column and down to the control lever.
Attach the cable to the lever assembly by threading it through the hole in the
lever assembly. Tighten just enough to test the action of the lever on the safety
latches. Each latch should engage and release fully. As the latches on the
main column are assembled in the factory it is likely that they are correctly
adjusted, adjust the cable so the latches on the far column move the same
amount as those on the main column.
Figure: Single point release cable routing for HAPP 70 floor plate hoist

HAPP 35
Figure: Single point release for HAPP 40 clear floor hoist
13. Lay out and connect the balance cables (wire rope) (not required for HAPP
90). The balance cables are designed to align the levels of the carriage and
distribute the load so the carriages lift evenly. Do not tighten the balance
cables fully at this stage.
Lift each carriage up until both safety latches engage about 400-800mm or
onto two blocks of equal height to enable the cable to be routed more easily.
The cables are installed so that one side pulls the other side if it is not aligned.
The pulley systems for both clear floor and floor plate models route the cable
from the bottom of one carriage through pulleys to attach from the top to the
other carriage. As the carriage is raised if the other carriage is not raising at
the same rate the cable will pull the other carriage up. The cable attached from
the bottom will be doing the pulling as the hoist lifts.
Conversely as the carriage is lowered if one carriage is lowering faster than
the other it will pull down on the cable attached from the top, pulling the other
carriage down by the other end of the cable which is attached from below the
carriage. These points are important when fine tuning the carriages to lift and
lower at the same time using the adjustment nuts. Once balance cables are
connected the safety latches can be released or blocks can be removed and
the carriages lowered to the floor.

HAPP 35
Steel cable
Cylinder Nut
Figure: Cable routing for clear floor hoist.

HAPP 35
Figure: Cable routing for floor plate hoist.
14. Install the floor plate. (Floor plate versions only. The floor plate will likely fit
exactly into position which confirms the correct location of the main column
from the slave column.
15. Install the main column anchor bolts. Drill and install anchor bolts for the
main column in the same manner as described previously.
16. Finish installation of slave column. Drill and install remaining anchor bolts
for the slave column in the same manner as described previously.
17. Assemble the arms: Attach each arm to the carriages. For hoists with smaller
arms or angled (asymmetrical arms) they are placed on the end of the hoist
that will lift the engine side of the vehicle. Remove the circlip from the base of
the pin, apply some grease to the carriage, arms and pin and knock the pin in
with a hammer. (the pins are often tight fitting)
18. Assemble the lock out pins. These pins are inserted behind the arm locating
pins on the carriage. They will lock into position once the carriage is lifted and
will be in operational when the carriage is in the lowered position so you can
move the arms underneath the vehicle.
19. Install the pump / power unit. Locate the pump assembly onto the main
column with four bolts and connect the hydraulic line from the pump to the ram
on that side. A qualified electrician will connect the power to the single or
three phase connection depending on the choice made. Some models have a
an extra white connector extending from the motor switch; these two wires in
the plug are connected to the lock out sensor which routes from the top bar on
the clear floor hoists. On floor plate hoists these two wires are bridged
(connected) to allow the pump to operate.
20. Lubrication: apply grease to chain and cables, particularly where they contact
the wheels. Apply grease and oil/ WD 40 lubricant to the inside of the column
where the carriage will ride.
21. Check all oil fittings for a tight seal. There should be no oil leakage from
joints.
22. Fill the oil container with 10L of ISO grade 46 oil. Shell Telus 46 or an
equivalent 46 grade oil should be used.
The lift is now installed and ready for commissioning.
Hoist operation
The hoist is now fully installed and ready for its first test operation. This is where we
fine tune the installation and fix any problems.
These tests should be repeated monthly.
1. Pump - Motor operation:
a. Check all fittings to pump assembly are tight (they are typically loose as
fittings may need to be swapped from side to side for some hoists and
other hoists have different fittings to standard.)
b. The qualified electrician will check that the wiring to the pump is
correct

HAPP 35
c. There are two connectors from the motor assembly one for power (3
wires), the other is a limit switch connector (white connector), on hoists
that do not have a limit switch this connector should be bridged (wires
connected) . If this connector is not bridged the motor will not start.
d. Check the oil container is full of oil – oil grad ISO grade 46
e. Push the green button on motor
f. The hydraulic oil should pressurize in the rams and lift the hoist
carriages.
g. Raise the hoist 300 mm and lower with the release lever just below the
pump motor
If you raise the hoist above the safety you will hear a clicking sound of
the safeties engaging in which case you will need to release the safety
latches as described below before lowering.
Test
 Check each oil line connection for leaks and tighten gently and retest.
 If arms do not lower automatically you may have:
o Some binding in the column, place some weight on the columns
and try lowering
o The oil release valve on the pump needs adjusting; a small allen
key with the lock nut in the center of the pump assembly is used
to adjust this. This is a rare problem and should not be adjusted
immediately.
2. Safety release operation Safety latches engagement -1
a. Raise the hoist until you hear the safety latches engaging, a definite
clicking sound will be audible.
Test:
Are both columns making the clicking noise?:
o If the slave column is not on single point release models you
most likely have the cable to the slave column too tight.
o If there is not clicking on dual point manual release models you
most likely just need to pull the release cables to free them up.
3. Safety release operation Safety latches engagement -2

a. Lower the carriages with the release lever on the pump (not the single
point release lever for single point release or cables on carriage for dual
point release)
b. The arms should lower and engage the safety latches on both columns
at close to the same time.
Test:
The safety latches did not engage.
o If the safety’s have not ‘clicked’ when raising the hoist, then most
likely it has not been raised enough. Continue to raise higher to a
height of 1m or until you hear the clicking sound of the latches
engaging. If you do not hear this the release cables are too tight.
Check cable routing and adjustment as above.
One side of the latches engages the other falls lower and stops:

HAPP 35
o It is likely that this is a single point release model and the cable
connecting the two sides is too tight and you did not hear the latch
engaging (clicking) on the way up.
o The balance cable is a long way out of adjustment. This is
addressed below in next section.
4. Safety release operation Safety latches release

a. Raise the hoist about 25mm to take the pressure of the safety latches.
b. Release the safeties on each column (lever for single point release or pull
latch cables on each carriage for dual point release with a firm pull. You will
hear a click as the safety’s release)
c. Lower the carriages with the release lever on the pump
d. The hoist should continue to lower until the carriages hit the floor.
Test:
The carriages did not lower to the ground.
o On single point release, the safety cables may be too loose and not
retracting the safety latch , lift the carriages to release pressure and
manually pull the safety latch out and try again. The latch that freed the
carriage is the one that needs to be tightened.
o On dual point manual release, it is likely the safety was not disengaged
firmly enough or the latch still had pressure on it when disengaging.
Raise the hoist again until pressure is off and firmly pull each release
cable.
5. Balance cable tension
Adjusting the balance cables to synchronize the lifting and lowering allows the
safety latches to engage at the same time.
a. Raise the column up until the safety latches engage

b. Lower the hoist onto the safety latches. It is important that both safeties
have engaged as this will set the level of the hoist and ensure consistent
raising and lowering of the hoist.
c. Adjust each balance cable to have a common tension with approximately
12mm of free play in the cable on each carriage.
d. Raise and lower the carriages and observe the hoist operation
The cable that comes from the top of the column down the carriage is lifting the
carriage up from the other side – the lifting cable.
The cable that comes from the bottom of the column up to the carriage is pulling
the carriage down from the other side – the lowering cable.
Test:
o The carriages are not rising evenly; one carriage is slow, it is behind the
other fast carriage.
Loosen the lowering cable and tighten the lifting cable on the fast carriage.
Re check tension of cables as before
HAPP 35
o The carriages are not lowering evenly, one carriage is slow it is behind the
other fast carriage
Loosen the lowering cable and tighten the lifting cable on the slow carriage
Re check tension of cables as before
6. Column mounting
e. Lift different weights on hoist starting with light increasing to normal load
weight
Test:
f. Check that anchor bolts are at correct tension
Re tension anchor bolts
g. Check surrounding concrete for any cracks or deterioration.
Stop all tests, footings are not sufficient for the hoist.
h. Check column level is the same as installed
i. Check location are correct. If columns are shifting at all stop all tests and
check footings / anchor bolts are stable.
j. Continue to recheck the bolts for sound fixing and tight location of nuts with
vehicles loaded for the first week and at regular intervals during operation
of hoist.
HAPP Installation Frequently asked question (FAQ)
Additional information is available on line in our frequently asked questions page.

Customers are recommended to review this page at. http://happ.com.au/faqinsthoist/.
A copy of this page is included in this document, refer to the website for the most
current version.
What oil do I use?

ISO grade 46 oil, Shell Telus 46, Castrol, Nulon or equivalent. If you use thinner
oil (e.g: 32 grade) you may find that your seals will leak prematurely. Oil is readily
available from Super Cheap auto and other leading automotive outlets.
What is the easiest way to add oil?

Use a long nose automatic transmission funnel from your auto shop. They are
typically about 600mm long and fit into the filler hole nicely. If you trim the end of
the funnel to match the filler hole size the oil will flow quickly.
How much oil do I need ?

10 litres of oil is required by the hoists, 20 litre drums of oil are recommended as
there is not much difference in price.
How do I install anchor bolts?

Different models use different types of anchor bolts. In general our 2 post hoists
use 20mm anchor bolts, 4 post hoists use 18mm anchor bolts or loxons as
described for HAPP 90. Before drilling holes ensure you know the size of the
anchor bolt and select drill bits accordingly.
HAPP 35
The HAPP 90 and HAPP 25 come with Loxons which require a 24mm hole.
It is strongly recommended you use a quad tip masonary drill bit in a masonary
drill.
As a reference you can buy all the bits and drill from Bunnings warehouse for a
reasonable price. The quad tip bit they supply provides a hole that will take our
equivalent sized bolts. Do not use cheap blade style masonry bits.
Make sure you measure the bolts supplied with your hoist before buying the bits.
You may elect to change the bolts to a suit your application. For example if you
have a HAPP 25 or 90 that is not going to be moved, use our anchor bolts instead
of the loxon. If you have deep concrete we can supply longer anchor bolts also.
HAPP will be happy to exchange your bolts for others if you like.
The bolts must be a firm fit into the hole, it may require a solid firm hit with a
decent hammer to drive them through, make sure you put the nut and washers on
before hitting them thru, in case you mis hit and damage the thread.
Do not drill pilot holes in cement, measure the bolt size and use the appropriate
bit. Some of the bolts have the size stamped on them, but they are hard to find.
Note : Do not use sleeve anchor type bolts with automotive hoists.
Floor plate hoist, what is the white connector on motor for, or my motor is wired up
but will not start?
Clear floor hoists use this limit switch connector provided on the motor (the white
connector), it should be disabled on other models. Whilst this is specified in the
manuals, electricians can miss this. To disable the connector the wires need to be
closed (joined / bridged) which then enables motor operation. Connect the two
wires and pull them inside the cover, if you decide to add a limit switch, use this
cable.
What are the top tips for installing my hoist?

Read the ‘pdf’ manuals that have been sent to you by HAPP when you purchased
the hoist (including this document). These are the most up to date manuals and
have special instructions and diagrams. Some key points in these manuals are:
Check all fittings and bolts are tight.
Floor plate hoists do not need the limit switch connector provided on the motor
(the white connector), disable the connector by bridging (Connecting the two
wires , pull them inside the cover), if you decide to add a limit switch, use this
cable.
Drill your anchor bolt holes right through the cement if possible, the anchor bolts
can then be removed by hitting them through into the underlying soil
The balance cables don’t fit, one side seems shorter than the other ?
Typically the cause of this is that the cables are not routed correctly. Check the
pulleys and cables to locate where the cable may not be fitted correctly.

HAPP 35
The fittings on the pump assembly are loose.
Pumps are used across different hoist models. If the fittings on the pump control
block are left loose, tighten these fittings till firm.
The hose does not reach the fitting on the pump assembly.
As pumps are fitted to different models the hose fitting can be on the wrong side.
The hose fitting can be located on either side of the pump assembly. To swap the
sides, swap the hose outlet with the plug outlet on the opposite side.
The hose fitting supplied is different to the one on the pump assembly.
As pumps are used on different models the fittings can be different. In these
cases the fitting is supplied in the parts supplied with the hoist, remove the black
fitting on the pump assembly and replace with the fitting supplied in the parts.

HAPP 35
My carriage won’t come down when I first lift the hoist?
This is quite rare but is possible and can be due to the following:
 Hoist balance cables are out of adjustment
Refer to sitting on safety lock, and adjust balance cables to synchronize lifting
/ lowering.
 Hoist carriage (nylon bushes) are tight in column
Make sure the carriage is lubricated with grease, place some extra weight on
the arms to allow them to lower. They will bed in quickly.
 Hoist carriage is sitting on safety lock
Lift the carriages and release the safety lock, then lower again
 Oil bleed valve needs adjustment
This typically only occurs when customers have not used the correct hydraulic
oil grade which can be resolved by adjusting the bleed valve.
The bleed valve may be seated too close to the control block assembly.
The bleed valve is located on the control block of the pump assembly; it has
an allen key with a locking nut. Note the position of the lock. Rotate the lock
nut to allow it to move out and retry. Another possible but unlikely cause can
be some blockage in the valve from an object in the hose during installation, in
this case remove the valve, clean and reload the valve.

HAPP 35
Some customer customizations
Custom door protection
Custom vehicle connectors

HAPP 35
Be happy and enjoy your HAPP hoist

HAPP 35
To Our Customers
We try our best to provide customers with specific
information for installation, operation and maintenance to
ensure that you can use the machine without mistakes. If
you have any questions during installation and
operation, we’ll be glad to help you.
Safe operating procedures and installation

Whilst all care is taken to ensure hoists are manufactured at the
highest standard, the installation and operating procedures for
any equipment are the responsibility of the owner of the hoist.
Lift installation and operating conditions can significantly impact
the effective operating capability of any hoist. It is the owner’s
responsibility to ensure all regulations and requirements are
met for the safe operation of the hoist and that all personnel are
aware of federal, state and local rules. Also codes, plant safety
rules, regulations and instructions are to be observed to make
certain operators, inspection and maintenance personnel are
properly trained.
This document does not relieve the owner / operator of its legal
responsibilities in accordance with the Workplace Health and
Safety Act 2011.

HAPP 35 Manual v3 (205684)

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Installation and Operation Manual

Dual point safety release

© 2013 HAPP Australia Pty Ltd Version 2 3|Page

Final notes on HAPP 35 -----READ ME FIRST-----

Connector available from HAPP

Safety first - ALWAYS

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If there is this signal before any passage, it means that

● Before operation of the hoist,

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Please read Safety Signage carefully, understand and remember them.

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Expected Rated Load Distribution

Rated Load Load Distribution Former part : Latter part

In principle, the lift the design supports double direction

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ⅰ. Operators should read the manual carefully to avoid accidents.

ⅲ. Check before operating and regular check must be carried out.

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Hoist Operating Procedures

Pre operation checks

 All fittings for tightness

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 Ensure all personnel are clear of hoist

 Ensure all personnel are clear of hoist

Isolate electrical circuits before performing maintenance procedures.

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3.3 Arm Operation

Vehicle in Raised Position

Safety plate in engaged position Safety Plate in disengaged position

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Maintenance by the Operator

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Rubber Pads of Disk Adapters

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Trouble Diagnosis Remedy

Hydraulic system leakage Contact service.

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Tru bolt sizes vary depending on the shipment of the

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STEP TWO: (Mounting two columns)

STEP THREE: (Routing the Equalizer cables)

NOTE: The equalizer cables should be checked weekly for equal

STEP FOUR: (Mounting the power unit.)

STEP FIVE: (Installing Hydraulic Lines.)

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No. Name No. Name No. Name

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Controls for operating the lift are:

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Figure: Electrical schematic for HAPP motors.

Limit switch wiring

Figure: Limit switch wiring inside wiring of single phase motor.

Figure: Electrical connection to motor

Electrical wiring – AS3000