Guide for replacing parts in Impact Lifter
Service guide for Impact 80-90-130 (also valid for Apollo 80-130)
Hovmand Lifter is a battery powered lifting device.
Two pcs 12 V, 9 Ah DC batteries, connected as a 24 V DC system, supply power to a motor which through a gear, drives a cam belt, where the sledge is attached.
1. Maintenance
The Hovmand Lifter does not require any daily maintenance. However, it is important to make sure the running parts are in good shape. The cam belt moves the sledge on which the tool is fastened. The cam belt should frequently be inspected for wear and tear. The steel reinforcement of the cam belt secures against breakage, but wear and tear of the plastic part may cause unstable lifting or crackling noises.
The one way bearing in the bottom belt wheel must be checked regularly. The function of the one-way bearing can be checked by lowering to lowest position and keep the down button pressed. The motor and drive shaft shall continue running after the sledge has stopped the movement.
Note: Depending on regional regulations the Lifter may, like other kinds of electro-mechanical handling equipment, need to be checked at intervals by a skilled technician like electro mechanic.
2. Mounting plate for tools
The mounting plate (sledge) is fitted with 8 holes M6. Screws must not go more than 3 mm through the sledge.
Make sure the surface of tool fixation is completely flat where it is mounted to the sledge. Otherwise, it may affect the angles of the sledge and cause unstable lowering or lifting.
Drawing with spare parts can be found in the user manual.
2.1. Removing the tools
Remove the screws. When reassembling, make sure the tool is horizontal before tightening the screws.
3. Fault finding
|
Type of Failure |
Check following |
Repair as follows |
|
The cam belt “jumps” on the pulley. (the cam belt does not lift continuously but slips on the gear wheel) |
Is the cam belt loose? |
The cam belt is tightened with the two screws on the top of the mast. Always tighten both screws the same amount. Start with one quarter turn on each screw. Take off front plate and measure tension in Hz. See section 4.1 |
|
|
Is the cam belt worn? (optical check) |
Change the cam belt, see section 4.1. |
|
The cam belt makes noises (creaks) - does not drive even on the wheel. |
Is the cam belt running on one side of the track on the upper gear wheel squeezing towards one side of the wheel edge? |
Adjust the cam belt as described in section 4.3. |
|
|
Is the cam belt worn (bits of the plastic are falling of)? |
Change the cam belt, see section 4.1. |
|
The sledge is jerking/jumping and not running at a constant speed |
Is there any dirt inside the mast where the sledge is running? |
Remove dirt. Clean with soap or alcohol.
|
|
|
Is there any dirt on the wheels on the sledge? |
Clean or change the wheels. |
|
The Lifter does not react
|
Check if the main stop is activated. |
Release the main stop. |
|
|
Check whether the item being lifted is too heavy. |
Remove the item. |
|
|
Check if the main fuse has blown. |
Change the main fuse as described in section 4.6 |
|
|
Check if the Battery LED shows green light when pressing the UP-button |
If LED turns red or flashes the batteries needs to be charged |
|
|
Check if the batteries are charged. |
Connect the charger.
|
|
The Lifter is moving slowly or in short steps like 10-30mm |
Control the power of the battery on the battery indicator |
The battery must be charged |
|
|
Check the charger. Is the charger lamp changing quickly (within 2-3 seconds) from red to green when connected? |
If the charger changes colour quickly, it is normally an indication of the batteries being worn. Change batteries. |
4. Service procedures
4.1. Removing the front plate
Lower the sledge to near the bottom position. Locate the 4-5 screws holding the front plate and unscrew these, see Figure 3. The screw in the middle is only present at Lifters of 2-2,5m height. After removing the screws, grip the front plate at the top and pull it slightly forward. The top plate may now be removed by pulling it up.
To reinsert the front plate, follow the reverse procedure of the above.
4.2. Checking the tension of the cam belt
Remove the front plate. Press the cam belt with a thumb as shown. The belt should have a springy feeling and should only deflect approximately 10 mm under moderate thumb pressure. If this is not the case, the belt needs tightening as described. Or use a frequency measuring meter.
|
Belt tension in Hz |
L |
M |
H |
H2 |
H3 |
|
Impact 80 |
28 |
22 |
NA |
NA |
NA |
|
Impact 90 |
30 |
25 |
19 |
NA |
NA |
|
Impact 130 |
30 |
25 |
19 |
17 |
14 |
4.3. Adjusting the tension of the cam belt
Locate the two screws on top of the mast as seen in Figure 5. To tighten the cam belt, turn the two screws clockwise with a 4 mm hex key as seen in Figure 6. Tighten the screws the same amount and check the tension of the cam belt for every time the screws are tightened a half turn.
In the case where the cam belt is not properly aligned, tighten the screw in the side the cam belt is drifting towards. Tighten one quarter turn at a time and run the sledge up and down intermediately to check alignment. See also figure 16. Make sure to keep all body parts clear of the belt, sledge and mast while this is done, since the protective front plate is not in place!
4.4. Replacing the cam belt
Remove the forks as described in section 2.1. Remove the front plate as described in section 4.1. Place the lift on a smooth surface with the handles down. Locate the two screws on top of the mast as seen in Figure 5 and loosen these by turning them counterclockwise. Alternate between the screws for each 2 turns. Once the screws are loose, remove the top plate as seen in Figure 7.
Next, remove the circlip holding the gear wheel by using a pair of needle-nosed pliers, as seen in Figure 8. Now pull the gear wheel off the axel as seen in Figure 9. Make sure to note the direction in which the gear wheel is mounted on the axel; such that it may be reassembled in the same direction. When correctly mounted, the gear wheel should be able to spin freely in the clockwise direction but not in the anti-clockwise direction.
Lift the cam belt over the axel and carefully slide the sledge out of the mast. Take care not to damage the micro switch seen in Figure 10 while doing this. Care shall be taken when the sledge is reinserted into the mast, since the micro switch will break if it is not pressed down by hand to allow the sledge to pass.
Now, remove the sledge and cam belt from the mast, as seen in Figure 11.
Loosen the four screws holding the cam belt on the sledge as seen in Figure 12. Use a 5 mm hex key and turn the screws anti-clockwise. After loosening the screws, pull out the cam belt as seen in Figure 13. Discard the old cam belt and insert the new cam belt, making sure that 4 teeth are held in place by the fastening plate at each end of the cam belt.
Reassembling the lift follows the reverse procedure of the dismantling described above. Take care not to damage the micro switch on reinserting the sledge into the mast and make sure the gear wheel is orientated correctly.
Refer to section 4.3 for tightening the cam belt, before the front plate is remounted.
Figure 14 – Aligning top belt wheel.
Use a try square to align the top belt wheel in 90° to make sure the belt will run precisely in the middle of the wheel.
4.5. Replacing the batteries
Switch the lift off at the main switch and remove the main fuse as described in section 4.6. Locate the screws holding the control box as shown in Figure 15. Move the control box next to a stable platform such as a table or boxes. Activate the wheel brakes and remove the screws holding the back box using a Torx 25 screwdriver. Gently place the control box on the platform as shown in Figure 16.
Locate the 4 screws holding the battery retainers in place as shown in Figure 17. Remove the screws with a Torx 20 screwdriver by turning the screws anti-clockwise. Then carefully remove the battery retainers, taking care not to damage any of the wiring.
Gently turn the battery such that the terminals are facing up and note which wires are connected to which terminals. Carefully disconnect the battery wires as shown in Figure 19. Now remove the old batteries. Note: Since the batteries contain lead, these should be disposed of according to local regulations.
Connect the new batteries in the same manner as the old ones. Reassembly is the reverse procedure of the above. Be careful not to damage any wires during the process.
4.6. Changing the main fuse
Switch the lift off at the main switch. Locate the fuse at the bottom left of the control box. Using a pair of flat-nosed pliers, or fuse pliers, the fuse may be removed as shown in Figure 20. Use only moderate force when gripping the fuse so as not to break the plastic. Discard the old fuse and insert a new one of the same rating by hand.
4.7. Replacing the wheels on the sledge
Remove the sledge from the mast as described in section 4.4 but do not remove the cam belt from the sledge. With the sledge is removed, gently pry the plastic wheels loss from their bearings with a large flat head screwdriver, as shown in Figure 21 and Figure 22. Discard the damaged wheels and insert the new wheels 40000609 over the bearings and tap them gently into place with a rubber mallet.
Reassemble the sledge and mast as described in 4.4.
5. Electrical connections
Electrical connections Standard Impact control unit 84250915 (Impact 80) and 84250965 (old Impact 130 before 2017).
Electrical wiring Impact 90-130 (84250975 from January 2017- sept 2021)
Electrical wiring Impact 90-130 (84252086-90 / 130 from october 2021 - )
Spare Parts in the control unit. See parts in the webshop
B1-B2 Batteries 2 pcs of 84010068
S1 Rocker switch 84100068
S2 On/off switch 84100092
Remote 84290030 (only for Impact 90-130)
D1 Charger protection diode 84170044
D2 LED for battery status 84170046
F1 Main Fuse 30A 84040233
F1 Fuse holder 84040231
F2 Charging Fuse 5A 84040234
F2 Charging fuse holder 84040232
CH1 – charger
84020020 for Models produced before October 2021.
Newer models = 84020071.
PLC1 – Controller for lifting/lowering:
Impact 80 = 84042050
Impact 90 = 84043053
Impact 130 (before January 2017) = 84042060
Impact 130 (after January 2017) = 84043040
X1-X28 Connector block 84040230
Housing:
Impact 80 = 30000866 (models before October 2021)
Impact 80 = 30017491 (models after September 2021 with new charger)
Impact 90-130 = 30000866 (models 2004- Jan 2017)
Impact 90-130 = 30008192 (models Feb 2017- Sept 2021)
Impact 90-130 = 30017441 (models Oct 2021 and newer with new charger)
Outside control unit:
E1 Top limit switch 84080016
M1 lifting motor:
Impact 80 = 85020022
Impact 90 = 85020010
Impact 130 = 40000896
Mh 4/1-2024