GYS ERGO Door Lift Instruction Manual

GYS ERGO Door Lift

Product Information

Specifications

• Product Name: ERGO DOOR LIFT
• Model Number: 73502 V1
• Date: 18/06/2024
• Maximum Working Load: 50kg (110lbs)

Product Usage Instructions

Installation and Inspection
Safety work and inspections should be carried out by specially trained personnel referred to as experts and/or authorised persons.

Intended Use
The ERGO Door Lift is designed for use in the repair of passenger cars and commercial vehicles. It assists in the replacement and fitting of front, rear, and sliding doors (with wide door accessory). The equipment allows safe and independent operation with a maximum working load of 50kg.

Controls and Maintenance
Regular maintenance should be performed according to the maintenance table provided in the manual. Monthly maintenance checks are recommended.

Troubleshooting
If you encounter any issues with the ERGO Door Lift, refer to the troubleshooting section in the manual for guidance on resolving common problems.

FAQ

1. Q: What is the maximum working load of the ERGO DOOR LIFT?
   A: The maximum working load of the ERGO DOOR LIFT is 50kg (110lbs).

2. Q: Who should carry out safety work and inspections on the equipment?
   A: Safety work and inspections should be conducted by specially trained personnel known as experts and/or authorised persons.

3. Q: What is the intended use of the ERGO DOOR LIFT?
   A: The ERGO DOOR LIFT is intended for use in the repair of passenger cars and commercial vehicles, providing assistance with door replacement and fitting operations.

Thank you for choosing GYS! In order to get maximum satisfaction from your ERGO DOOR LIFT and for your own safety, please read these instructions carefully before using the unit for the first time, and keep them in a safe place for future
reference.

BACKGROUND INFORMATION
These instructions contain important information regarding installation and commissioning in order to ensure the safe operation of the ERGO Door Lift. Compliance with this documentation reduces risks and extends the service life of the product. This manual contains a form to certify regular safety checks. Use the «Regular safety check» form and the «Maintenance log» to record your inspections (it is advisable to make a copy of the form before filling it in for the first time).

Installation and inspection:
Safety work and inspections are reserved exclusively for specially trained personnel. These individuals are referred to in this documentation as experts and/or authorised persons.

LIMITATIONS OF LIABILITY
The ERGO Door Lift is a mobile mechanical column jack designed to comply with standard EN 1494. All the information and advice given in this manual has been compiled in accordance with the relevant standards and regulations, as well as our extensive knowledge and experience.

The manufacturer shall not be held liable for any material damage or personal injury resulting from:

• Non-compliance with the operating instructions
• Improper or dangerous use
• Employment of unqualified personnel
• Unauthorised modification of the product
• Insufficient maintenance

INTENDED USE

• The ERGO Door Lift is intended for use in the repair of passenger cars and commercial vehicles. It provides assistance with the replacement and fitting of front, rear and sliding doors (when fitted with the wide door accessory). Using this equipment enables you to carry out the operation safely and
• independently. This unit has a maximum working load (MWL) of 50kg (110lbs).
• The product may only be used by persons who have read and understood the user manual.
• The lifting of persons or other objects is not allowed.
• The product must be used inside a working area and must be protected from bad weather (wind, rain, and negative temperatures).
• The operating temperature range is between 5°C and 50°C maximum.
• Do not use in excessively humid conditions.
• Never lift anything that is on sloping ground. The ground must be level, and solid enough to avoid the wheels sinking under the weight of the load.
• In the event of a heavy impact on the load-bearing and/or structural elements of the product, it is imperative that the unit be taken out of service and that your distributor or the manufacturer be contacted in order to assess the damage before it is put back into service.
• Intended use also includes familiarisation with this manual and observing all the instructions contained herein, particularly the safety instructions.
• Ensure compliance with national safety and risk prevention standards in the workplace.
• In addition, this also includes the obligation to carry out all inspection and maintenance work at regular intervals.
• In the event of improper use of the unit, operational safety of the door support cannot be guaranteed.
• Personal injury and property damage, including to vehicles, caused by improper use of the device are not the responsibility of the manufacturer, but that of the individual operating the unit.
• The product must not be used in a potentially explosive atmosphere and it is not recommended to work in close proximity to a heat source. The ERGO Door Lift has not been designed for use in paint booths.
• It is strictly prohibited to use any spare parts other than the original ones certified by the manufacturer.

PACKAGING AND UNLOADING
The ERGO Door Lift is packed in a cardboard box and placed on a pallet. Inside the packaging you will find the instructions for using and checking the unit. On delivery, check for external transport damage. If there is visible damage, leave the goods and packaging as they are. Do not use the goods and contact your distributor directly. Otherwise, it is necessary to make a formal reservation with the carrier.
Unloading can be carried out by two people wearing gloves and safety shoes, or using a forklift truck.

INDIVIDUAL PROTECTION
The operator must be equipped in accordance with the work risk prevention standards applicable in their country, and must implement all necessary measures to maintain safety in their workplace. During manoeuvring, the operator must ensure his own safety and that of the people and objects around him. The operator must take into consideration all the recommendations quoted in this manual.

ASSEMBLY

Make sure you have the necessary protection: gloves, appropriate clothing and safety shoes.

Screw M10x30: 4
Washer 43253: 4
M10 fan washer: 4
M10 nut: 4
Screw M8x16: 16
Lock nut M8: 16

1. Attach both the wheels with and without brakes to the longitudinal rail, each using an M10 screw, a Ø40 washer, an M10 fan washer, and an M10 nut. (x2)
2. Fix the longitudinal rail to the cross rail using 8 x M8 screws and 8 x M8 nuts. (x2)

Screw M8x16: 6
Lock nut M8: 6

1. Fix the pillar to the chassis using 6 x M8 screws and 6 x M8 nuts.

Screw M8x70: 2
Lock nut M8: 2

1. Insert the base into the trolley (with the holes at the ends facing downwards for assembly in step 8) and place the cable (connected to the cover) in the trolley.
   (make sure the cable runs in front of axis 1, behind axis 2, and in front of the base of U), place it fl at on the base of the trolley.

2. Insert the 2 x M8x70 screws used to secure the base of U. Make sure you pass them through the cable loop. Tighten with 2 x M8 nuts.

Screw M8x16: 3

1. Insert the carriage assembly into the column. Slide it all the way down (be careful not to pinch the cable).
2. Insert the cover and secure it with 3 x M8 screws

Screw M8x16: 3
Lock nut M8: 1

1. Remove the fl ange (greyed plastic part) by unscrewing the 2 screws holding it to the winch with a Phillips screwdriver.
2. Fix the winch to the column using 2 M8 screws, then screw the fl ange back onto the winch.
3. Secure the cable to the winch using an M8 screw and an M8 nut.

Do not use the cable fi xing system on the winch, which consists of a bolt and a plate. Remove it by unscrewing it.

M8x30 screws: 2
M8 lock nut: 2

1. Screw 2 screws and 2 lock nuts onto the bar support. Place the nuts loosely against the plate, the bar must be able to slide between the plates (next step).

Handwheel M10x20: 2

1. Insert the bar into the bracket by turning the 1st screw and then pivoting around it until you reach the other screw.
2. Screw the 1st M10 handwheel into the top nut until the bar is tight. Screw the second hand wheel into the tube nut by using only a few screw threads.
3. Insert the quick-release clips on the bar (press the button to change the position).

Tube plug 40×40: 1
Set screw M8x16: 1

1. Insert the stem into the trolley assembly and secure its position using the M10 handwheel.
2. Insert a 40×40 tube plug into the upper column on the opposite side to the hole in the column.
3. Insert the upper column into the trolley assembly (hole facing the back of the product) and secure it using the M8 grub screw (screw in until you reach the stop).

If you have the wide door option, please refer to its assembly instructions, then insert it into the trolley assembly before the stem.

Screw M8x16: 2
Lock nut M8: 2
Slatted plug 40×40: 2
Slat plug 30×30: 4

1. Insert a 30×30 tube into the base (foam side up) and secure it with an M8 screw and nut. (x2)
2. Insert a 40×40 slatted plug into the base. (x2)
3. Insert a 30×30 slatted plug into both ends of the 30×30 tube. (x2)

Screw M8x16: 1

1. Screw a handle onto the column. (x2)
2. Fix the bolt box to the column using an M8 screw (bend the fixing lug).

Once the lift has been assembled and is located on the floor, make sure it is both stable and structurally sound. Carry out a no-load test to check that the product is working properly.

DISASSEMBLY AND RECYCLING
To dismantle the ERGO Door Lift, refer to the «Assembly» section of this manual and perform the same procedure in reverse.
For recycling, For recycling, deliver the unit to a waste management organisation /company to ensure that the components are recovered for reprocessing.

APPLICATION

Winch
The ERFO Door Lift is fitted with a winch for raising and lowering the support. To raise the carriage, simply turn the crank clockwise. To lower the carriage, turn it in the opposite direction. The winch is fitted with a self- locking brake that holds the carriage and door at a certain height, and prevents it from lowering.

Brake
The ERGO Lift Door is fitted with independent brakes on each of the two rear wheels. To engage them, press the brake on each wheel with your foot.

Bar storage
The unit is fitted with a recess for storing the bar when you have the wide door option fitted. This manoeuvre helps prevent any potential collision with the vehicle. The procedure for storing the bar is as follows:

1. Loosen the M10 handwheel, rotate the bar upwards, and remove it from its housing.
2. Position the bar in the side housing.

NB: To use the bracket again, perform the exact reverse operation.

SAFETY

• The user must use the appropriate personal safety equipment (safety shoes, gloves, etc.).
• The specified maximum load limit must not be exceeded.
• It is prohibited to work underneath a raised load.
• The ERGO Lift Door must not be used to lift people.
• The ERGO Lift Door must be stored in a dry place.
• When being transported, the unit must be packed in such a way as to prevent it from overturning.

Safety when moving:

• lower the carriage as far as possible to improve stability and safety.
• take particular care when passing under doorways, over electrical wires, or other objects on the floor.
• hold the handle in such a way that you do not run the risk of catching your hands on objects protruding from walls, shelves, etc.

Loading / unloading and lifting
The user is responsible for loading and unloading.
Engage the rear wheel brakes during loading/unloading.
The door should be positioned on the carriage as closely as possible to the centre column, and as centrally as possible on the supports, to ensure good balance and stability.
There is a risk of pinching when the trolley is raised or lowered. Do not place hands or other body parts under the load.

CONTROLS AND MAINTENANCE

Inspections and maintenance work must be carried out by authorised personnel at the maintenance intervals specified in this manual. The following points must be observed in order to ensure both a long service life and correct usage of the product.

• Only genuine spare parts may be used «Spare parts»;
• The recommended maintenance intervals in the «Maintenance Table» must be observed and documented;

The «Regular inspection» table lists all the points to be checked and inspected during any maintenance operations, commissioning, and following any repairs or re-assembly. Use the «Regular inspection» and «Maintenance table» forms to archive routine inspections.
Visually inspect the unit before each use. Do not use it if you notice any damage or significant wear.

Maintenance table

authorised person and to be completed and signed.

TROUBLESHOOTING

The ERGO Lift Door is built to be safe and reliable, provided that the maintenance instructions are properly followed. If there are any operational problems, here are a few tips:

• If the carriage does not move, or moves with difficulty:
  • Check that the cable is securely attached.
  • Check that the cable is correctly positioned in the groove on the pulley.
• If the product makes a strange noise:
  • Check that all the components of the unit are correctly attached, see the section entitled «Assembly».
  • Refer to the «Maintenance» section.

If the problem persists, contact either your repairer or the manufacturer.

WARRANTY

The warranty covers any defects or manufacturing faults for two years, from the date of purchase (parts and labour).

The warranty does not cover:

• Any other damage due to transport.
• Normal wear of parts (eg. : cables, clamps, etc.).
• Incidents caused by misuse (dropping, disassembly).
• Issues caused due to the environment (pollution/ingress, rust, dust).

In the event of a fault, please return the unit to your distributor, along with:

• a dated proof of purchase (receipt, invoice…) a note explaining the malfunction.
• A copy of the «regular safety checks»

NAMEPLATE
The technical identification plate is located on the right-hand side of the column, along with the serial number of the product, the year and month of manufacture.

• Serial number: 24.06.082670.000001
• Year of manufacture: 24 (2024)
• Month of manufacture: 06 (June)
• Product reference: 082670

REGULAR SAFETY INSPECTION

Operation of the wheels and brakes (for the rear wheels), and wear and tear on the surfaces.| | |
No-load test over the complete length| | |
Test with the MWL (50 kg) over the complete length| | |
Inspection result

| Commissioning is not authorised
| No anomalies: commissioning authorised

Safety check carried out on: ………………………………………………………………………………………
Name and address of the authorised person: ………………………………………………………………..
Signature of the authorised person

MAINTENANCE LOG

Purchase date: ……………………… commissioned by ……………………………………………………………………… on ………………/………………/………………
Serial number: ……………………………………………
Archiving monthly and annual checks: tick the boxes to certify periodic inspections.

Year:

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DIMENSIONS

SPARE PARTS

SPECIFICATIONS TECHNIQUES

PICTOGRAM

****| EN Device complies with europeans directives, The EU declaration of conformity is available on our website (see cover page).

| EN Equipment in compliance with British requirements. The British Declaration of Conformity is available on our website (see home page).

| EN This product should be recycled appropriately

|

• Danger with risk of accident leading to death.

|

• Relevant information

GYS France
Siège social / Headquarter
1, rue de la Croix des Landes – CS 54159 53941 Saint-berthevin Cedex
France
www.gys.fr
+33 2 43 01 23 60
service.client@gys.fr

GYS Italia
Filiale / Filiale
Via Porta Est, 7 30020 Marcon – VE Italia
www.gys-welding.com
+39 041 53 21 565
italia@gys.fr

GYS UK
Filiale / Subsidiary
Unit 3
Great Central Way
CV21 3XH – Rugby – Warwickshire United Kingdom
www.gys-welding.com
+44 1926 338 609
uk@gys.fr

GYS China
Filiale / 子公司
6666 Songze Road, Qingpu District
201706 Shanghai
China
www.gys-china.com.cn
+86 6221 4461
contact@gys-china.com.cn

GYS GmbH
Filiale / Niederlassung Professor-Wieler-Straße 11 52070 Aachen Deutschland
www.gys-schweissen.com
+49 241 / 189-23-710
aachen@gys.fr

GYS Iberica
Filiale / Filial
Avenida Pirineos 31, local 9 28703 San Sebastian de los reyes España
www.gys-welding.com
+34 917.409.790
iberica@gys.fr

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