USER MANUAL
Contents
1. For complete manual refer to http www ctek com Manuals 300W da pdf INDICATIONS NORMAL SUPPLY RECOND AR Indication Description Fault status charging interrupted Fault see below Soft Start Bulk charging Absorption charging Maintenance charging Supply Recond reconditioning of totally discharged batteries Charging without temperature compensation Supply voltage connected Normal Supply Recond rm gG G GG gt O Q Q N PF O Fault Status The charger will go into fault status if the time for soft start has been exceeded or if the battery self discharging is too high 30 English SL 250 2010 WIRING DIAGRAMS VI T0 1 8007 11 70 amp uorsta24 a u 4 Sikkerhed switch for stor v gt p kran 2 ox 9 NG P0 00 0 3uuAis urergeips utup27 dovi med z L00 S LINN EL 0007 JOUINN we to prepues R Y apus 0 00Z00 02 0007 JOUINN L16 CLL6 St Xt 11677246 SH JIL WODNISOXNAN 006L L fJASNISNAFISRIKI VN 8007 1 1 t L YIA RA FOEOO OE zauneu ajy yu unsyo wot Guns j Hr YIGAYGIVAIAOH 31 English SL 250 2010 I16 CLL6 St X94 IOTTLLO St JIL W ONIHOXNAN 0062 n dren L 3ASN3SN31SPIIH2 VN Lan aavwS Lu z AWISOSSINd I LV1SOSS3IYd 5 S OG L je mina LVOV VET 3S TROLS vw 32 English SL 250 2010 PT 0 1 8007 60 702. Smart lift v 5L250 STANDARD Table of Contents Table of Contents Introduction EU Declaration of Conformity General Description Transport Handling Putting into Operation Storage Technical Data Safety Rules Overview General Description Operation for Vacuum function Control for arm and yoke Important Operation vacuum amp electric functions Electric Functions Charger amp Battery Case View of Vacuum system top and bottom of machine Control Box Switches and Alarms Control Panel for arm and yoke Load Diagram Stop Down Troubleshooting of SmartLIFT Information and manual charger Wiring Diagrams 10 10 11 11 12 13 14 14 15 16 17 27 28 29 33 English SL 250 2010 English SL 250 2010 Introduction Congratulations on your new Smart LIFT Smart Lift has been designed and constructed so as to safeguard product users against accidents as far as at all possible Unfortunately certain functions in a machine cannot be safeguarded This is why safety rules have been prepared by way of warnings in this instruction Read these safety rules on the following pages before putting your Smart LIFT into operation and imagine how you may in your daily use of the machine ensure that warnings and safety rules will be adhered to Manufacturer Smatlift ApS N A Christensensvei 7 7900 Nyk bing Mors Danmark Importer INSTANT Avd Oslo Avd Trondheim Avd Bergen Kontakt
3. English SL 250 2010 1 Stop Down at Vacuum System Vacuum suction on both pressure gauges to be 0 62 between 0 6 0 7 Slide Valve w safety lock for activation and deactivation of vacuum suction If vacuum pump will not run Always check that there is power on the machine and that it has not been disconnected by switch or by fuse in the control box Relay for pump may also be defective If vacuum pump runs constantly Check that the slide valve is closed should be closed to generate vacuum Read pressure gauge should be about 0 60 If the pressure gauge indication is constantly about 0 7 or more In that case there will be a fault on the vacuum guard If the pressure gauge is constantly appr 0 55 or less and the pump is running In that case there would be a fault on the vacuum pump or a leak on the hose connection between check valve and vacuum pump If the pressure gauge indication drops after the main switch has been disconnected and the slide valve closed In that case there will be a fault a leak between slide valve and check valve Pressure gauge slide valve or vacuum guard may be defective If hoses are dismantled at couplings and the pressure continues to drop the fault will be with the slide valve If the vacuum pump starts and runs constantly possibly with dropping pressure when the slide valve is opened in connection with suction of work Check that all suction c
4. oss Enebakkveien 441B Fremo n ringspark Midttunlia 17 Tel 23 19 11 00 NO 1290 OSLO NO 7234 LER NO 5224 NESTTUN Fax 23191101 post instant no www instant no English SL 250 2010 EU Declaration of Conformity Manufacturer Smartlift ApS N A Christensensvej 7 DK 7900 Nyk bing Mors Hereby declares that The machine system Lift Model type Smart Lift 250 500W Serial No Year Month 2010 has been made in conformity with Council directive Machine directive 2006 42EF Low voltage directive 2006 95 EF EMC directive 2004 108 EF The following standards have been applied DS EN ISO 12100 1 2005 Machine Safety Basic concepts DS EN ISO 12100 2 2005 Machine Safety Basic concepts DS EN 1050 1997 Principles of Risk Assessment DS EN 294 Machine Safety Danger Areas and Safe Distances DS EN 1757 1 2001 Lift with walking operator DS EN 13155 A1 2005 Cranes Safety not fastened lift devices for loading DS EN 60204 32 2001 Electric equipment on machines part 32 Provisions for lifting machines Date Signature Ole Kobaek Director General Description List of Spare Parts Posno Product Numb vem 7 2 tmp Gh w Lou o a suetioncupdiamaso CA Check Valve vacuum 5 sidevave wock vacuum ho l6 Vacuummeter diam 63 1 4 stainless e po Manm it S E toro wo i ho Lou Cd ts ose counting pb 2 smo pa Acoustic alarm Vacuum s
5. RM function The movement is made via actuator placed under the lift arm pos 23 SIDE DISPLACEMENT function This movement is performed via actuator placed between the two front wheels pos 22 Electric functions pages 9 11 14 STOP EMERGENCY STOP function The emergency stop button pos 33 is placed on the actual control panel This button will switch off vacuum actuator electric control as well as drive motor 10 English SL 250 2010 MAIN SWITCH Pos 38 Placed on the battery case inside Turn handle to switch off all electric functions DRIVE MOTOR pos 47 The drive motor is activated by an on off switch pos 47a Then turn the regulating lever pos 48 FORWARD AND BACK function pos 52 Toggle switch forward and back SAFETY function pos 51 Activating the safety switch will stop the car and the car will move forward Important Operation vacuum amp electric function Service plate 14 Vacuum Hoses 2 circuit Vacuum Safety System 32 Control Panel placed in 7 holder q a 47a ON OFF switch f drive motor w green LED light 6 Vakuummeter two reading on both pressure 48 Stepless motor speed control gauges to range between 0 6 0 7 31 Overload Safety Switch 52 Forward and back 51 Safety function f back machine moving forward automatically 11 English SL 250 2010 Charger CTEK MULTI XT 14000 pos 26 B
6. a li NINIP P 23 Actuator Telescopic Arm IP66 1 24 Actuator lif AmIP66 o Power Supply Wheels C E EC 3 zs whee easy ph FGP 10 fork with plate 30 e N gt N Mm T English SL 250 2010 English SL 250 2010 me TI mm y Transport Handling Smart Lift is for indoor use May not be exposed to rain and snow Prior to transport switch off all electronics on main switch pos 38 Smart Lift to be fastened securely in truck trailer for transport and protected against rain and SNOW Lifting by crane or similar Always lift Smart Lift in lift eye intended for this purpose pos 41 NEVER lift under Smart LIFT by forks truck and similar For transport on the transport frame Smart Lift must always be fastened in the lock fitting pos 42 Putting into Operation Prior to putting into operation insert vacuum hoses and charge battery fully Storage Always switch off your Smart Lift on the main switch pos 38 before storage Smart Lift should be kept in a dry place Batteries should always be fully charged English SL 250 2010 Technical Data 16 5 kg x 10 units 165 kg Charger 230 V CE connector Safety Rules Pages 9 11 14 Daily Use Your Smart LIFT may only be used by persons who have been given qualified training in the operation of this machine and its safety functions Before use user should check that there are no loos
7. aep woysysas a e g LIGETLL6 Sp X04 I I6TZLL6 St IL W DNIH NAN 0062 L TJASNASNILSPIHI V N 13l118VWS 33 English SL 250 2010 r I IGEZLL6G St NVA 8007 1 l t L UIA RA POLOO OE p Il622LL6 St JLL 99 10 51 8007 60 70 W ONIHOXNAN 006L L FJASNISNALSNIHJD V N INO BJ IAB L pn aed o 3 34 English SL 250 2010 PO CC EI 8007 11 10 amp uomaa a u 4 LATSGOINGIHA ONIIALSYOLON SLLANIO capa 3384 330 Proq espepuiqioj W334 NO SPPUIGIO yy8 SNIJIS SNOISITIOM H6 CLL6 St XVI I16CCLL6 St JIL W ONIGOXAN 006L LfA3ASNISNAISTHHO V N LIMLYVWS 8007 1 l t L UIA NMA TOLOOOE www op pd o 35
8. attery Charger for lead acid batteries The charger has been set on SUPPLY In this setting the charger will deliver a constant voltage This is the best maintenance setting for the battery In this setting the charger may also be used as a voltage unit without having the battery connected NOTE The charger will NOT be sparkless in this setting Also please refer to the attached CTEK user guide page 28 Battery Case 47b Sikring 80 Ampere for fremdriftsmotor English SL 250 2010 View of Vacuum System top of machine 11 Slangekoblinger 2 Suction Cups standard diam 250 5 Slide Valve w lock Aktivating vacuum Load Diagram 10 Hose Set 2 circuit vacuum Double Vacuum Chamber 12 Spiralslanger bottom of machine 17 Line filter f vacuum suction 13 Control Box 36 Control MULTIMOC Side Change 39 Fuse 30 amp re 34 Control MULTIMOC Lifting Arm 33 Emergency Stop 16 Acoustic Alarm Vacuum 15 Alarm Light Vacuum 44 Battery Indicator English SL 250 2010 35 Control MULTIMOC telescopic arm and Tilt 14 Control Panel for arm and yoke pos 32 Lift arm up Tilt forward Telescopic Arm in Side Displacement English SL 250 2010 Lift Arm Down Tilt back Telescopic arm out Side displacement 15 LOAD DIAGRAM DATA English SL 250 2010 En
9. ck for telescoping and tilt Control Unit front for lift arm On control box for lift arm actuator LED No 7 on when lift arm is down all the way If LED is on at some other time there will be a fault at actuator 2 green LED s on for indication of correct potential difference Power supply has been established 25 Control Unit front for lift arm 30 A fuse for control pe English SL 250 2010 Red light in diodes 1 and 3 indicates that actuator has been disconnected due to overcurrent For old version 1 52 keep Up Down control panel button in for fault indicator indication at LED s For new version 3 0 fault indicator will indicate until up down function is activated Releasing the button will reset fault and push again for function Red light in LED 1 indicates a too large difference non parallellity between the 2 lift actuators Remedying may be run by running up and down alternately If this does not work check the potential difference SEE PICTURES PAGES 25 amp 26 Check for loose lines and connectors Relay for control of vacuum pump 26 English SL 250 2010 Supply voltage to be checked should always be 25 Volt At lack of LED light always check voltage Always check for loose lines and connectors for faults on machine fault may frequently be detected there 27 English SL 250 2010 Potential difference between 3 and 4 from right to be appr 5 Volt If le
10. control panel all functions Has emergency stop been released Reconnect emergency stop by turning the release pressure Check whether main switch is on placed on battery case between lift actuators to be turned clockwise to switch on Check whether the control panel connector is correctly placed in the control box Have batteries been charged on off button on handle for drive should be on to read battery indicator Is 30 ampere fuse in control box OK Has the safety switch been activated If activated try to deactivate by pulling in the telescopic arm or act as follows The safety switch has correctly switched off the machine 19 12 2007 h fa TU To re establish function on the machine you may for instance using a screwdriver E j push up the switch and the safety switch will resume its function The telescopic arm is run back in and work too heavy for the machine is lowered back in place Should the safety switch switch off again at this manoeuvre You may using your body weight push the machine in place by applying pressure on the weight blocks 22 English SL 250 2010 lf no response when pushing control panel individual functions Has the safety switch been activated If activated try one of the possibilities above There may be a fault on actuators for movements or when controlling these Actuators and Control of these For faults on movements of actuators always first check v
11. e objects on the machine since this would entail breakdown and danger risks WARNING Vacuum Working at the machine will entail danger if the various safety devices pressure gauge pos 6 and acoustic alarm pos 16 are faulty Work may not be lifted until the light and acoustic alarms pos 15 pos 16 have stopped Do NOT lift moist or greasy work by the suction cups WARNING Risk of overturning This machine MUST stand on a horizontal firm and stable base with its supporting legs pos 46 unfolded WARNING Prior to using the lift yoke check that nut and lock split have been securely fastened Always see that weight blocks pos 45 have been locked using lock split pos 40 English SL 250 2010 WARNING Explosion Danger This machine may NOT be used in ATEX area Explosion danger environment DANGER Staying under the lifted work is strictly prohibited PROHIBITED May NOT be used for person lifting Overview General Description pages 8 9 11 14 21 Actuator Tiltefunktion Telescopic Arm 41 Lift E 2 Suction Cups diam 250 45 Weight Blocks 46 Supporting Leg with 50 Safety Clamp English SL 250 2010 32 Control Panel in holder 2 circuit vacuum safety system 5 Slide Valve w lock Vacuum 6 Two vacuummeters One for each vacuum circuit 48 Regulating Lever w ON OFF function for drive motor 31 Overload safety breaker 52 53 Fo
12. glish SL 250 2010 Smartlift 250 kg with 200 Arm in With the arm driven completely into the possible load of 250 kg max L1 1750 mm L2 1250 mm L3 250mm L4 50mm L5 560mm 17 English SL 250 2010 Smartlift 250 kg with 200 Arm out H2 With the arm driven completely out of possible load of 140 kg max L2 2250 mm L3 100 mm H2 2740 mm H4 1660 2050 mm H5 1950 2300 mm 18 English SL 250 2010 Stop D own Troubleshooting For any fault on Smartlift first look into the options below Has anything visible been broken or is anything unusual about the machine Is there any murmuring or noise Have the batteries been charged and the main switch switched on the On Off button on the drive handle shall have been switched on lighting to read battery voltage on battery indicator Has the emergency stop button switched the machine off placed on grey control box Has the safety switch been switched off on account of overloading placed under pressure switches Is the hose set intact and has it been connected correctly Troubleshooting and remedying of faults will be divided into 3 overall categories 1 2 Vakuum machine capacity for sucking work Movements controlled via control panel up and down function of lift arm tilting of yoke side displacement of machine Drive controlled by regulating lever Forward and back function of machine 19
13. isually and by review of the machine whether anything visible is wrong or wrong from an acoustic point of view from one of the actuators Lines may be loose or torn and bolts may be loose Finally the actual actuator telesciopic arm may be bent The machine has totally five actuators 1 for tilting of yoke 2 for lifting of arm 1 for telescoping of arm and 1 for side change Actuator for tilting standard SL Line should be in holders Main switch to be turned clockwise to be on In particular lines at the bottom of these two lift actuators may by carelessly wrong and unfortunate operation of SL 250 have been damaged at connector or line 23 English SL 250 2010 Actuator for f telescoping of arm Here too all lines should be undamaged and placed correctly at lead ins etc 80 A fuse f drive motor Motor control for drive motor with fuse for same Nothing to do with actuator for side change s EE D Wa y re 2 lt Actuator f side change To check this actuator remove the protective screen In case of lacking or wrong function check for any murmuring noise and loose lines 24 English SL 250 2010 Control Box for actuators dismantle cover Control Unit for side change LED red under capacitor On at max deflection on actuator for side change If light at side change middle position there will be a fault at actuator motor Control Unit ba
14. rward and back switch with protective cap 42 Lock Fitting Transport Frame 51 Safety Switch for back function 40 Lock Split 5 Slide Valve w lock f activation and deactivation 12 Spiral Hoses 2 of vacuum suction 2 circuit vacuum circuits N 10 Hose Set Load Diagram 26 Battery Charger Beskyttelsessk rm I CTEK Multi for motorstyring og sideskiftsactuator 37 CE Connector f battery charger English SL 250 2010 Operation for VACUUM function page 13 This function pos 5 will switch vacuum on and off The vacuum pump is controlled by a vacustat At short arm window arm starting at 55 and stopping at 60 At long arm plaster arm starting at 25 and stopping at 37 The vacuum function is operated by the brass handle placed on the actual body pos 5 To release vacuum push safety button in and pull down handle Control Panel pos 32 for arm and yoke pages 8 9 15 Users should make a point of reading the function description below so as to become familiar with the functioning of the machine Smart LIFT is operated manually This machine generally has four functions which may be operated individually UP DOWN function This function will make the arm move either up or down The movement is made via the actuators pos 24 TILTING function This function will make the work turn round The movement is made by actuator pos 21 TELESCOPIC A
15. ss than 4 5 Volt there may be a fault on control or network Potential difference between terminals 1 and 3 as well as 2 and 3 to be the same all the time Showing 0 volt will indicate something wrong with network or with actuator 28 English SL 250 2010 3 Stop Down at Drive Section If no response at activation on regulating lever no click sound Check whether the main switch is on to be turned clockwise to switch on Has the red On Off switch on the regulating lever been put into On position green lamp on Have batteries been charged check indicator Is the 80 ampere fuse beside the motor control under the screen at the front of the machine OK Check regulating lever and cables for visible faults and damage There may be no faults on lever or control unit Control light on switch may show error code at various flash signals contact Smartlift ON OFF switch w control light Fuse 80 A for drive If no movement when activating regulating lever but click sound The electrical brake may be stuck possibly on account of moisture Taking the measures below may release the brake A EIE w ND en W Ma te fas V av Yo Loosen the 3 bolts on the brake Carefully remove the cover on the brake and then release the disc Mount the 3 bolts again and test 29 English SL 250 2010 Battery Charger CTEK Multi XT 14000 The charger has been set and should be set on Norma
16. ups bear correctly on the work i e that the particular suction cup is parallel with the work and that no parts of the suction cups protrude from the work IMPORTANT 20 English SL 250 2010 If the vacuum pump starts and stops at very brief intervals Dismantle spiral hoses at couplings and close the slide valve if this has not been done already If the vacuum pump still starts and stops at very brief intervals there may be a fault on the check valve If the vacuum pump starts and runs and stops at brief intervals possibly with dropping pressure on one or both pressure gauges when the slide valve is opened after correct suction of work Close slide valve Disconnect one vacuum circuit at hose coupling and then open the slide valve for vacuum suction again If the vacuum suction on the pressure gauge for disconnected circuit is now constantly 0 6 there will be a fault on the hose set or at the suction cups in disconnected vacuum circuit Test the same procedure in case of fault on the other vacuum circuit system You may listen for leaks vacuum pump Check Valves 2 circuits Bottom of b ea ris HS QM LE its se utt w Z l H Vacuum Guard Vacuum Guard light green when Vacuum Guard light red pump is running 2circuits when correct vacuum suction reached 21 English SL 250 2010 2 Stop Down at movements controlled via control panel If no response to pushing
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