Smart Lift SL 580 MAXI User manual
US SL 580 MAXI 03/2016
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Table of Contents
Table of Contents 2
Introduction 3
EU Declaration of Conformity 4
General Description 5
Transport/Handling/Putting into operation/Storage/Technical Data 6
Safety Rules 7
Overview/ - General Description 8
Load Diagram. Safety Function for vacuum 9
Drive Operation and Vacuum function 10
Stop – Emergency stop 11
Control Panel 12
Main Switch. Battery 14
Battery Charger 15
View of Vacuum System. Top/bottom 16
Operation of Yoke 17
Stop-Down Troubleshooting 18
Stop-Down at Vacuum System 19
Stop-Down at movements 21
Control box for actuators 23-26
Stop-Down at drive 27
Dimensioned sketch 28
Wiring Diagram 29-31
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Introduction
Congratulations on your new SL 580 MAXI
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.
Yours Sincerely,
Nicolai Tange Jørgensen
Smartlift A/S
N.A. Christensensvej 39
DK - 7900 Nykøbing Mors
Telephone: +45 9772 2911
E-mail : smart@smartlift.dk
www.smartlift.dk
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EU Declaration of Conformity
Manufacturer
Smart LIFT A/S
N.A. Christensensvej 39
DK - 7900 Nykøbing Mors
Hereby declares that:
The machine/system: Lift
Model/type: SL 580 MAXI – 1.36 hp
Serial No.:
Year/Month: 2016 /
has been made in conformity with Council directive
-Machine directive 2006/42EC
-Low voltage directive 2006/95/EC + 2014/35/EU
-EMC directive 2014/30/EU
The following standards have been applied:
DS/EN ISO 12100 (Safety of machinery - General principles for design -- Risk assessment and risk reduction)
DS/EN ISO 14121-2 (Safety of machinery - Risk assessment -- Part 2: Practical guidance and examples of
methods)
DS/EN ISO 13857 (Safety of machinery - Safety distances to prevent hazard zones being reached by upper and
lower limbs)
DS/EN ISO 13849-1 (Safety of machinery - Safety-related parts of control systems - Part 1: General principles for
design)
DS/EN 13155+A2 (Cranes - Safety - Non-fixed load lifting attachments)
DS/EN ISO 3691-1 (Industrial trucks - Safety requirements and verification - Part 1: Self-propelled industrial
trucks, other than driverless trucks, variable-reach trucks and burden-carrier trucks)
DS/EN ISO 3691-5:2015 (Industrial trucks - Safety requirements and verification - Part 5: Pedestrian-propelled
trucks)
DS/EN 60204-32 (Safety of machinery - Electrical equipment of machines - Part 32: Requirements for hoisting
machines)
DS/EN ISO 13856-3 (Safety of machinery - Pressure-sensitive protective devices - Part 3: General principles for
design and testing of pressure-sensitive bumpers, plates, wires and similar devices)
Date: Signature:
____________ ____________________________________
Nicolai Tange Jørgensen, Director
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General Description/List of Spare Parts
Pos.nr.
Product
Number
Vacuum
1
Pump 007 BDC 24V
2
2
Suction Cup diam 15,75”
4
3
Check Valve ½", vacuum
2
5 Slide Valve w/lock, vacuum 2
6
Vacuummeter diam 40, stainless
2
10
Hose Set
1
11
Hose Coupling
2
12 Spiral Hoses 2
13
Vacuum Guard
2
14
Vacuum Hose diam 10 mm
2
15
Alarm light, Vacuum
1
16 Acoustic alarm, Vacuum 1
17
Line Filter VTF – 38-IN
2
19
Stainless spring on Yoke
4
20
Clamp MRX.80 P-M10-25
6
21 Actuator – Tilting function - LA 36 1
22
Actuator – Side Change- LA 36
1
23
Actuator – Telescopic Arm LA – 36
1
24
Actuator – Lift Arm LA – 36
2
Power supply
25 Battery 2 x 90A 2
26
Charger Blue Power Charger IP65
1
Wheels
27
Wheel, EK-MASSIV 16 – 30
2
30
Supporting wheel
2
24 V
31 Safety Switch/Telemecanique 1
32
Control Panel
1
33
Emergency Stop
1
34
Control, Lift Arm
1
35 Control, Telescopic Arm/Tilt 1
36
Control, Side Change
1
37
CE Connector
1
38
Ermax Main Switch 24 V
1
39 Fuse 30 Ampere Control
Various
40
Lock Split
1
41
Lift Eye
1
44
Battery indicator
3
45 Weight Blocks 10
46
Supporting Leg
2
Drive
47
Motor 1.36 hp/24 V
1
47a
On/OFF switch for Drive Motor
1
47b Fuse 80 Ampere Motor 1
48
Regulating Lever
1
49
Curtis Motor Control
1
50
Safety Clamp
1
51 Safety Switch 1
52
Forward and back switch
1
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Transport/Handling
Smart Lift is for indoor handling and should only be used outdoors on a completely stable and firm
base.
May not be exposed to rain / snow and much moisture
Prior to transport, switch off electronics on main switch (pos. 38).
Smart Lift to be fastened securely in truck/trailer for transport.
Lifting by crane and similar: Always lift Smart Lift in lift eye intended for this purpose (pos. 41).
NEVER lift under Smart LIFT by forks (truck and similar)
Putting into operation
Prior to putting into operation, insert vacuum hoses, and charge battery fully. The operator must
have read the user manual and make sure that all security issues are respected. The user manual
must always be at hand by the machine.
If the yoke has been dismantled, be aware that the washer is placed between the castle nut and
the yoke.
Storage
Always switch off your Smart Lift on the main switch (pos. 38), before storage.
Smart Lift should always be kept dry. Moisture may affect the machine functionality.
Batteries should always be fully charged for long-term storage.
Technical Data
Total Height
55.9 in
Total Width
30.7 in
Total Length
66.9 in
Net Weight
1051 lb
Weight Blocks
48.5 lb x 10 pcs. = 485 lb
Total Weight incl. 10 weight blocks
1536 lb
24 V DC
Charger 110 V – CE connector
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Safety Rules
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 loose 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 (pos. 45) has been locked with lock split (pos. 40).
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 lifting persons.
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Overview/ - General Description
Adjustable yoke with clamp
2 - 4 stk suction cups diam.
15,75 In
14 – Vacuum Hoses
2 safety circuits
Flexible turning head on
telescopic arm
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21 – Actuator tilt
23 – Actuator udskydning
24 – Actuator løftearm
41 – Lift Eye
27 – Wheel,
Massive
46 – Supporting Leg with
wheel
25 – Battery Box two 90 A
45 – Detachable weight
blocks
47 – Drive Motor with electric
brake function
Control Handle with
control for drive
motor
Double Vacuum
Chamber
Control Box
for actuators
Protective Screen for actuator
for side change and motor
change
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Load Diagram
Safety Function Vacuum
Safety Lock vacuum
33 – Emergency Stop
16 – Acoustic alarm vacuum
15 – Alarm light vacuum
44 – Battery Indicator,
on-button on
regulating lever(48)
must be on
NOTE!!
Load diagram attached to
left side of machine
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Drive Operation (forward and back)
Operation for VACUUM function: (machine viewed from above)
This function (pos. 5) will switch vacuum on and off. The vacuum pump is controlled
by a pressure gauge and will start the pump at 0.53, and will switch off at 0.62. The
vacuum function is activated by using the handle on the slide valve and is
deactivated by the same – simultaneously with pulling out the button on the safety
lock.
47 – On/Off- switch for Drive
Motor. Green light when ON
48 – Stepless speed control, forward
and back
51 – Safety Switch at back.
Machine moving forward
automatically by pushing from the
body
Fast and slow speed
5 – Slide Valve, activating and deactivating
vacuum suction.
Safety Lock for vacuum suction
Double vacuum circuit system always
providing at least suction on two cups.
Each suction cup approved for sucking
1278 lb
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STOP/EMERGENCY STOP function:
The emergency stop button, ( pos. 33), has been placed on the actual control box.
This button will turn off the actuators, electric control, as well as the drive motor.
2 separate vacuum
chambers
6 – 2 vacuummeters. One for each circuit.
To show 0.5 – 0.7 for normal operation
Should show 0.5 – 0.7 for normal
operation
31 – Safety switch for overload on yoke.
For activation of disrupted machine see
section “Troubleshooting”
CE Identification Sign
Control Box, containing controls for
actuators, fuse 30 A for same.
16 – Acoustic alarm for
missing vacuum suction
15 – Alarm light for missing
Vacuum suction
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Battery-indicator
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Control Panel (pos. 32) for operation of lift arm telescopic
arm, tilting of yoke, and side change
:
It is important that users read the function description below so that the operator
will be familiar with the machine mode of operation
Smart LIFT is operated manually. This machine generally has four functions which
may be operated individually or simultaneously
UP/DOWN function:
This function will make the arm move either up or down. This movement is
performed via the actuators, (pos. 24).
TILT Function:
This function makes the work turn round. This movement is performed by actuator,
(pos. 21).
TELESCOPIC Function:
This movement is performed via actuator which is placed under the lift arm (pos.
23).
SIDE DISPLACEMENT Function:
This movement is performed via actuator which is placed between the two front
wheels. (pos. 22).
32 – Operation panel placed in special
holder on the machine right hand side. May
be kept manually free out of holder but be
aware that the connector may not come
loose at the control box
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Control Panel
Lift Arm down
Tilt backwards
Telescopic arm out
Side displacement
Lift arm up
Tilt forward
Telescopic arm
Side displacement
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Main Switch:
Main switch for all electric functions is placed on the battery case by the lift actuators. Turn the
switch clockwise to switch on the electric connection on the machine, and the opposite way to
switch off all.
Battery Case:Battery Charger:
The battery case contains two 12 volt
batteries connected in series for 24 volt
operation. The batteries are maintenance
free
Integrated 24 volt charger with 110 volt CE
connector. The charger can also be used as a
voltage unit without having the battery
connected. PLEASE NOTE the charger is not
sparkless in this position.
38 – Main Switch, switching off all
functions on el. on the machine
25 – Two 90A
26 –Charger
37 – 110 Volt
CE–connector
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Battery charger Victron Energy - Blue Power Charger IP65
For complete manual refer to:
https://www.victronenergy.com/upload/documents/Datasheet-Blue-Power-Battery-Charger-IP65-
90-135VAC-EN.pdf
INDICATIONS:
LED indication Description
Yellow LED on: battery being charged.
Yellow LED on and green LED on: absorption charge.
Green LED on: battery fully charged, float charge.
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View of Vacuum System
Top of machine
Bottom of machine
(drive and vacuum)
5 – Slide valve with safety lock,
activating and deactivating vacuum
suction
6 – Vacuum meters for 2-circuit vacuum suction.
11 – Hose couplings for 2 circuits
BLUE CIRCUIT / RED CIRCUIT
2-4 suction cups with
spiral springs
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1 – 2 vacuum pumps 24 volt
3 – Check valves – double circuit
17 – line filters – double circuit
49 – Curtis controller for
drive
47B – Fuse 80A for driving
engine
22 – Actuator for side shift
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Operation of Yoke
Turning vertically Turning horisontally
For max. stability at transport of sucked work, the
suction cups are to be centred and adapted to the
transport work chosen. Operation of yoke with
sucked work should always be conducted with
caution
46 – supporting legs always to be
unfolded during work with the machine
20 – 6 clamps for setting of width and
height for suction cups mounted on the
yoke
Smartlift MAXI may with sucked
work turn round 3600 vertically
and 1800horizontally.
NB !!
Always be aware that all
handles and locks are
locked and in position
Positioning bolt. Keeping the
turning head locked in fixed
position when yoke is required to
be turned to one of the sides.
Span 180⁰
Safety locking pawl for turning
vertically 360
⁰
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Stop-Down Troubleshooting
On 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 switche d 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? (located 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. Vacuum (machine capacity for sucking work)
2. Movements controlled via control panel up and down function of lift arm, telescoping
of lift arm, tilting of yoke, side displacement of machine.
3. Drive controlled by regulating lever – Forward and back function of machine
Vacuum
Moveing of
actuators
Drive
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Stop-Down at Vacuum System
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 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 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 – 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 cups 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!!).
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.
Slide valve with safety
lock for activation and
deactivation of vacuum
suction.
Vacuum suction on both
pressure gauges to be
0.62 between 0,6 -0,7)
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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 Guard (two)
Vacuum Guard light green when
pump is running (2 circuits)
Vacuum guard light - red when
vacuum suction has been
attained
(Note: Frame no.)
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Vacuum pump
Check valves – 2 circuits + filters
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