Sunwa CARRY-UP CU406 User manual

SUNWA LTD.
Doc. No.
ME - 08 - 1
OPERATION
MANUAL
CARRY-UP

Serial number
Purchased date Year Month Date
Please write the serial number and date purchased in the following blank space.
When you inquire about the machine, please inform us of its serial number and purchase date.
Thank you for purchasing Heavy Duty Carrier Series, SUNWA CARRY-UP.
This manual describes proper operating procedure, inspection and maintenance.
Before running the machine, be sure to read this manual thoroughly.
Please keep this manual on easy place to take it.
All machines are referred to by each own serial number. Whenever you inquire about a machine, be sure to
inform us of its serial number.
The serial number is inscribed on the side of the machine. Please write down the number and year, month and
date of purchase in the operation manual.
● This instruction manual applies to several models. Please refer to the following instructions.
● Type, Serial number ● CARRY-UP
CU406/CU606SF
CU606/CU606SF
INTRODUCTION
To maintain safe operation, important safety precautions, classified into Danger, Warning and Caution, are indicated in
corresponding parts of the operation manual. The definition of each precaution is explained in the following section.
– If you transfer this machine, be sure to attach this operation manual to the machine. –
SAFETY PRECAUTIONS
Neglecting this warning indication or operating the
machine improperly may cause serious personal
injury or even death.
Neglecting this warning indication or operating the
machine improperly may seriously endanger the
concerned person's health or life.
Neglecting this warning indication or operating the
machine improperly may cause injury to the concerned
person or damage the machine or related items.
型 式
製造番号

TABLE OF CONTENTS
1. ESSENTIALS OF SAFE OPERATION
1~2
2. CONFIGURATION AND SPECIFICATIONS
3. NAME OF EACH UNIT
4
2-1 PRODUCT CONFIGURATION ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3
2-2 SPECIFICATIONS  ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 3
4-1 KEY SWITCH ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 5
4-2 SWITCHES ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 5
4-3 WHEEL BRAKE・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 6
4-4 ASSIST WHEEL ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 7
4-5 SLIDE FORK UNIT (SF type) ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 8
4-6 BATTERY PACK REMOVAL AND REINSTALLATION ・・・・・・・・・・・・・・・・・・ 9
4-7 BATTERY GAUGE INSPECTION・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 10
7-1 CARGO SECURING PROCEDURE ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 18
7-2 TRANSFERRING ON THE GROUND・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 20
7-3 ASCENDING STAIRS ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 22
7-4 DESCENDING STAIRS ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 27
4. DESCRIPTION OF EACH UNIT
5~10
5-1 BATTERY ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 11
5-2 CHARGER ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 11
5-3 CHARGING PROCEDURE ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 12
5-4 VOLTAGE RANGE SELECTION ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 13
5-5 POWER OUTPUT FUSE REPLACEMENT ・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 13
5-6 MALFUNCTION, INSPECTION, RESOLUTION PROCEDURE ・・・・・・・・・ 14
5-7 BATTERY REPLACEMENT ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 15
5. BATTERY CHARGE SYSTEM
11~15
6. PRE-USE INSPECTION
16~17
7. OPERATION
18~31
9. DAILY MAINTENANCE AND CARE
10. INSPECTION AND MAINTENANCE
9-1 BATTERY ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 37
9-2 RUBBER CRAWLERS ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 37
9-3 LUBRICATION・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 37
37
8. RUBBER CRAWLERS ADJUSTMENT AND REPLACEMENT
8-1 ADJUSTMENT ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 32
8-2 PITCH ERROR COLLECTION PROCEDURE ・・・・・・・・・・・・・・・・・・・・・・・・・ 34
8-3 RUBBER CRAWLER REPLACEMENT PROCEDURE ・・・・・・・・・・・・・・・・・ 35
38
3
32~36

1
1
11. .. ESSENTIALS OF SAFE OPERATION
1
< Spiral staircase ><
Staircase with curve >
< Staircase angle exceeding 35 degrees >
35 degrees
or larger
< Stairs with rough edges >
Before using CARRY-UP
●CARRY-UP cannot be used on spiral staircases, curved staircases, staircase angle exceeding 35 degrees, Stairs
with larger pitch or Stairs with rough edges.
Always check CARRY-UP before using it
●The operator must check CARRY-UP before using it.
The initial inspection is necessary for safe operation.

2
4
5
3
2Handling of Battery
●Battery is a sealed type. It is unnecessary to refill it with water.
Never dismantle Battery.
●Never position Battery near a flame or short-circuit Battery.
●If Battery is cracked and its electrolytic solution contacts skin
or clothes, immediately rinse the contaminated area with
plenty of water.
If electrolytic solution splashes into the eye, rinse the eye with
plenty of clean water and consult an ophthalmologist.
●Use Battery Charger of CARRY-UP for charging Battery.
Safe operation with proper knowledge
●The operator needs sufficient training. Be sure the training is
undertaken before the operator attempts to run this machine
for the first time.
●Proper clothes, suitable to machine control, must be worn.
●Be sure to observe the weight limit. Over weight operation
will cause machine malfunction or produce improper or dan-
gerous machine function.
Operation on a staircase
●Never run the machine on a staircase angle exceeding 35 degrees,
on a curved staircase, an oily staircase, an icy staircase, a wet
or slippery staircase or any other inappropriate staircase.
●Never load any cargo which center of gravity is difficult to
maintain at the same point.
●Before the carrier is set on a stair landing, be sure to allow
enough space for the carrier to be handled.
●Whenever running the machine upward, the operator must
always pay attention to the area behind himself.
Do not run CARRY-UP if the stairs are crowded.
●Whenever running the machine downward, the operator must
always pay attention to the front of the machine.
Do not run CARRY-UP if the stairs are crowded.
●Never let go of the machine unless unavoidable circumstances
separate the operator from the machine.
Machine stoppage
●If the machine gives trouble, malfunctions or is damaged,
immediately stop operating the machine.
Running it with a trouble cause existing can result in a serious
accident.

3
ac
b
f
180mm ｅ
2053mm
（1900mm） （1600mm） （1350mm）
Straight Handle (1790mm)
1200mm
ｄ
• Cargo Frame • Drive Unit • Assist Wheel 
• Battery Pack
• Slide Fork (Model SF)
• Cargo tie (5m) 1 set
• Charger (24V)
1 unit
• Parts List
1 copy
Standard
accessories
a : 495mm b : 580mm c : 630mm
d : 920mm e : 458mm f : 678mm
120kgWeight 120kg 135kg135kg
200
−−
200
−−
400 400
Charger Input:115 / 230VAC, 50/60Hz, 1.0A MAXOutput:24VDC, 3A
Maintenance free type sealed lead battery 24V-24Ah/20HRBattery
Rubber Crawler Brake Spring loaded electromagnetic brake
Motor
Type : permanent-magnet DC motor
1020 steps / 60 min 780 steps / 60 min
840 steps / 60 min 660 steps / 60 min
Stair descent speed 4.0m / min5.2m / min
4.3m / min 3.3m / minStair ascent speed
Operators 3 or more
Rubber Crawler 2 Rubber Crawlers (Width : 90 mm)
Maximum stair angle 35°
Maximum load 400kg 600kg
CU606SFModel CU406SF CU606CU406
External dimensions
Down
Slide fork
elevation range
Up
Descending
Running
time (min) /
charge
Ascending
External dimensions :
2
22. .. CONFIGURATION AND SPECIFICATIONS
CARRY-UP consists of the following assemblies.
2-1 PRODUCT CONFIGURATION
2-2 SPECIFICATIONS

4
Relay Box
Battery Gauge
Key Switch
3
33. ..NAME OF EACH UNIT
Battery Pack
Relay Box
Battery Pack
Main Wheel
Assist Wheel
Assist Wheel
Assist Wheel Lock Pin Assist Wheel
Lock Pin
Assist Wheel Lock Lever Assist Wheel
Lock Lever
Main Wheel
Slide Fork Unit
Wheel Brake
Wheel Brake
Brake Lever
Brake Lever
Toe Plate Toe Plate
Switch Box
Operation Switch
Switch Box
Operation Switch
Handle
Straight Handle
Handle
Drive Unit
Frame Unit
Frame Unit
Drive Unit
●Sliding Fork Type
(Model SF)
Relay Box :
●Fixed Fork Type

5
Relay Box
Key Switch
① TOE PLATE/DRIVE
 SELECT Switch
Switch Box
③ Emergency Stop
 Switch
② UP/DOWN Switch
4
44. ..DESCRIPTION OF EACH UNIT
4-1 KEY SWITCH
4-2 SWITCHES
If Key Switch is kept in the ON position, Battery will
more quickly discharge.
When the machine is not to be in use, be sure to turn
off Key Switch and remove it.
①TOE PLATE/DRIVE SELECT Switch
WINCH or RUN modes can be selected by press-
ing the corresponding side of Seesaw Switch.
・When Winch mode is selected, it will be possible to
command Winch Unit (Model SF) to elevate Slide
Fork for adjusting the cargo's center of gravity.
・When Run mode is selected, it is possible that
CARRY-UP climbs/descends a stair by Rubber
Crawler.
②UP/DOWN Switch
Selects ascent or descent mode.
Only while this Switch is pressed, does the machine
run. If UP side is pressed, the machine will as-
cend. If DOWN side is pressed, the machine will
descend.
When the finger is released, Switch will automatically
return its neutral position and the machine will stop.
③Emergency Stop Switch
When this Switch is pressed, the machine will stop
immediately. CARRY-UP won't restart. Even when
the other Switch is pressed.
To release the emergency stop condition, turn
Emergency Stop Switch in the "arrow" indicated
direction.
Key Switch, positioned atop relay box turns on/off
the power supply.
When it is turned clockwise, the power will be ON
and when turned counter-clockwise, the power will
be OFF.
NOTE : When CARRY-UP is not to be used (to be
stored, to be charged, to be transported), turn
off Key Switch, remove Key and keep it in
an appointed place.

6
4-3 WHEEL BRAKE
When Brake Lever is set to its ON position, Main
Wheels will be prevented from running.
To release the brake, set the brake position to OFF.
Before stopping CARRY-UP on level ground or rais-
ing/lowering its frame, be sure to apply the brake to
prevent dangerous movement of the machine.
If the brake pressure weakens, turn in Adjustment
Screw clockwise/counter-clockwise.
Set enough brake pressure for the lever to lock Main
Wheel. Excessive adjustment is unnecessary.
Wheel Brake
Adjustment
Screw
Adjustment Screw
「ON」
「ON」
「OFF」
「OFF」
Brake Lever
Adjust the
screw length.

7
Before CARRY-UP climbs the stairs, be sure to fully
retract its Assist Wheels.
● When Assist Wheels are to be used:
① Pull Assist Wheel Lock Lever in the arrowed di-
rection shown in the figure at right. Lock Pin will
be released and Assist Wheels will extend from the
machine. After Assist Wheels extend, return Lock
Lever to its normal position. Lock Pin will reset
itself.
② When the frame is vertically oriented, pull Assist
Wheels while pulling Lock Lever.
There are eight holes for securing Assist Wheels.
You can set Assist Wheels to the desired angle.
● To retract Assist Wheels:
While pulling one of Assist Wheels stow them fol-
lowing the reverse procedure of their extension.
・Before using Assist Wheels check that
the two Lock Pins (right and left sides
of the machine) are securely locked.
・Before starting to climb the stairs, be
sure to check that Assist Wheels are
completely retracted.
To maintain safety, only when Assist
Wheel is unloaded, can Assist Wheel's
lock be released. Before Assist Wheel
is to be retracted, be sure to remove
the load from Main Wheels and pull
Lock Lever to the arrowed direction
shown in the figure at right.
If the lock is released while a load is
applied to Assist Wheels, the frame will
fall due to gravity resulting in a danger-
ous situation.
4-4 ASSIST WHEEL
Assist Wheel
Assist Wheel
Lock Lever
Lock Pin

8
Upper Limit Switch
Lower Limit Switch
4-5 SLIDE FORK UNIT（ModelSF）
Slide Fork Unit is used for stair ascent/descent and
during ground transfer for cargo balance adjustment.
Set Select Switch on Switch Box to TOE PLATE and
control Slide Fork Unit via its switch.
When Slide Fork Unit reaches its highest or lowest
positions, the upper or lower Limit Switches will ac-
tivate, and Slide Fork Unit will automatically stop.
Before starting operation, be sure to
check that Limit Switches function nor-
mally.
It is normal that Slide Fork Unit stops
when it contacts the upper or lower Limit
Switch.
Center of gravity

9
①Loosen Battery Pack's Plug Screw and disconnect
Plug from its receptacle. Pay attention not to pull
the cord to disconnect Plug.
②Loosen Butterfly Head Bolt that secures Battery
Stopper and remove Battery Stopper.
③Remove Battery Pack from the machine lifting
by its handle and body.
To install Battery Pack, follow the reverse
procedure of its removal.
Battery Pack
Battery
Stopper
Handle
4-6 BATTERY PACK REMOVAL AND REINSTALLATION
• After Battery Pack is reinstalled, be sure to retighten Battery
Plug's Screw.
• After Battery Pack is reinstalled, be sure to retighten Battery
Stopper's Butterfly Screw.
• If Battery Pack is dropped, Battery may be damaged.
Pay attention to safe handling during Battery removal/re-
installation.
Screw
Receptacle
The lower receptacle is
exclusive for battery
charging.
Charger's Plug
Battery Stopper
Butterfly Bolt

10
Relay Box
■BATTERY GAUGE
•
Check that the right end lamp of Battery Gauge
is illuminated.
When the charge level decreases, the
illumination will shift to the left.
If Battery Gauge is not illuminated at the right
end, it means Battery is not fully charged or
battery capacity is reduced due to its
deterioration. The total running period will be
diminished.
4-7 BATTERY GAUGE INSPECTION

5
4
3
2
1
Battery Gauge Available time (Charging percentage)
●
When the Key Switch is set to ON, Battery Gauge
indication may differ from its previous indication.
(when the power was last turned on.)

11
5
55. ..BATTERY CHARGE SYSTEM
5-1 BATTERY
A Sealed Lead Battery is used in CARRY-UP. It is a maintenance-free and non water requiring Battery.
Whenever Battery is handled, be sure to follow the cautions shown below.
NOTE : Immediately after Battery is used, Battery must be charged using Battery Charger of CARRY-UP. If insuffi-
cient battery charge is left, less power for following operations will result in difficulty of operation. Or if
Battery is left depleted for a long period of time, it may be damaged.
Use Battery Charger of CARRY-UP.
Battery is automatically charged depending on battery
discharge rate at a given time.
This Battery Charger is not equipped with a timer func-
tion.
Be sure to disconnect Charger's Plug from Battery Pack
after Green LED illuminates.
(Charging Battery completely will take 8 hours.)
5-2 CHARGER
• Never charge Battery in a closed room.
• Never bring Battery near a flame.
• Never disassemble Battery.
• Never connect Battery Terminals with tools or metals.
• Use Battery Charger of CARRY-UP for charging Battery.
• Always check Battery's condition. If any crack or
deformation or water leakage is observed, replace
with a new one.
• Clean and wipe Battery with a cool or warm water
moistened cloth. Never wipe with gasoline, thinner,
organic solvent or oil moistened cloth.
• If the electrolytic liquid from a damaged Battery
contacts skin or clothes, rinse the area with plenty
of water immediately. If the electrolytic liquid invades
the operator's eye, rinse it with clean water immediately
and consult an ophthalmologist.
• Battery is a sealed type. Never remove its cover. If
the cover is removed, Battery will become unusable.
• Battery may lose its usefulness if it is over discharged.
• If Battery is not to be used for a long period of time,
remove it from the machine and charge it completely.
Keep it in cool and dry place and charge it again
monthly.
Even though Battery is not used during storage, its
capacity constantly decreases. Therefore its perfor-
mance will decrease compared with the previous
occasion the machine was used.
115/230V AC outlet
Charger
Battery Pack

12
5-3 CHARGING PROCEDURE
②Connect AC Adapter to outlet (AC115/230V) and
connect Power Plug.
①Connect Battery Charger's Plug to Receptacle of
Battery Pack.
Power Plug
115/230V AC outlet
AC Adapter
Prepare an area-specific AC conversion Adapter for
installation between AC outlet and Power Plug.
Charger's Plug
Charger
Voltage Range
Power Plug
Cooling Fan
Power Output
Fuse
Charging LED（Yellow ⇒Green）
Power LED（Red）
[ Front Panel ] [ Rear Panel ]
OFF ON
Power Switch
Battery Pack
Receptacle
Charger's Plug

13
5-5 POWER OUTPUT FUSE REPLACEMENT
Turn Fuse Cap counter-clockwise to open. Then remove
the blown Fuse and replace it with a new one (10A,
250V).
③Turn on Charger's Power Switch. (Set it to )
When Red and Yellow LEDs illuminate, the
charging process will start.
④When the charging process advances and Green
LED illuminates instead of Yellow LED, the
charging process will stop.
⑤Turn off Charger's Power Switch. (Set it to )
⑥Disconnect Power Plug from the 115V/230V AC
outlet.
5-4 VOLTAGE RANGE SELECTION
The twin power supply voltage (115VAC / 230VAC)
can be selected by setting Voltage Selection Switch.
A table of initial settings for the destination countries
is shown in the table below. Before using Charger for
the first time, be sure to check that the power voltage
is set to suit to the site's voltage.
• Within 12 hours after Battery Charger's Green LED
illuminates (indicating Battery Pack is fully charged),
be sure to turn off Power Switch. (Set it to )
Over charging will cause deterioration of Battery and
decrease Battery capacity and shorter Battery life.
• High temperature will be indicated on Battery Charger while
it is charging Battery Pack. Never leave any combustibles
near Charger.
ON
Power Switch Red LED
[ Rear Panel ] Yellow LED
(Start of charging process)
Green LED
(Completion of charging process)
[ Rear Panel ] Power Output
Fuse (10A, 250V)
Fuse Cap
Voltage Range
115
230
Charger
AREA / COUNTRY
NORTH AMERICA
115VAC
SINGAPORE
TAIWAN
EUROPE / UK
MALAYSIA
KOREA
○
○
○
○
○
230VAC
○
○
HONG KONG
OCEANIA
○CHINA
○

14
5-6 MALFUNCTION, INSPECTION, RESOLUTION PROCEDURE
The charging
process is
completed however
workable period is
shortened.
Green LED
illuminates soon
after the start of
charging.





No power supplied.
LED won't illuminate.
Insufficient insertion of Power Plug
into outlet.
Check outlet and securely connect
Power Plug.
TROUBLE CAUSE COUNTERMEASURE
Power Cord is broken. Arrange its repair or replacement.
Check power and other relevant parts.No power is supplied.
Check the connecting parts and
securely connect them.
Receptacle and Plug are improperly
connected.
Battery Pack is improperly connected. Check the connecting parts and
securely connect them.
Battery Charger's power source trouble. Arrange a check or repair.
Replace with a new Battery. (See P15.)Battery nearly dead.
Charge Battery in an ambient
temperature between 5 and 40℃.
Ambient temperature is low during
charging.
Battery is normally charged. Normal.
Battery malfunction. Replace with a new Battery. (See P15.)
• For safe handling of Charger, be sure to read the
instructions thoroughly before using Charger.
• Charger is only to be used with an AC115V/230V
power source. Never connect Power Cable to any
other power source specification.
• Extended charging may reduce Battery capacity re-
sulting in shorter Battery life.
•Battery and Charger's Output Terminals have polarity.
Confirm that those Terminals are correctly connected
according their polarity. Improper connection will
result in a short circuit and cause a cable to melt or
other serious charger malfunction.
• Never remove Charger Cover or you will risk re-
ceiving an electric shock.
• Keep Charger indoors, away from direct sunlight
and water splashes. Neglecting this can cause fire,
electric shock or equipment malfunction.
• As Battery deteriorates, its voltage will fail to reach
normal full-charge voltage.

15
5-7 BATTERY REPLACEMENT
①Unscrew the screws mounting Battery Case and
Cover.
②Disconnect cables from Battery Terminals, remove
exhausted Batteries, and install new ones.
③Connect cables to Battery Terminals as shown in
the figure below. Confirm that cables are properly
connected to the proper terminals. Then apply an
adhesive to Connectors to prevent their loosening.
While Key Switch is set to ON, power will be supplied
from Battery. If CARRY-UP is not be used, be sure to
set Key to OFF and remove it from Key Switch.
Screw
Screw
Battery
Battery
Case
Battery
（−） （＋）

（−） （＋）

（−） （＋）
（−） （＋）

Battery
Case
Cable connectoin figure
Battery
Battery

16
• Check that there is no crack or damage affecting Frame
or Slide Fork Units.
• Check that Assist Wheel's lock system functions nor-
mally.
Relay Box
Key Switch
Switch Box
Emergency Stop
Switch
UP/DOWN
Switch
TOE PLATE/
DRIVE SELECT
Switch (Model SF)
Upper Limit Switch
Lower Limit Switch
Assist Wheel
Assist Wheel Lock Pin
Assist Wheel
Lock Lever
6
66. ..PRE-USE INSPECTION
• Check that all Switches function correctly.
Before using the machine, be sure to carry out the daily inspection.
The daily inspection will prevent trouble. It is essential before handling CARRY-UP.
SWITCH INSPECTION
ASSIST WHEEL INSPECTION
FRAME AND SLIDE FORK UNIT INSPECTION
Slide Fork Unit
Frame Unit

17
• Check that Main Wheel Brake for ground transfer functions normally.
WHEEL BRAKE INSPECTION
Adjustment
Screw
Adjustment Screw
Brake Lever
Wheel Brake
Adjust the
screw length.
「ON」
「OFF」
「ON」 「OFF」
The right end LED illuminates
BATTERY GAUGE INSPECTION
• Check that the right end lamp of Battery Gauge is
illuminated.
When the charge level decreases, the illumination
will shift to the left.
If Battery Gauge is not illuminated at the right end,
it means Battery is not fully charged or battery
capacity is reduced due to its deterioration. The total
running period will be diminished.
RUBBER CRAWLER INSPECTION
• Check that there is no crack, wear or pitch error regarding
Rubber Crawlers.
• The pitch error can be confirmed from Slip Mark deviation.
• Check that no Screw has dropped out and that all Screws
are tightly attached.
SCREWS INSPECTION
Slip Mark
Rubber Crawler