Expresso lift2move Operating Manual Download Page 47

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lift2move

Lifting aid

May 2014

10 Functional

faults

10.1 General notes on functional faults

The

lift2move

is an extremely safe and reliable piece of equipment,

designed for a long service life and high availability.

In case of functional faults, the

lift2move

must be shut down

imme-

diately

, and secured.

In case of a fault in the control unit, the

lift2move

must be stopped

immediately

by pulling out the battery connector from the battery

pack.

DANGER!

In case of damaged electrical components, the

lift2move

must be shut down

immediately

WARNING!

In case of the following functional faults or
damage, the lifter must be shut down

immediately

●

Failure of brakes, securing mechanisms or
other safety devices.

●

Any other damage, deformations or fractures in
the lifter‘s structure (e.g. after a fall from a step
or ramp).

Functional faults

Summary of Contents for lift2move

Page 1: ...Lifting aid May 2014 Operating manual ...

Page 2: ...May 2014 2 lift2move Lifting aid EXPRESSO Deutschland GmbH Phone 49 0 561 95 91 0 Antonius Raab Straße 19 Fax 49 0 561 95 91 2138 34123 Kassel Germany E mail info expresso de www expresso group com ...

Page 3: ...ded incorrect use 20 3 4 Special hazards 21 4 Transport packaging and storage 22 4 1 Safety notes for unloading transport after delivery 22 4 2 Checking the delivery 22 4 3 Dealing with packaging material 23 4 4 Notes on storage and transport 23 5 Description 24 6 Assembly Disassembly 25 7 Operation 27 7 1 General notes on operation 27 7 2 Commissioning the lifting aid 28 7 3 Operating the lifting...

Page 4: ... sheet for lift2move 85 51 11 3 Data sheet for lift2move 125 52 11 4 Data sheet for lift2move 175 53 11 5 Data sheet for lift2move 225 54 11 6 Wheelbase versions 55 11 7 Max payload 56 11 8 Efficiency service life curve for the batteries 58 11 9 Circuit diagram for lift2move 85 7 2 Ah 59 11 10 Circuit diagram for lift2move 125 12 Ah 60 11 11 Circuit diagram for lift2move 175 17 Ah 61 11 12 Circuit...

Page 5: ...products Every person involved with the transport assembly commissioning operation maintenance and repair of our lift2move lifting aids and handling attachments must have read and understood the operating manual the brief instructions for the load handling attachment the safety regulations the relevant safety instructions To prevent operating errors and to ensure trouble free operation of our prod...

Page 6: ...as well as general safety instructions must be observed and followed when using the pallet lifter Important notes such as those involving the safety of operating personnel third parties or the equipment are indicated by means of corresponding symbols Observe these notes to prevent bodily injury and material damage Observe and follow the safety regulations 2 2 Copyright This operating manual is int...

Page 7: ...peration of the product the use or installation of parts and or components that have not been approved by EXPRESSO for the respective purpose negligence normal wear and tear excessive loading interference by third parties accidents or force majeur On no account will EXPRESSO be liable for indirect or consequential damages We reserve the right for technical changes in the interest of constant produ...

Page 8: ...instructions have not been observed the instructions for the load handling attachment have not been observed the equipment has not been used correctly the equipment has not been used for the intended purpose the equipment has not been repaired correctly no genuine spare parts from EXPRESSO have been used impermissible devices e g load handling attachments not authorized by EXPRESSO have been used ...

Page 9: ...r faults or damage due to incorrect storage and or transport after the day of delivery to the place of destination or resulting from improper use and or assembly by the customer or third parties through incorrect maintenance or incorrect operation of the product the use or installation of parts and or components that have not been approved by EXPRESSO for the respective purpose negligence normal w...

Page 10: ...an immediate dangerous situation that can result in severe or fatal injuries if the warning is not observed WARNING Indicates a potentially dangerous situation that can result in severe or fatal injuries if the warning is not observed CAUTION Indicates a potentially dangerous situation that can result in slight or minor injuries if the warning is not observed CAUTION Indicates a potentially danger...

Page 11: ...ppropriate standards accident prevention regulations and working conditions is able to carry out maintenance and servicing work as assigned by the owner operator in addition to normal operation of the equipment The Expert must be able to assess the assigned tasks recognize possible dangers and take preventive measures Hazard specific symbols WARNING Risk of injury from suspended loads Falling or s...

Page 12: ...rms of wear corrosion and damage as well as constructional or other modifications are assessed Hereby the completeness and correct operation of safety devices must also be checked See Section 9 Servicing Maintenance Recurring inspections must be carried out in accordance with the regulations of the Machinery Directive 2006 42 EC The results of the inspection must be recorded See Chapter 12 Blank f...

Page 13: ...are parts with them as well as the necessary tools and equipment to provide expert maintenance of your lifting aid on site Should you have any questions regarding the use of our products or should problems occur please contact EXPRESSO directly see contact details below When ordering spare parts please indicate type year of manufac ture and the article number of your lift2move This will help us to...

Page 14: ...all activities on or with the lifting aid all rules and general regulations for accident prevention applicable for the workplace must be observed Their instructions must be followed Any non observance of the safety instructions given in this operating manual can lead to bodily injury or even death The operating manual must always be available at the workplace and be kept readily accessible for all...

Page 15: ...s responsible for ensuring this regulation WARNING The user may not have long open hair or wear loose fitting clothes or jewellery including rings as there is a risk of injury through getting caught Users under the influence of substances that have an effect on their reactions or awareness as contained in alcohol medication or nar cotics may not operate the lifting aid If person s in the vicinity ...

Page 16: ...ft2move Lifting pillar EXPRESSO logo Type identification Indication of max permissible payload NOTE i i Only specifies the construction dependent max load The effective max load can be less depending on the load handling attachment s design distance from the lifting pillar etc The value on the load handling attachment must always be observed Push handle Safety instructions Do not stand under the l...

Page 17: ...Wheelbase top right Safety instructions Do not transport persons Risk of impact crushing Wheelbase top left Safety instructions Risk of impact crushing Do not stand under suspended loads Never move suspended loads over persons All illustrations are exemplary Safety instructions ...

Page 18: ...and markings on the load handling attachment Load handling attachment Type label with CE marking Load handling attachment Indication of max permissible payload Additional labels and or markings are possible and are adapted individually to the lift2move as well as the load handling attachment according to the application All illustrations are exemplary Safety instructions ...

Page 19: ...or tipping and turning might be fitted The max permissible payload is clearly marked on the lift2move s lifting pillar Depending on type the rated payload of the load handling accessory can be less than the max permitted payload of the basic lift2move In all cases the lower payload must not be exceeded Intended use also includes the observance of all operating maintenance and repair instructions s...

Page 20: ...urfaces e g with defects such as potholes that could lead to an accident Use on inclines or ramps especially when loaded Operation of the lifting aid while the battery charger is connected Outdoor use or in surroundings with high air humidity and or splash water Operation and or storage at temperatures below 10 C and above 50 C Trailing behind ground transport vehicles e g walkie type WARNING The ...

Page 21: ...ifting aid without supervision Wear personal protective equipment in the danger area Moving parts of the equipment WARNING Risk of injury from moving parts Moving equipment parts can cause severe injuries Therefore Never stay in the danger area Before starting operations check that there are no persons or obstructions within the working range Never use the lifting aid without supervision Do not to...

Page 22: ...in perfect condition Only use lifting tackle slings with adequate load rating Observe the center of gravity Wear suitable personal protective equipment Hitching points CAUTION Do not attach the lifting tackle to projecting parts or motors of the lift2move 4 2 Checking the delivery Immediately after receipt check the delivery for completeness and signs of transport damage Proceed as follows in case...

Page 23: ...n many cases 4 4 Notes on storage and transport CAUTION During storage and transport of the lifting aid the connector of the control unit and the cable to the motor must be pulled out disconnected The battery charger must be disconnected from the battery pack CAUTION Do not operate or store the lifting aid at temperatures below 10 C and above 50 C If necessary and after consultation with EXPRESSO ...

Page 24: ...ents Basic components 1 Wheelbase general 1a Standard wheelbase FW 1 2 each or 1b Lowered wheelbase FW 2 2 each or 1c Flat enclosed wheelbase FW 3 2 each 2 Battery pack 3 Two stage control unit with spiral cable 4 Lifting pillar 5 Lift carriage 6 Push handle 7 Central motor mount and brake handle 8 Battery charger with spiral cable 9 Load handling attachment example Figure Basic components of lift...

Page 25: ...sembly work can be carried out by a single person WARNING Only original EXPRESSO parts may be used for the lift2move lifting aid All screw fasteners must be tightened securely See Section 9 5 Screw torquing values All screw fasteners must be replaced after they have been released tightened five times Self locking nuts may not be reused and may not be replaced with other nut types Screw fasteners m...

Page 26: ...ARNING During assembly disassembly work on the lift2move for the purpose of maintenance or repair the necessary personal protective equipment should be worn All work must be carried out on level ground Only use tools that are in perfect condition Assembly Disassembly ...

Page 27: ...ng aid immediately Keep clear of the load handling attachment while it is in operation Users under the influence of substances that have an effect on their reactions or awareness as contained in alcohol medication or narcotics may not operate the lifting aid The transport areas must be free of obstructions unevennesses and contamination CAUTION The maximum payload may not be exceeded CAUTION Opera...

Page 28: ...f the yellow LED on the charging unit lights up The batteries should be recharged in case of a low charge and or longer periods of non use e g after weekends or pauses of at least one week Also see Section 8 2 Batteries Battery pack 2 Disconnect the charging unit from the battery pack 3 Actuate the control unit The lift2move is switched on automatically NOTE i i After 10 minutes of non use of the ...

Page 29: ... with a three stage parking brake By actuating the brake lever the castors can be 1 Locked in the driving direction upper rear position 1st stage 2 Can swivel freely central neutral position 2nd stage 3 Locked with parking brake applied lower front position 3rd stage All illustrations are exemplary Operation ...

Page 30: ...parking brake must be applied Press the brake lever into the lower front position 3rd stage To prevent the lifter rolling away always apply the parking brake 3rd stage after every moving operation or when the required posi tion has been reached Release the brake 1st or 2nd stage before starting to move again 1 2 3 WARNING Moving over uneven surfaces can cause the lifting aid to vibrate As a result...

Page 31: ...push handle height Turning knobs NOTE i i To ensure an ergonomic working posture the push handle should always be adjusted to the correct height Check the handle height every time before star ting work and readjust it if necessary While moving the lifter always keep both hands centrally inside the push handle This will prevent hand injuries e g when coming too close to a wall a corner or some othe...

Page 32: ...xed with screws The holder can be adjusted to the most convenient angle Using the two stage control unit Upward movement low key at bottom left fast key at top left Downward movement slow key at bottom right fast key at top right Left hand keys upward movement Right hand keys downward move ment CAUTION Do not use the control unit in jogging mode WARNING Make sure not to press the control unit keys...

Page 33: ...tachment Load handling attach ment Platform Lift carriage CAUTION The maximum payloads of lifter and or lifting attach ment may not be exceeded CAUTION For customized load handling attachments the brief instructions supplied with the attachment must be observed Customized load handling attachments may only be used to lift the individual parts objects or contai ners they have been designed for and ...

Page 34: ...e through the brush strip or insert objects into the slot The load handling attachment is fixed to the lifting spindle by means of a safety slip clutch If the load handling attachment meets an obstruction during lowering this safety clutch decouples the lifting carriage from the ball screw During lifting operations an overload monitor controlled by the current drawn by the drive motor prevents dam...

Page 35: ...lways ensure that no parts of your body or other obstructions are anywhere within the lifter s entire operating range Do not allow the load to drop freely This applies in particular to load handling attachments with magnets or suction pads Avoid moving the lifting carriage against the upper or lower end stops The lifting aid should always be moved at an appropriate speed especially when moving thr...

Page 36: ...andling attachment s designed specifically for the respective application The load must always be centered on the platform center of gravity in order to achieve the best possible stability and prevent tipping during transport For customized load handling attachments the brief instructions supplied with the attachment must be observed See Section 15 Brief instructions for load handling attachment N...

Page 37: ...t so that the batteries can be recharged 2 Connect the battery charger to the battery pack and plug the charger s mains cable into the power outlet Also see Section 8 1 Battery charger and 8 2 Batteries Battery pack 3 Clean the surfaces of the lift2move with a clean dry and lint free cloth Also see Section 9 2 Daily measures Operation ...

Page 38: ...harging characteristic If other charging units are used the batteries may become damaged and any guarantee claims will be invalidated NOTE i i The battery charger supplied with the lifter has a defined charging characteristic for fast and safe charging This ensures optimal control of the charging curve for a long battery service life 8 2 Batteries Battery pack During every longer period of non use...

Page 39: ...When the lifter is switched on the indicator on the battery pack should show a fully charged battery NOTE i i If a red LED lights up on the charging unit the battery is defective Charging is not possible Charging time There is no fixed charging time The electronically controlled charging unit prevents the batteries being overcharged However the charging time should be at least as long as the opera...

Page 40: ...er on the battery pack indicates the batteries present charging state NOTE i i The batteries must be recharged at the latest when the charge status indicator starts to flash All illustrations are exemplary Handle of quick exchange battery pack Charge status indicator Power supply ...

Page 41: ... of maintenance repair trouble shooting or cleaning must be replaced enabled before putting the lifter back into operation Before switching on again make sure that all covers and safety devices are in perfect working order Maintenance work may only be carried out by experts see Section 2 6 Terminology CAUTION Risk of material damage due to incorrect main tenance If components are replaced Make sur...

Page 42: ... Section 8 2 Batterien Akkumula toren Checking the safety devices Check all safety devices on the load handling attachment and ensure that they are working correctly Check all safety devices on the lifter and ensure that they are working correctly Cleaning Clean the surfaces of the lift2move with a clean dry and lint free cloth CAUTION Do not use aggressive cleaning agents Do not use high pressure...

Page 43: ...isconnected certain compo nents in the control unit can still have an electrical charge During all repair work on the electrical sys tem the cables to the battery terminals must be disconnected Screw fasteners Check all screw fasteners on the lifter for tightness and retighten if necessary Check all screw fasteners of the load handling attachment for tightness and retighten if necessary CAUTION Ob...

Page 44: ...uctions Do not stand under the load Wheelbase rear Type label with CE marking Wheelbase top right Safety instructions Do not transport persons Risk of impact crushing Wheelbase top right Safety instructions Risk of impact crushing Do not stand under suspended loads Never move suspended loads over persons Battery pack Safety instructions Warning of risks from batteries Information on battery voltag...

Page 45: ... and other equipment used during maintenance have been removed from the workplace 4 Clean the workplace and remove any substances such as liquids processing materials or similar that might have leaked out 5 Make sure that all protective devices are in good working order 9 5 Screw tightening torques Standard metric threads The table shows the tightening torques in Nm for obtaining the max permissib...

Page 46: ...e condition of the lifter s components and functional elements Checking the complete and correct function of the safety devices Preparing an inspection report The report must include at least Date and scope of the inspection with indication of possible additional partial inspections Result of the inspection with indication of any faults found Assessment of any risks involved with continued operati...

Page 47: ... of a fault in the control unit the lift2move must be stopped immediately by pulling out the battery connector from the battery pack DANGER In case of damaged electrical components the lift2move must be shut down immediately WARNING In case of the following functional faults or damage the lifter must be shut down immediately Failure of brakes securing mechanisms or other safety devices Any other d...

Page 48: ...ssembly Load handling attachment moves too slowly Check the battery voltage Check all electrical connections plugs while the batteries are being charged Check the lamp functions indicator LEDs during charging Noises during up down movement of load handling attachment Clean the lifting pillar grease the ball screws and the spindle see Section 9 3 Annual measures DANGER When opening covers parts tha...

Page 49: ...the fault that caused a shutdown has been remedied and continued operation of the lifter does not represent a hazard In case of unusual behaviour or other faults with your lift2move please contact your local sales partner or the EXPRESSO Custo mer Support Center in Kassel immediately EXPRESSO Deutschland GmbH Phone 49 0 561 95 91 0 Antonius Raab Straße 19 Fax 49 0 561 95 91 2138 34123 Kassel Germa...

Page 50: ...izes depen ding on undercarri age front rear lift2move 85 60 75 100 mm 100 150 mm lift2move 125 60 75 100 mm 100 150 mm lift2move 175 60 80 100 mm 100 150 mm lift2move 225 60 80 100 mm 100 150 mm Battery type Maintenance free fleece technology Battery voltage battery capacity lift2move 85 125 24 V 7 2 Ah alternativly 12 Ah lift2move 175 225 24 V 17 Ah alternativly 34 Ah Charging parameters 230 VAC...

Page 51: ...92 mm Overall lengths 877 977 1 077 mm Widths B 460 500 580 any dimension between 400 and 1 300 mm Battery rating 7 2 Ah 24 V 12 Ah 24 V Wheel sizes front rear 60 100 mm Lifting speed empty with full load about 115 and 92 mm s respectively Payload 85 kg Empty weight 40 kg Charging voltage 230 Volt AC 50 Hz For different widths B the dimensions C change accordingly underlined values refer to the ba...

Page 52: ...92 1 892 2 192 mm Overall lengths 877 977 1 077 mm Widths B 460 500 580 any dimension between 400 and 1 300 mm Battery rating 7 2 Ah 24 V 12 Ah 24 V Wheel sizes front rear 60 100 mm Lifting speed empty with full load about 95 and 80 mm s respectively Payload 125 kg Empty weight 40 kg Charging voltage 230 Volt AC 50 Hz with wheelbase 2 For different widths B the dimensions C change accordingly unde...

Page 53: ...1 360 1 860 2 360 mm Overall lengths 971 1 171 mm Widths B 460 500 600 1 200 mm any dimension between 460 and 1 200 mm Battery rating 17 Ah 24 V 34 Ah 24 V Wheel sizes front rear 60 100 mm Lifting speed empty with full load about 108 and 80 mm s respectively Payload 175 kg Empty weight 83 kg Charging voltage 230 Volt AC 50 Hz with wheelbase 2 For different widths B the dimensions C change accordin...

Page 54: ... 260 mm Overall lengths 971 1 171 mm Widths B 460 500 600 1 200 mm any dimension between 460 and 1 200 mm Battery rating 17 Ah 24 V 34 Ah 24 V Wheel sizes front rear 60 100 mm Lifting speed empty with full load about 100 and 75 mm s respectively Payload 225 kg Empty weight 83 kg Charging voltage 230 Volt AC 50 Hz with wheelbase 2 For different widths B the dimensions C change accordingly underline...

Page 55: ...lift2move Lifting aid May 2014 55 11 6 Wheelbase versions Examples ofapplication specific wheelbases Y wheelbase L wheelbase A wheelbase T wheelbase X wheelbase Omega wheelbase Technical data ...

Page 56: ...on the load handling attachment described as off center 100 mm 200 mm 300 mm Maximum payload depending on distance from the lifting pillar load diagram lift2move 85 Central 100 200 300 400 0 500 600 700 800 900 1000 0 10 20 30 40 50 60 70 80 90 Payload kg Distance from lifting pillar mm off center 100 off center 200 off center 300 Maximum payload depending on distance from the lifting pillar load ...

Page 57: ...Distance from lifting pillar mm off center 100 off center 200 off center 300 80 100 120 140 160 180 200 off center 400 Maximum payload depending on distance from the lifting pillar load diagram lift2move 225 Central 100 200 300 400 0 500 600 700 800 900 1000 0 50 Payload kg Distance from lifting pillar mm off center 100 off center 200 off center 300 100 150 200 off center 400 250 Technical data ...

Page 58: ... far the batteries are discharged 50 discharge max 750 charging cycles 80 discharge max 250 charging cycles Recommendation Charge the batteries daily at the end of the shift Interim charging results in a longer service life NOTE i i Recharging should be done on a daily basis because higher discharge rates also reduce the number of possible charging cycles CAUTION Long periods of non use can lead t...

Page 59: ...lift2move Lifting aid May 2014 59 11 9 Circuit diagram for lift2move 85 7 2 Ah Technical data ...

Page 60: ...May 2014 60 lift2move Lifting aid 11 10 Circuit diagram for lift2move 125 12 Ah Technical data ...

Page 61: ...lift2move Lifting aid May 2014 61 11 11 Circuit diagram for lift2move 175 17 Ah Technical data ...

Page 62: ...May 2014 62 lift2move Lifting aid 11 12 Circuit diagram for lift2move 225 34 Ah Technical data ...

Page 63: ...______________________ Lifting pillar _________________________________________ Central motor mount _________________________________________ Checks OK Remarks Measures Wheelbase Check for damage and firm mounting Wheelbase Screw fasteners Check that wheel treads are clean secure and undamaged Check castors for smooth operation and firm mounting Noise generation while driving Brakes Brake tests Fu...

Page 64: ...le for damage Check battery terminals for corrosion Check battery capacity Charging unit Check charger cables and connectors for damage Check contacts of the charging connector Charging function Charge status indicator Function Miscellaneous Surfaces damaged paintwork scratches dirt Type label fitted Inspection label fitted updated Remarks faults found _____________________________________________...

Page 65: ...f the parking brake Custom mounted lifting device Holder for the charger mounted at the correct position Holder for operator unit mounted at the correct position Checking the push handle 2 Power supply charger control unit Charging voltage from the charger 27 2 28 4 V Battery pack charged Buttons on the control unit tested 3 Driving Test Commissioning Lifting to endpoint without load Lowering to e...

Page 66: ...lift2move 225 Article no 14 196 ___________________ in Kombination mit dem montierten Lastaufnahmemittel ___________________________________ Article no _________________________ for lift2move complies with the relevant safety and health provisions of the EU Machinery Directive 2006 42 EC The following standard s and or technical specification s were applied for the correct implementation of the EU...

Page 67: ...lift2move Lifting aid May 2014 67 EXPRESSO Deutschland GmbH Phone 49 0 561 95 91 0 Antonius Raab Straße 19 Fax 49 0 561 95 91 2138 34123 Kassel Germany E mail info expresso de www expresso group com ...

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