user’s manual · 2019-09-14 · platform then requires two hands for operation. one hand is...

User’s Manual

Powerlift DC Trolley

How to install, Use and Maintain

Version no: A

December 2016

Powerlift DC Trolley| User’s Manual| Version no: A 3

Contents 1.0 Introduction ........................................................................................................................ 4

1.1 Disclaimer ............................................................................................................................ 4 1.2 Copyright © 2016 ................................................................................................................. 4 1.3 Owner’s Responsibility ......................................................................................................... 4 2.0 Safety .................................................................................................................................. 5

3.0 Unpacking the Trolley ........................................................................................................ 7

3.1 Lifting and Handling.............................................................................................................. 7 3.2 Transit Damage .................................................................................................................... 7 3.3 Batteries ............................................................................................................................... 7 3.4 Operational Restrictions ....................................................................................................... 7 4.0 Operating the Trolley ......................................................................................................... 8

4.1 Basic Operation .................................................................................................................... 8 4.2 Battery life .......................................................................................................................... 10 4.3 Load Capacity .................................................................................................................... 10 5.0 Operating the Trolley for the First Time ......................................................................... 10

6.0 Maintenance ..................................................................................................................... 10

6.2 Identification ....................................................................................................................... 11 6.3 Spare Parts ........................................................................................................................ 11 7.0 Warranty ........................................................................................................................... 11

8.0 Safetech Divisions ........................................................................................................... 12

9.0 Trouble Shooting ............................................................................................................. 13

10.0 Hazard Identification, Risk Assessment and Control for Powerlift Dc-Trolley ............ 14

10.1 Hazard One - Crush and Shearing Injuries as a Consequence of Pinch Points .................. 14 10.2 Hazard Two - Electrocution ................................................................................................ 15 10.3 Hazard Three - Crushing .................................................................................................... 15 10.4 Hazard Four - Crushing through falling loads ..................................................................... 15 10.5 Hazard Five - Collision ....................................................................................................... 16

Powerlift DC Trolley| User’s Manual| Version no: A safetech.com.au 4

1.0 Introduction

The Powerlift range of trolleys has been designed to take the effort out of lifting and carrying. The

Powerlift range consists of the DC250 (see Fig. 1) and the DCD100 (see Fig. 2). The DC250 has a

lift capacity of 250 kg and stroke of 485mm. The DCD100 has a lift capacity of 100 kg and stroke of

970mm. The trolleys conform to ergonomic guidelines in order to make them as comfortable and

safe as possible. The batteries that power the platform are sealed for safety and can be charged

and recharged many times.

In the interests of safety please read the entire manual carefully and be familiar with its contents

before using the trolley. If in doubt about the appropriate procedure, please contact your Safetech

agent.

This instruction manual is not intended to be or to create any other warranty, express or implied,

including any implied warranty of merchantability or fitness for a certain purpose, all of which here

are expressly excluded to the extent limited by law. As set forth specifically in the warranty,

Safetech's obligation under warranty is limited to the repair or replacement of defective components,

which shall be the buyer's sole remedy, and Safetech shall not be liable for any loss, injury or damage

to persons or property, nor for any direct, indirect or consequential damage of any kind resulting from

use of the trolley.

Safetech trolleys are fitted with an identification plate, located on the central cross member, directly

above the linear actuator. The identification plate is stamped with the model number, capacity and

serial number. This data should be quoted when making any technical or spare parts enquires.

1.1 Disclaimer

Although every effort is made to ensure accuracy, currency and completeness of the information

contained in this manual, Safetech does not guarantee, warrant, represent or undertake that the

information is correct, accurate or current.

Safetech is not liable for any loss, claim, cost or expense of any kind arising in any way whatsoever

from the information contained in this manual.

1.2 Copyright © 2016

Safetech of 39-45 Della Torre Road, Moe Victoria, 3825, all rights reserved.

No part of this document may be reproduced or utilised in any means, by any means, electronic or

mechanical, including photocopying, recordings or any information storage or retrieval system,

without the express permission from Safetech.

1.3 Owner’s Responsibility

To ensure both your safety and the safety of others, and the continued effective operation of your

Safetech Tilter, your responsibilities are as follows:

• Before operating the Tilter, please read and ensure you understand both the safety instructions and the operating instructions.


• If you do not fully understand these instructions, contact either Safetech or an authorised Safetech agent for clarification before operating your Tilter.

• The Owner must review the Risk Assessment in this manual.

• Please Note: That in the Risk Assessment a number of items have been flagged as Completed? = No. The Owner must include these hazards in their own operational risk assessment and ensure that action is taken to address the hazard.

• The owner is responsible to ensure all operators have been adequately trained on the safe operation of the Tilter.

• The owner is responsible to ensure that a risk assessment on the Tilter in their operating environment is done.

2.0 Safety

The safety of all persons operating, maintaining, repairing, or in the vicinity of the trolley is of

paramount concern to Safetech. Therefore, throughout this manual, Safetech has identified certain

hazards, which may occur in the use of the trolley and provided appropriate instructions or

precautions, which should be taken to avoid these hazards. In some cases, Safetech has also

pointed out the consequences that may occur if Safetech's instructions or precautions are not

followed. Safetech uses the following system of identifying the severity of the hazards associated

with its products:

"Danger" Immediate hazard that could result in severe personal injury or death.

"Warning" Hazardous or unsafe practice that could result in severe personal injury or death.

"Caution" Hazardous or unsafe practice that could result in minor personal injury or property

damage.

Please read and follow the instructions in this manual, including all safety instructions and

precautions, carefully and completely.


Figure 1 Powerlift DC-250 Trolley

Figure 2 Powerlift DCD-100 Trolley

Deck

Actuator

Power

Cable

Brake Castor

Battery

Box

Handle

Centre Pivot

Thumb

Screws

Bottom Pivot

Middle Pivots

Rollers


3.0 Unpacking the Trolley

3.1 Lifting and Handling

Set up the trolley by:

a. Cut strapping and remove the trolley from the box.

b. Unscrew the thumbscrews from the handle pins.

c. Fit the handle to the trolley by sliding it over the pins.

d. Replace the screws, ensuring that they are tightly fastened.

e. Plug the power cable from the actuator into the bottom of the battery box, ensuring the

plug is all the way home.

3.2 Transit Damage

Inspect the trolley for signs of damage in transit, paying particular attention to the electrical cabling.

If there is evidence of damage, contact your Safetech agent before using the trolley.

3.3 Batteries

The trolley is supplied with two 12 Volt batteries encased in the battery box, which is fixed to the

handle. The batteries are sealed lead acid cells. This means that there is no risk of spilling acid

even if the trolley is turned on its side. The batteries can be recharged at any time without any

"memory effect".

Warning: The batteries contain highly corrosive acid and should not be punctured. Seek urgent

medical advice if acid contacts skin or clothing. Ensure that batteries are disposed of

safely and according to local regulations.

3.4 Operational Restrictions

3.4.1 Wash-down

The Powerlift trolley can be washed down without damaging the mechanism. However do not direct

a jet of water at the Actuator. The actuator powering the unit is rated to IP54. This makes it dust-

resistant and capable of withstanding a light water spray from any direction. An actuator rated to IP

56 is available if higher degree of water protection is required. Please note however, that the battery

box is not water or dust proof and must be removed before the trolley is washed down.

3.4.2 Hazardous Environments

The Powerlift trolley electrical equipment is not suitable for use in flammable or explosive

environments and must never be used when such hazards exist.

3.4.3 High Cycle Applications

The Powerlift trolley is designed for intermittent use. For high cycle operations, the following should

be observed:

a. The Powerlift trolley mechanism is designed to achieve a minimum life of approximately

10,000 cycles. For manual intermittent use, this equates to many years of service.


b. The Powerlift trolley motor should not exceed nine (9) full cycles per hour. The

recommended duty cycle for the Powerlift trolley motor is 10 %. This means that the

motor should not be operated for more than 6 minutes of every hour.

4.0 Operating the Trolley

4.1 Basic Operation

4.1.1 Platform control

The position of the platform is controlled with the rocker switch located on the top of the battery box

(see Fig. 3). The trolley can be raised by pressing the top part of the switch or lowered by pressing

the bottom part of the switch.

The battery box may be fitted with an optional control interlock push button. The control of the

platform then requires two hands for operation. One hand is required to operate the rocker switch as

described above. The other hand is required to press and hold the control interlock button (located

on the right hand side of the box) to make the rocker switch active.

Warning: As the trolley platform moves up and down, "pinch points" are created where the scissor

legs cross, where the legs meet the base and platform and in the path on which the

rollers travel. When operating the trolley, be careful to ensure that nobody becomes

caught in the moving parts.

Caution: Do not continue to press the switch once the platform has reached either the top or the

bottom of its travel, as this may damage the unit.

The trolley incorporates an overload protection device that may cut power to the unit if the control is

pressed continuously after the trolley reaches either the top or the bottom of its travel. The device

will reset within a matter of seconds and power will be restored.

4.1.2 Wheel configuration

The trolley is supplied standard with two fixed wheels at the front and two rear swivelling wheels.

One of the rear wheels is fitted with a brake.

The trolley may be fitted with two swivel wheels on the front instead of the fixed wheels. One of these

front swivel wheels will incorporate a directional lock. Please contact your Safetech agent for details.

Brake

The brake is located on one of the rear castors of the trolley. It prevents the castor from both

swivelling and rolling. Press the silver lever located on top of the castor to engage the brake.

Caution: The brake is an important safety device. Please ensure it is engaged when the trolley is

unattended. Attempt to find level ground whenever possible.


Direction lock (fitted to optional front castors)

The directional lock prevents the castor from swivelling but allows the wheel to rotate as usual. Use

it when pushing the trolley in a straight line to provide greater stability. The direction lock castor has

a black or green lever and is located on the front right hand corner of the trolley.

The direction lock will not engage until the castor is in the correct position. To negotiate corners and

change direction, release the directional lock by pressing the black or green button on top of the

castor. This will make the lever on the castor "pop up", releasing the lock.

4.1.3 Charging the batteries

When the up/down switch is pressed, a light in the lower right hand corner of the battery box will

glow. If the light glows green, the battery is sufficiently charged. If the light is red, the battery is low

and should be recharged.

Once the light glows red, the batteries should be charges as soon as possible. Prolonged use of the

trolley with the batteries at a low state of charge may damage the batteries.

A charger, which has a plug to suit a standard 240V power point on one end and a plug on the other,

is supplied with each trolley. The plug fits into a hole at the bottom right hand corner of the rear face

of the battery box (see Fig. 3).

Plug the charger into a power point. The light will glow during charging. If the batteries are low, the

light will glow red during charging. The light will change to green when there is enough charge to

operate the trolley, but the batteries are still not fully charged. The batteries require a further 12

hours to reach full charge. Do not flatten the battery before recharging. There is no risk of damage

to the battery if it is left on charge for longer than 12 hours. Do not operate the trolley while the

battery is being charged.

The battery box can be easily removed from the trolley for recharging if required. First, unplug the

power cable from the bottom of the battery box. Next, unscrew the thumbscrew that fixes the box to

the trolley handle. Gently lift the battery box upwards and away from the trolley.

Figure 3 Powerlift Battery Box

Rocker Switch

Thumbscrews (THSCRM8X20) (Attach Battery Box to handle)

Battery Box

Low Battery Warning Light

Charger Power cable

Box

Optional Control

Interlock Pushbutton


4.2 Battery life

Small lead acid batteries of a similar type to those used in cars are the power source for your

Powerlift trolley. The batteries are relatively inexpensive and do not suffer from the 'memory effect'

experienced with NiCad batteries. However, like any battery, they have a finite life span. Provided

the batteries are recharged in a timely manner as described in 4.1.3 and not subjected to prolonged

operation at low charge, the batteries should be able to be recharged approximately 400 times before

needing to be replaced. Under most circumstances, this equates to 18 months of use or more.

4.3 Load Capacity

The load capacity is stamped into the identification plate located on the central cross-member, above

the actuator. Ensure that the capacity placarding remains legible. The trolley contains an overload

protection device that may cut power to the unit if overloaded. If this occurs, ensure that the trolley

is not loaded beyond its capacity. The device will reset within a matter of seconds and power will be

restored. The load capacity is based on the load applied centrally and uniformly to the platform. If

the load is not central, please consult Safetech before using the trolley.

Caution: Do not overload the trolley, as this may damage the unit.

Caution: Do not let loads significantly overhang the platform, as this may lead to instability and

could result in the platform being overloaded

5.0 Operating the Trolley for the First

Time

Your Safetech trolley has been tested before leaving the factory. However, the batteries may be low

in charge. Press the control button to raise the platform and check that it is fully functional. Check

whether the red low battery warning light is illuminated. If so, the battery needs to be recharged.

6.0 Maintenance

Safetech Powerlift trolleys require minimal maintenance. They are designed for a life of

approximately 10,000 cycles after which a new actuator may be required.

Monthly maintenance

a. Check that all circlips are in position. There are 6 circlips in total on the DC250 and 12

circlips in the DCD100. They are located at the top pivot (2 off), centre pivot (2 off) and

bottom pivot (2 off). The DCD 100 also has two middle pivots (4 off), and an extra centre

pivot (2 off)

b. Turn the trolley on its side and check that the castor bolts are tight.


c. Check that the Nyloc nuts on the actuator pivot bolts are in place. The Nyloc nut should

not be tight against the clevis of the actuator. During operation the clevis of the actuator

should rotate on the bolt.

d. Inspect the cable and plug for signs of damage

e. Inspect the battery box for obvious signs of abuse.

f. Use a clean rag to wipe the paths along which the rollers travel.

Annually or 3000 cycles

a. Dismantle

b. Grease roller pins with a small amount of “Loctite” Anti-seize

c. Clean Rollers, Roller paths, and pivot pins

d. Reassemble

6.2 Identification

All Powerlift trolleys carry an I.D. plate with the serial number. Please quote the serial number when

ordering parts.

6.3 Spare Parts

Spare parts are currently available from your agent or directly from Safetech. Please quote the serial

number of your trolley when ordering spare parts.

7.0 Warranty

Refer to Safetech complete Terms of Sale and Warranty at

http://www.safetech.com.au/terms-sale-warranty/

http://www.safetech.com.au/terms-sale-warranty/


8.0 Safetech Divisions

Head Office

Head Office – Moe, Victoria Address: 39-45 Della Torre Road, Moe, Victoria, 3825

Postal Address: PO Box 360, Moe, Victoria, 3825

Phone: 1800 674 566

Fax: 03 5127 4431

Email: [email protected]

Service

Service Enquiries Phone: 03 8546 5600

Fax: 03 9558 6550

Email: [email protected]

Sales offices

Victoria Address: 1/21 Lionel Road Mt Waverley VIC 3149

New South Wales Address:14a/65 Elizabeth Street Wetherill Park NSW 2164

Queensland Address: 12-23 Armada Street, Banyo, QLD, 4015

Western Australia Address:11/288 Amherst Road, Canning Vale, 6155

mailto:[email protected]

mailto:[email protected]


9.0 Trouble Shooting

Safetech Powerlift trolleys should provide years of trouble-free service. However, in the event you

experience difficulties with your trolley, the following may assist to identify the problem.

You may, of course, contact your Safetech agent or phone Safetech direct on 1800 67 4566 for

assistance.

Problem Possible causes Remedy

Trolley will not raise 1) Power not supplied to

trolley

Check whether the power

cable is plugged in.

2) Batteries are flat. Recharge batteries overnight,

using charger as supplied.

3) Thermal overload on

motor may have

tripped.

Will reset automatically

4) If none of the above,

an electrical fault may

exist or the motor may

have burnt out.

Contact your Safetech agent.

Trolley is slow to raise or will

not rise to the top.

1) Batteries are flat Recharge batteries

2) Trolley is overloaded

and overload is

tripping.

Remove load and try again.

6) If none of the above, a

fault may exist with the

motor/switch.

Contact your Safetech agent.

Trolley will not lower 1) Power not supplied to

the table.

Check whether the trolley is

plugged in.

2) Batteries are flat. Recharge the batteries.

In the event of difficulty charging the batteries or fault, the following steps may assist to diagnose the

problem:

1. Plug the charger into the battery box and 240V outlet and turn on. The light on the battery

box should illuminate, either red or green.

2. Unplug the charger from the battery box. Operate the rocker switch. The light on the box

should illuminate, either red or green.

If the light illuminates in step 2, but not step 1, the charger is faulty. If the light illuminates in

step 1, but not in step 2, the likely cause is dead flat or faulty batteries although a faulty circuit

board or wiring loom within the battery box cannot be ruled out at this stage. If the light does

not illuminate in step 1 or step 2, the circuit board inside the battery box is faulty.


3. If the light illuminated in step 1, plug in the charger and attempt to charge the batteries, noting

the colour of the light. If the light was red in step 2, but is now green and the batteries struggle

or are unable to raise the platform, the batteries probably have an internal fault, the most

likely cause being prolonged use when flat.

4. If the light was green in step 2 but the other conditions of step 3 are observed, the actuator

may be faulty or the thermal overload may have been tripped.

5. If the light did not illuminate in step 2 but the other conditions of step 3 are observed, the

rocker switch or wiring loom may be faulty. However, battery failure is still the most likely

cause.

6. Continue to attempt to charge the batteries. After 20 minutes, feel the end of the battery box

adjacent to the power cable socket. The battery box should feel warm to touch. If not, the

circuit board is faulty.

7. After some time, (2 minutes to one hour), the light may turn red. If so, or if the light was

always red in step 2, continue to charge for 12 hours. If the light does not turn green within

12 hours, the batteries are faulty and should be replaced.

10.0 Hazard Identification, Risk

Assessment and Control for Powerlift

DC-Trolley

10.1 Hazard One - Crush and Shearing Injuries as a Consequence

of Pinch Points

The trolleys have pinch points where the scissor legs meet and where the legs meet the platform

and the base. A crush injury is possible if a person's body fouls these areas or is caught between

the platform and other fixtures nearby.

10.1.1 Risk Assessment

The risk of such an injury is slight. The pinch points develop slowly as the trolley moves and are

located well within the machine, not close to the operator. A separation of 30 mm is provided

between the legs to minimise the risk of entrapment. If sustained however, the injuries could be

serious or fatal.

10.1.2 Control Measures

Two-hand controls (if fitted)

The trolley may be fitted with an extra control interlock pushbutton. This means that the trolley will

only operate while both the control interlock and the rocker switch is pressed. Releasing either of

the controls will halt the movement of the trolley.


Deadman controls

The trolleys are fitted with deadman controls. This means that the trolley will only operate while the

control is pressed. The release of the control will halt the movement of the trolley.

Separation between legs

A gap of 30 mm between the scissor legs greatly reduces the risk of a crush injury.

Education

Train operators to ensure that no-one is likely to be caught in the moving parts before operating the

trolley. Clear the area around the trolley before operation.

10.2 Hazard Two - Electrocution

The trolleys are 24V, DC powered. If the electrical system is damaged, there is the potential for

electrical leakage.


The risk of damage to the electrical system is generally low, although this would need to be assessed

in situ. An electric shock could lead to minor injuries only.


Should work be required on the electrical system of the trolley, ensure that a qualified electrician is

used.

10.3 Hazard Three - Crushing

It is possible to push the wheels of the trolley over a another person's foot.


The risk of this type of crush injury is very low. It would be difficult to wheel the trolley over a person

without awareness. The extent of the injuries sustained would be minor to medium, depending on

how the trolley was loaded.


Educate users to ensure that the area is clear before moving the trolley.

10.4 Hazard Four - Crushing through falling loads

Unsecured or unstable loads may fall off the elevated platform onto the operator or other people.


If the load is placed centrally on the trolley and is compactly stacked, the risk is low. Injuries that

may occur could be serious.


Ensure that loads are stable and stacked securely on the trolley. Separate the trolley work area and

pedestrian areas. Ensure the area around the trolley is clear of persons before operation. Do not

exceed the load capacity of the trolleys.

Make sure that the trolley platform is in the lowered position before moving.


10.5 Hazard Five - Collision

The trolley could roll away if left unattended on a slope. There is the potential that the trolley could

then hit a person and cause injury.


The likelihood of collision depends on the environment, but if steep grades are encountered, the risk

of collision is high. Injuries, if sustained, would most likely be relatively minor unless a large or

dangerous object was loaded on the trolley.


One of the Castors fitted to the Powerlift DC trolley incorporates brake. Instructions for their correct

use are included in the User's Manual. Ensure that all trolley users are familiar with the operation of

the brakes and their function.

user’s manual · 2019-09-14 · platform then requires two hands for operation. one hand is...

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