INSTALLATION, OPERATION AND SERVICE MANUAL FREIGHTLIFT Model FLH P.O. Box 1058 1058 West Industrial Avenue Guthrie, OK 73044-1058 888-811-9876 405-282-5200 FAX: 405-282-3302 www.autoquip.
TABLE OF CONTENTS Introduction & Company Contact Information 3 Inspection & Identification of Parts 4 Responsibility of Owners/Users 5 Safety Signal Words 6 Safety Practices 7 Safety Features 14 Label Identification 18 Specifications 21 Blocking Instructions 22 Installer Guidelines & Responsibilities 24 Installation Instructions 29 Operating Instructions 68 Routine Maintenance 73 General Maintenance 76 Replacement Parts List 93 Troubleshooting Analysis 94 Glossary of Terms 9
INTRODUCTION CODE REQUIREMENTS VRCs are NOT elevators. This lift is designed for the transfer of material only from one level to another. Absolutely NO RIDERS! VRCs have their own national safety code (ANSI/ASME B20.1) and are specifically exempt from the National Elevator Code. Some states require special components and have specific guidelines regarding how the equipment must be installed, inspected, and tested.
INSPECTION & IDENTIFICATION Your FREIGHTLIFT arrives packaged as follows: The two (2) masts with cylinders/sheaves/cable, and platform come banded together, you also receive parts crates/boxes which normally contain the smaller of the following items: The following items are typically shipped within each FREIGHTLIFT order: A. Two Carriage Upright Assemblies B. Four Carriage Side Guards (Handrails) C. Two Upper & Two Lower Guide Wheel Assemblies D. Two Tension Roller Assemblies E.
RESPONSIBILTY OF OWNERS/USERS CODE COMPLIANCE Ultimate responsibility for gaining state and local code approval is the responsibility of the buyer of the VRC. Please acquaint yourself with the permitting and/or licensing expenses and requirements of the local regulatory agencies in the installation area. . INSPECTION & MAINTENANCE The lift shall be inspected & maintained in proper working order in accordance with this manual and with other applicable safe operating practices.
SAFETY SIGNAL WORDS SAFETY ALERTS (Required Reading!) The following SAFETY ALERTS are intended to create awareness of owners, operators, and maintenance personnel of the potential safety hazards and the steps that must be taken to avoid accidents. These same alerts are inserted throughout this manual to identify specific hazards that may endanger uninformed personnel. Identification of every conceivable hazardous situation is impossible.
SAFETY PRACTICES DANGER! High voltage! May cause personal injury or death. Repairs should only be performed by a qualified service/control technician. DANGER! Never go under a platform! To avoid personal injury or death, always be sure the load has been removed from the platform and that it has been adequately blocked from underneath. See “Blocking Instructions” section. DANGER! Qualified personnel only!! Only qualified personnel should perform procedures labeled as “dangerous”.
SAFETY PRACTICES DANGER! Practice field safety procedures! To avoid personal injury or death, utilize all applicable precautions for steel erection and equipment assembly in addition to OSHA Lock-Out, Tag-Out procedures. DANGER! Support all beams and components! Illustrations in this manual may show them unsupported. This is done in order to make the equipment and its installation clearly understood. Be sure to properly secure all lift beams and components on the actual unit.
SAFETY PRACTICES WARNING! Slack cables require factory help! Do not attempt to repair slack cable conditions alone! Always contact the local representative or call the Autoquip Service Department at 888-811-9876. WARNING! Never run the unit with the gates or doors open! Do not operate unit with doors open or with the interlocks “defeated” (bypassed)! Serious injury or death could result.
SAFETY PRACTICES WARNING! Never operate unit when parts are broken or damaged! Do not operate this equipment when non-factory approved or damaged parts are in use! Contact the local FREIGHTLIFT Service Representative to rectify all such situations.
SAFETY PRACTICES WARNING! The velocity fuse (VF) must be properly installed! The VF is attached to the elbow fitting in the rod port of the cylinder. If the VF is installed improperly, it will not lock the carriage in place in the event of a catastrophic hydraulic line break! WARNING! Do not over travel! Mechanical stops must be in place to prevent the carriage from over traveling. Over-traveling can cause permanent damage to the carriage or failure of the lifting cables.
SAFETY PRACTICES CAUTION! The hydraulic cylinder-retaining strap must be in place! A secure strap will prevent the cylinder from falling after the cable is removed! NOTICE Purge air in the system! The presence of air in the system can lead to a lock-up of the velocity fuses. (Air reacts like a spring when it is compressed.) NOTICE Automatic cylinder retraction possible! Be aware that the cylinder rod may retract into the cylinder body automatically when the hydraulic hose is disconnected.
SAFETY PRACTICES NOTICE Protect cylinder rods, hydraulic ports and lines at all times! Welding splatter and dust from grinding operations can cause severe damage to this equipment. NOTICE Do not damage the pump or motor! If the motor needs to run during the installation process and the electrical work is not complete, only do so for a second or two after the mechanical stop is pressed. Longer activation could cause damage to the pump or the motor.
SAFETY FEATURES There are several primary active safety features and devices to help protect personnel, property, and the equipment. MECHANICAL LOCKING SAFETY CAMS Each wire rope is terminated at the platform carriage in a clevis, which is attached to a tension spring loaded steel safety cam. This safety cam pivots on a high strength steel pin which is chrome plated. The safety cam has serrated teeth cut into one of its faces that are adjacent to the guideway flange.
SAFETY FEATURES HYDRAULIC VELOCITY FUSES Each hydraulic cylinder has a hydraulic velocity fuse (HVF) installed in the cylinder ports. These HVFs are installed in the predetermined hydraulic oil flow velocity as the oil returns to the reservoir. Should a catastrophic rupture or breach occur in the hydraulic system and oil flows through the breach that exceeds the HVF rating, the HVF will trigger and lock up. This lock up will occur within one to two inches of downward movement of the platform carriage.
SAFETY FEATURES CONTROL TRANSFORMER SECONDARY FUSE This fuse is attached to the electrical control transformer and protects the 115 volt control circuit from damage should a fault occur which would result in excessive electric current flow. Should the fuse activate (blow), it will prevent the operation in either direction and the interlock circuit will not operate. These fuses are located in the control enclosure. DANGER! High voltage! May cause personal injury or death.
SAFETY FEATURES SAFETY INTERLOCKS/LATCHES - GATES OR DOORS (where applicable) These are electro/mechanical devices that prevent operation of the FREIGHTLIFT when the gates or doors are left open on any level. They also prevent the gates or doors from being opened at any level unless the platform carriage is in place at that floor level.
LABEL IDENTIFICATION 1 4 2 ITEMS #4 IS LOCATED ON BOTH FRONT AND BACK SIDE OF OVERHEAD CHANNEL 3 ITEMS #1 & #2 ARE 1 LOCATED ON BOTH 2 FRONT AND BACK SIDE OF UPRIGHTS 6 5 6 Field-locate & apply one “WARNING – Do Not Tamper” label adjacent to (within 6”-12”) each sensing device (limit switches, door status switches, door interlocks, etc.) in a location that is visible to the operator. 4 Figure 1 Label Placement Diagram for FLH Item # Qty.
LABEL IDENTIFICATION Note: Labels shown here are not actual size.
LABEL IDENTIFICATION Figure 5 Label 36401586 Figure 7 Label 36403720 Figure 8 Label 36405705 20
GENERAL SPECIFICATIONS FLH Standard Models Model Max Travel Capacity (pounds) Platform (Min) WxL Platform (Max) WxL HP (Min) Speed (FPM) FLH-1 30’ 1000 4’ x 4’ 8’ x 12’ 5 25 FLH-2 30’ 2000 4’ x 4’ 8’ x 12’ 5 25 FLH-3 30’ 3000 4’ x 4’ 7’ x 7’ 5 25 FLH-4 30’ 4000 4’ x 4’ 8’ x 12’ 5 25 FLH-5 30’ 5000 4’ x 4’ 8’ x 12’ 5 25 FLH-6 30’ 6000 4’ x 4’ 6’ x 6’ 5 25 FLH-6HD 30’ 6000 6’ x 6’ 8’ x 10’ 5 22 DO NOT EXCEED RATED CAPACITY OF THE LIFT.
BLOCKING INSTRUCTIONS WARNING ! Only authorized personnel should perform inspection or maintenance and service procedures. Unauthorized personnel attempting these procedures do so at the risk of personal injury or death. DANGER ! Failure to properly adhere to lift these Blocking Instructions is to risk the sudden and uncontrolled descent of the lift carriage during maintenance or inspection. A falling carriage can cause severe injury or death. I. ROUTINE MAINTENANCE (Carriage is completely lowered) 1.
BLOCKING INSTRUCTIONS DANGER ! If for any reason you are unable to lower the lift completely onto the drums, stop immediately and consult the factory at 888-811-9876. Failure to use a system of adequately stable and strong lift blocking devices could result in severe injury or death. II.
INSTALLER GUIDELINES/RESPONSIBILITIES Proper installation of Vertical Reciprocating Conveyors (VRCs) is vital to the safety of the operators, the efficiency of the unit, and the ultimate satisfaction of the end user. These guidelines have been prepared by member companies of the Material Handling Industry’s VRC Subcommittee to assist the VRC installers in understanding their role and responsibility in providing customers with a safe and reliable VRC. 1. PRE-INSTALLATION ACTIVITY A.
INSTALLER GUIDELINES/RESPONSIBILITIES B. Assuming no damage has occurred to the crate, check the components against the packing list. This will provide assurance that every item shipped has been received. C. Make sure you have a copy of the latest version of the general arrangement and electrical drawings before beginning installation, changes could have been made since original purchase order submittal and order entry. D.
INSTALLER GUIDELINES/RESPONSIBILITIES 5. MECHANICAL INSTALLATION A. Most work can be done with the lift carriage fully lowered. Never work under the lift carriage unless it is blocked in place per the Installation and Service manual. B. Never allow a person to ride on the carriage of the lift. C. Use only the hardware supplied by the Manufacturer to assemble the lift. hardware is often high grade, some hardware is metric. This D.
INSTALLER GUIDELINES/RESPONSIBILITIES C. All electrical work must meet the requirements of ASME B20.1 as well as all state and local codes. D. Make sure that only qualified electricians perform all wiring and that they are familiar with the electrical drawings shipped with the equipment. E. Do not operate the lift until the carriage is leveled and the guide beams are plumbed and secure. F. Never operate the lift by “manualling” the electrical controls (using the contactors located inside the control panel).
INSTALLER GUIDELINES/RESPONSIBILITIES C. Ensure proper operation and engagement of carriage brake assemblies. 9. TESTING A. Test up and down speeds. B. Test all limiting devices, gate interlocks, gate status switches, sensors, and any other safety features or devices as outlines by the Installation and Service manual. C. Some states or municipalities may require testing of the carriage free-fall arrest system (carriage brakes) – consult the local regulatory agency or the manufacturer. 10.
INSTALLATION INSTRUCTIONS THE TOOLS REQUIRED FOR INSTALLATION Listed below are some of the tools needed to install the FREIGHTLIFT in a professional and prompt manner. Individual site situations and a basic variation in the types of units may dictate the need for additional items. Welding Machine and Equipment Cutting Torch with Full Tanks Fire Extinguisher Forklift Chain Fall Come-A-Long Cables or Hook Chains with 1,000# Cap.
INSTALLATION INSTRUCTIONS MAST CROSS CHANNEL MAST ASSEMBLY CYLINDER OVERHEAD CHANNEL CARRIAGE UPRIGHT WELDMENT HAND RAIL CARRIAGE WELDMENT Figure 9 – Identification of Parts, FLH 30
INSTALLATION INSTRUCTIONS NOTE: All illustrations contained in this manual are for reference purposes only. Specific applications and site conditions may require different anchoring and bracing procedures. The ultimate responsibility for the anchoring and bracing rests with the installation crew. A. LAYING OUT CARRIAGE POSITION & MARKING FLOORS FOR ALLIGNMENT 1.
INSTALLATION INSTRUCTIONS Mark Center Line Here Determine the location or position of lift at upper level. SECOND FLOOR Locate the center of tie opening or position and clearly MARK IT.
INSTALLATION INSTRUCTIONS Opening or Lift Position A Plumb Line Center Line of Carriage Mark This Point B Figure 13 Locating Center of Carriage Edge on the First Floor (Front View) SECOND FLOOR Plumb Lines Mark This Point Mark This Point Figure 14 Locating Outside Edges of Carriage at the First Floor (Front View) 33
INSTALLATION INSTRUCTIONS C B D Figure 15 Chalking the Edge of the Carriage at the First Floor (Front View) C L Figure 16 Aligning the Carriage with the Chalk Lines 34
INSTALLATION INSTRUCTIONS OVERHEAD CHANNEL RUBBER STOP BAR CARRIAGE UPRIGHT WELDMENT HAND RAIL CARRIAGE WELDMENT Figure 17 Carriage Assembly 35
INSTALLATION INSTRUCTIONS B.
INSTALLATION INSTRUCTIONS 8. For Pit Mounted Lifts - the pit has been poured 1/2" – 3/4" deeper than the total thickness of the carriage platform for shim and grout as required. 9. For Through-Floor or Shaft Installations – when clearances are tight, you may choose to position the carriage after the beams have been assembled and raised into place. For these installations, refer to Figure 18 to see how to properly lay out and locate the beams prior to setting the carriage.
INSTALLATION INSTRUCTIONS C. POSITIONING WHEEL GUIDE ASSEMBLIES (Reference Figures 19 and 20) Items Needed: Qty Description 2 Mast Beams – Left & Right 2 Upper Wheel Guides – left & right (“L” & “R” on the assembly) 2 Cable Adaptors 4 Cotter Pins 2 Cable Adaptor Pins (with cotter pin holes) 1. Place the upper wheel guide assemblies in the beam as shown in Figure 19a by sliding them into the beam running space from below the guide angle near the bottom of the mast beam.
INSTALLATION INSTRUCTIONS GUIDE ANGLE WHEEL GUIDE ASSEMBLY LOCKING CAM MAST BEAM Figure 19a Upper Wheel Guide Assembly in Mast Beam (Top View) LIFTING CABLE OR CHAIN ADAPTOR ADAPTOR PINS / COTTER PINS LOCKING CAM MAST BEAM Figure 19b Upper Wheel Guide Assembly in Mast Beam (Side View) 39
INSTALLATION INSTRUCTIONS D. RAISING THE BEAMS & WHEEL GUIDES (Reference Figures 21 through 23) Items Needed: Qty Description 2 Lower Wheel Blocks (left & right) 2 Wheel Tensioner Assemblies with Metric mounting bolts 1 Installation Angle (with bolts in each end) – if needed varies 1/2" x 1-1/2”L grade 8 Hex Head Cap Screws, Washers & Nuts 1. Raise the beams into position (see Figure 21).
INSTALLATION INSTRUCTIONS SPLICED BEAMS (when used) 1. Set the upper mast on its respective lower mast (plates & beams are marked) in the orientation shown on Figure 23, taking necessary precautions not to bend or damage transition plates. 2. Verify that both beams are true, straight, and plumb within 1/8” over any 10 foot span and not to exceed 3/8” over the entire length of the beam. NOTE: This tolerance may not be exceeded or immediate & permanent damage to the hardened wheel guide wheels will occur.
INSTALLATION INSTRUCTIONS Figure 21 Raising the Mast Beams 42
INSTALLATION INSTRUCTIONS BOLTS FOR UPPER & LOWER WHEEL GUIDE ASSEMBLIES – TORQUE TO 99 FT-LBS. A DETAIL - A TENSIONER MTG BOLT (METRIC THREAD) TORQUE TO 63 FT - LBS. B BOLTS FOR UPPER & LOWER WHEEL GUIDE ASSEMBLIES – TORQUE TO 99 FT-LBS.
INSTALLATION INSTRUCTIONS TOP MAST WELDMENT TOP MAST WELDMENT TYP TYP BOTTOM MAST WELDMENT 1/4 1/4 1/4 BOTTOM MAST WELDMENT Figure 23 Mast Splice Detail 44
INSTALLATION INSTRUCTIONS E. SECURING THE MASTS Items needed: Qty Description 1 6” Mast Cross Channel, pre-drilled 6 1/2" x 1-1/2”L Grade 8 Hex Head Cap Screw, Washer, and Nuts 1. Raise the mast cross channel into position above the mast beams in the orientation shown in Figure 24 and bolt into place using the hardware provided. Torque to 99 ftlbs. NOTE: Alignment of the main beams is very important! Check the guide angle dimension (from bottom to top) against the GA drawing. 2.
INSTALLATION INSTRUCTIONS MAST CROSS CHANNEL Figure 24 Mast Cross Channel 46
INSTALLATION INSTRUCTIONS F. BRACING THE BEAMS (Reference Figure 25) All illustrations on the GA drawing for bracing preferences are for reference only. Site conditions may require different anchoring and bracing. The installers are ultimately responsible for the proper and safe anchoring and bracing of the equipment. Autoquip Corporation supplies material for bracing on standard applications, but special bracing may be required by the installer on non-standard models.
INSTALLATION INSTRUCTIONS WARNING! Do not weld on the guide flanges of the masts. The field welding of any structural steel member into or across the guide beams in the path of the wheel guides is strictly forbidden.
INSTALLATION INSTRUCTIONS ANCHORING TO BLOCK WALLS USE BACKUP PLATES WRONG WELD TO CURB ANGLE ANCHORING TO FACE OF FLOOR RIGHT WRONG WOODEN FLOORS PREFERRED THROUGH BOLTING POOR Figure 25 Approved Methods for Upper Level Mast Bracing 49
INSTALLATION INSTRUCTIONS THROUGH A CUTOUT OR OVERSIZED HOLE Figure 25 (cont’d) Approved Methods for Lower Level & Diagonal Bracing 50
INSTALLATION INSTRUCTIONS LOWER BRACING FOR TALL UNITS SEE DETAIL A 3/4" 6" X 6" WIDE FLANGE BEAM (MAST BEAM) 3" X 2" X 3/8" ANGLE (GUIDE ANGLE) 4" CHANNEL DIAGONAL MAST BRACE BRACE PLATE DETAIL A FRONT VIEW Figure 25 (cont’d) Approved Methods for Lower Level & Diagonal Bracing 51
INSTALLATION INSTRUCTIONS TO A MEZZANINE Figure 25 (cont’d) Approved Methods for Lower Level & Diagonal Bracing 52
INSTALLATION INSTRUCTIONS G. HYDRAULIC INSTALLATION DETAILS Items needed: Qty Description 1 50’ length of 3/8” low pressure rubber tubing 3 20’ lengths of 3/8” high pressure wire braided hose & misc. fittings 1. Locate the power unit behind the lift or beside either mast beam (the lift is supplied with an extra 20-foot connecting hose for the cylinder furthest away from the power unit – if required).
INSTALLATION INSTRUCTIONS 5. Fill the power unit with oil. Do not over-fill! The oil level should be approximately 2” from the top of the tank (See “Oil Specifications” in the General Maintenance section). 6. Connect electrical power to the power unit. 7. Remove any air from the hydraulic system per the “Bleeding Air from the System” instructions found in the General Maintenance section.
INSTALLATION INSTRUCTIONS CYLINDER HOSING WARNING! The velocity fuse must be installed as illustrated. Never use a swivel fitting between velocity fuse and cylinder. The velocity fuse should always be attached to a cylinder with a solid fitting. Street Elbow 3/8 mp x 3/8 fp Hex Nipple, Straight 3/8 mp x 3/8 mp Velocity Fuse Staight Swivel 3/8 mp x 3/8 fps Braided High Pressure Hose 3/8-2W x 240", swivel (1) end.
INSTALLATION INSTRUCTIONS 3/8" SWIVEL 3/8" X 240" HIGH PRESSURE HOSE 3/8" PUSH-ON LOW PRESSURE RUBBER HOSE DETAIL - "A" DETAIL - "B" 3/8" X 240" HIGH PRESSURE HOSE B A 3/8" PUSH-ON LOW PRESSURE RUBBER HOSE (CUT TO LENGTH) Figure 27a Connection of Cylinders, Models FLH-1, 2, 3 56 3/8" FLARE FITTING
INSTALLATION INSTRUCTIONS 3/8" PUSH-ON LOW PRESSURE RUBBER HOSE 3/8" SWIVEL 3/8" X 240" HIGH PRESSURE HOSE 3/8" PUSH-ON LOW PRESSURE RUBBER HOSE DETAIL - "A" 3/8" FLARE FITTING 3/8" X 240" HIGH PRESSURE HOSE 3/8" PUSH-ON LOW PRESSURE RUBBER HOSE Figure 27b Connection of Cylinders, Models FLH-4, 5, 6 57 A
INSTALLATION INSTRUCTIONS ADJUSTABLE MECHANICAL STOP LOCATED ON EACH MAST BEAM Figure 28 Adjustable Mechanical Stops 58
INSTALLATION INSTRUCTIONS H. INSTALLING LEVEL/LIFT STATUS LIMIT SWITCHES Items needed: Qty Description Varies 1 N.O. – 1 N.C. Limit Switch Kits (depends on interlock style & Qty) Level limit switch Kits (quantity depends on application – typically one (1) 1N.O.-1N.C.
INSTALLATION INSTRUCTIONS CAM CARRIAGE BRACE CARRIAGE BRACE CAM UNISTRUT MAST SIDE VIEW CAM CARRIAGE BRACE Field-locate & apply one “WARNING – Do Not Tamper” label adjacent to (within 6”-12”) each sensing device (limit switches, door status switches, door interlocks, etc.) in a location that is visible to the operator.
INSTALLATION INSTRUCTIONS UniStrut Nut & Spring UniStrut Channel Switch Arm Switch Actuator Rotate Switch Head 90 Deg per Fig.
INSTALLATION INSTRUCTIONS Loosen 8-32 socket head cap screw to adjust arm in and out, then re-tighten Loosen 8-32 socket head cap screw to adjust arm rotation, then re-tighten Loosen (4) flat head machine screws to rotate head, then re-tighten Switch actuator Figure 31 Sensing Switch Adjustments (Solenoid Interlocks only) 62
INSTALLATION INSTRUCTIONS I. TEST RUN (EMPTY) & MAKE ADJUSTMENTS DANGER! Never go under a platform! To avoid personal injury or death, be sure the platform has been blocked from underneath! See “Blocking Instructions.” WARNING! Never operate the lift by “manual-ing” the electrical controls (using the contactors located inside the control panel). All safety devices are bypassed in this mode of operation and lift damage or severe personal injury could occur.
INSTALLATION INSTRUCTIONS NOTICE The pressure switch is not functional with temporary power! The power unit will continue to run as long as the contact button is pressed. Permanent damage to the lift may result if power to the electric motor is not shut off once the carriage makes contact with the stop bolts. NOTICE Take extreme caution when running the unit before mechanical stops are installed and adjusted properly! Lift over-travel can cause severe damage. 4.
INSTALLATION INSTRUCTIONS 2. All gates or doors accessing the lift must have electrical contacts and mechanical locks to prevent the lift from operating if a gate is left open. The gate should lock until the carriage is at the nearest landing. There are many variables that can affect your installation: the type of gate; the type of door; conditions unique to a specific site.
INSTALLATION INSTRUCTIONS Figure 32 Barrier Bar Installation Details (when required) 66
INSTALLATION INSTRUCTIONS Figure 33 Backstop Panel Kit (when required) 67
OPERATING INSTRUCTIONS DANGER! To avoid personal injury or death, do not operate this equipment with substandard, defective, or missing parts or equipment supports. Contact a local FREIGHTLIFT service representative if a deficiency is found. WARNING! No riders! The FREIGHTLIFT is provided for the sole purpose of transporting goods between floor elevations. At no time should it be used to transport personnel.
OPERATING INSTRUCTIONS 2. The rotating motor shaft is mechanically coupled to a positive displacement gear pump. The pump will rotate, drawing oil from the reservoir, pressurizing it, causing flow through the check valve, and out to the cylinders through high pressure hoses. The incoming volume of oil flows to the rod side of the cylinder pistons, causing the rods to retract into the cylinders. 3. Attached to the cylinder rods are double sheave clevis blocks.
OPERATING INSTRUCTIONS 3. The carriage will come to a stop when it reaches the lower stops or the floor level. At this point, there is no pressure remaining in the hydraulic system and there is no flow through the down valve, even though the valve remains open. One of two things can happen at this point in the operation of the lift. a. The programmed timer can “time-out” and allow the down valve to close, OR b.
OPERATING INSTRUCTIONS PREVENTING DAMAGE TO THE LIFT 1. Exceeding the Capacity of the Lift The load capacity rating is stamped on a metal serial number plate attached to the lift. This figure is a net capacity rating for a lift furnished with the standard platform. The hydraulic relief valve (HRV) has been set to raise the weight, plus a small amount for overload.
OPERATING INSTRUCTIONS A. DO NOT walk out onto the carriage or attempt to physically free the jam until the carriage has been safely supported from beneath per instructions given in the “Lift Blocking” section of this manual. B. Call Autoquip (888-811-9876) to provide assistance in discovering the source & acceptable remedy for the carriage jam. C.
ROUTINE MAINTENANCE DANGER! To avoid personal injury or death, all maintenance procedures described in this section should only be performed by qualified service personnel. DANGER! To avoid personal injury or death, do not operate this equipment with substandard, defective, or missing parts. Contact a local FREIGHTLIFT service representative if a deficiency is found.
ROUTINE MAINTENANCE DANGER! To avoid personal injury or death, before performing any static inspections, make sure the platform carriage is fully lowered and the power has been disconnected at the safety disconnect switch. Also, put signs at all gates, doors, controls, etc. indicating that the system is out of service for maintenance per OSHA Lock-Out, Tag-Out procedures. Inspection List – Every 3 Months (1,000-1,200 hours of operation): 1. Inspect cables for damage, unusual wear, or fraying 2.
ROUTINE MAINTENANCE b. Locking Cam Spring – any broken, rusted, bent, or damaged springs or spring mounting bolts c. Locking Cam Back-up Bar – a bent bar, or any damaged or missing mounting bolts, or bolts which are not Grade 8 d.
GENERAL MAINTENANCE DANGER! To avoid personal injury or death, the procedures described in this section should only be performed by qualified service personnel. WARNING! Never operate the lift by “manualling” the electrical controls (using the contactors located inside the control panel). All safety devices are bypassed in this mode of operation and lift damage or severe personal injury could occur.
GENERAL MAINTENANCE The oil level in the reservoir should be 1” to 1 ½” below the top of the reservoir with the lift in the fully lowered position. NOTICE Use approved fluids only! Use of unauthorized fluids may cause damage to seals and hosing.
GENERAL MAINTENANCE NOTES: 1. Industrial hydraulic oils formulated for high pressure uses and of the proper viscosity contain anti-wear, anti-foaming, anti-rust additives making them acceptable. However, it is best to contact Autoquip Customer Service for advance approval! 2. Use of improper oil will VOID the FREIGHTLIFT warranty! 3. The unit must be fully lowered to perform the filling operation.
GENERAL MAINTENANCE DANGER! To avoid personal injury or death, all maintenance procedures described in this section should only be performed by qualified service personnel. Flushing Procedure 1. Lower the carriage completely to the floor. 2. Lock out and tag the electrical disconnect. 3. Remove the hydraulic hoses and either pump or Deltatrol valve. 4. Drain the hydraulic tank. 5. Remove the suction filter. 6. Flush the hoses with the cleaning solvent. 7.
GENERAL MAINTENANCE BLEEDING AIR FROM THE SYSTEM NOTICE Avoid air in the system! The presence of air in the system can lead to a lock-up of the velocity fuses. (Air reacts like a spring when it is compressed.) 1. Fully extend the cylinder rods to expend air from the cylinder barrel after the FREIGHTLIFT has been lowered. 2. Carefully loosen the bleeder bolt (located in the 90° elbow) to allow all air to escape. 3. Press the “UP” button and let the motor run briefly, then press the Emergency Stop Button.
RESERVOIR Figure 34 Hydraulic Schematic, Models FLH(C)-1, 2 & 3 THE FREIGHTLIFT IS DESIGNED AND FABRICATED TO THE ORDER. IT IS NOT A STANDARD PRODUCTION PRODUCT THAT CAN BE REPLACED IN STOCK FOR FUTURE SALE. THE COST OF WORK IS FAR MORE EXPENSIVE THAN INITIAL PRODUCTION. CANCELLATION CHARGES WILL REFLECT THAT COST. THE CHARGES WILL BE CALCULATED ON TOTAL LIST PRICE OF ORDER. ALL FREIGHTLIFT INSTALLATIONS REQUIRE ENCLOSURES IN ACCORDANCE WITH ANSI B20.
RELIEF VALVE RESERVOIR Figure 35 Hydraulic Schematic, Models FLH(C)-4, 5, & 6 82 THE FREIGHTLIFT IS DESIGNED AND FABRICATED TO THE ORDER. IT IS NOT A STANDARD PRODUCTION PRODUCT THAT CAN BE REPLACED IN STOCK FOR FUTURE SALE. THE COST OF WORK IS FAR MORE EXPENSIVE THAN INITIAL PRODUCTION. CANCELLATION CHARGES WILL REFLECT THAT COST. THE CHARGES WILL BE CALCULATED ON TOTAL LIST PRICE OF ORDER. ALL FREIGHTLIFT INSTALLATIONS REQUIRE ENCLOSURES IN ACCORDANCE WITH ANSI B20.
GENERAL MAINTENANCE PIPE THREAD SEALANT Loctite PST #567 pipe thread sealant or equivalent is recommended. Do not use Teflon tape. Tape fragments can cause malfunctioning of the hydraulic system. VELOCITY FUSE REPLACEMENT DANGER! Do not attempt to remove the velocity fuse until the lift is securely supported with the lift blocking devices and all hydraulic pressure has been removed from the lifting cylinders and hydraulic hoses.
GENERAL MAINTENANCE CYLINDER REMOVAL AND REPACKING 1. Press the “DOWN” button and lower the carriage to the fully down position. Continue to hold the button for five to ten seconds to relieve all hydraulic pressure and cable tension. 2. Cut off the electricity to the power unit (lock out-tag out). 3. Disconnect the hydraulic hose from the power unit and place the loose end of the hose in the fill hole of the power unit for draining oil. 4.
GENERAL MAINTENANCE 14. Check the piston head nut for tightness and torque to 600-650 ft. lbs on 3 ½” bore cylinders or 850-950 ft. lbs. on 4” bore cylinders. The thread or cotter pin hole may be used to prevent the rotation of the rod while tightening. 15. Liberally lubricate the piston and seal with CLEAN grease or oil. 16. Reinsert the piston into the barrel, taking care not to pinch or nick the new seal. 17. Slip the bearing assembly into place and align the retainer hole with the slot in the barrel.
GENERAL MAINTENANCE POWER UNIT A. “Vertical” Heavy Duty Power Unit – Models FLH-4 thru FLH-6 DANGER! HIGH VOLTAGE!! Disconnect and/or lock out the electrical supply to the power unit prior to any maintenance being performed per OSHA Lock-Out, Tag-Out procedures. 1. The “vertical” unit utilizes a heavy duty 5 HP/208, 230, or 460 Volts/60 hertz/3 phase motor coupled to a high-pressure positive displacement gear pump, and Autoquip Corporation’s patented Deltatrol valve assembly.
GENERAL MAINTENANCE 2. Because Autoquip "Super-Torque" motors actually deliver substantially more horsepower than their nameplate rating, they must always be wired for heavier current-draw than standard motors of the same nameplate rating. However, because of the "Super-Torque" motor’s starting efficiency and superior running characteristics, circuit components do not have to be as large as for standard motors of equal delivered horsepower.
GENERAL MAINTENANCE 64306660 1 OF 1 PRESSURE PORTS (ONLY ONE USED FOR THE FREIGHTLITE) PRESSURE SWITCH RESERVOIR PRESSURE GAUGE MOTOR DOWN SOLENOID DOWN FLOW CONTROL PUMP NO. This drawing is the sole property of Autoquip Corp, and cannot be used for design and construction without permission of Autoquip Corp.
GENERAL MAINTENANCE 64305022 1 OF 1 MOTOR PRESSURE SWITCH DOWN SOLENOID PRESSURE PORTS DELTATROL VALVE PRESSURE GAUGE NO. This drawing is the sole property of Autoquip Corp, and cannot be used for design and construction without permission of Autoquip Corp. DESCRIPTION BY REFERENCE DRAWING: DRAWING TITLE: APPROXIMATE WEIGHT: DRAWN BY: <1k FLH VERT PWR UNIT TC DATE: QTY REQ'D: 8/21/01 PAGE: REV.
GENERAL MAINTENANCE CABLE (WIRE ROPE) ADJUSTMENT PROCEDURE (Figures 38 & 39) DANGER!!! To avoid personal injury or death, this procedure should only be performed by qualified service personnel. 4½" of adjustment is available in 1½" increments for the lifting cables. Adjustment is made by changing the clevis pin between four sets of holes in the dead head clevis and mounting bracket. The mounting bracket is located on the outside of the masts, at the top, near the masthead.
GENERAL MAINTENANCE TO CARRIAGE TO MAST Figure 38 Cable Routing Diagram 91
GENERAL MAINTENANCE ADJUSTMENT POSITIONS Figure 39 Cable Adjustment Bracket 92
REPLACEMENT PARTS LIST Specific part numbers vary from job to job, depending on the model and options chosen for the application. Call the Autoquip Service Department at 888-811-9876 or 405-2825200 with the serial number of the specific FREIGHTLIFT equipment to order the appropriate parts.
TROUBLESHOOTING ANALYSIS DANGER! To avoid personal injury, NEVER go under the lift platform until it is securely blocked (See "Blocking Instructions" section) and the load is removed.
TROUBLESHOOTING ANALYSIS PROBLEM Freightlift will not raise (motor is running or “humming”). WARNING! a safety device may have been activated – if you are not familiar with how safety devices interact with the operation of the lift, you must find someone who does. Or, call Autoquip Customer Service at 888-811-9876. POSSIBLE CAUSE AND SOLUTION WARNING! The lifting cables may be disconnected or broken.
TROUBLESHOOTING ANALYSIS PROBLEM The Freightlift will not lower (electrically). WARNING! a safety device may have been activated – if you are not familiar with how safety devices interact with the operation of the lift, you must find someone who does. Or, call Autoquip Customer Service at 888-811-9876. Motor labors or heats excessively. The Freightlift does not raise completely to the upper level (press “emergency stop” button to stop motor.
TROUBLESHOOTING ANALYSIS PROBLEM Unit operates in a “spongy” or jerky fashion. The Freightlift lowers too slowly with a load. Freightlift raises, then lowers back slowly. POSSIBLE CAUSE AND SOLUTION The load may exceed the stated capacity of the unit. Overloading causes the pressure switch valve to activate and deactivate if the “UP” button is depressed. (Motor may start and stop if this condition exists.) Remove the excess load. The hydraulic system may have air in it. The unit requires bleeding.
GLOSSARY OF TERMS TERM DEFINITION Anchors Bolts used to fix masts to the floor ATF Automatic transmission fluid Autotrol A seven-function valve block that performs the hydraulic functions of Freightlifts. Back frame The vertical portion of the carriage on the cantilever Freightlift Cable Wire rope that is used in lifting the carriage Cable Reeving The path of the wire rope beginning at the connection to the carriage, over the sheaves, and ends at the top of the masts.
GLOSSARY OF TERMS TERM DEFINITION Mechanical stop A mechanical means of stopping travel at a predetermined spot or to prevent overtravel of a lift. Nonoperating end The side(s) of the platform not used for loading/unloading. Handrails with midrails and kick plates are supplied as minimum safety protection. Operating end The side(s) of the platform used for loading/unloading. A safety chain is supplied as minimum safety protection.
APPENDIX INSPECTION CHECKLIST This checklist is intended to assist qualified maintenance and inspection personnel to inspect Freightlift installations for proper installation and maintenance concerns. The lift should be run several times, and carriage sent to each loading level, in unloaded condition for static inspection, and loaded condition during the dynamic inspection. In this way, a wider variety of issues will present themselves as actual operating conditions are duplicated as closely as possible.
APPENDIX 1 2 3 4 1 2 3 4 5 6 7 8 9 C. MECHANICAL Lifting cables are installed properly (pp. 26,63,90-92) a. correctly fed through the reeving path & running in sheaves? b. cable adaptor/pins/swages are factory-supplied & undamaged? c. Are lifting cables frayed or damaged ? d. Are the sheaves undamaged and turning freely ? Guide wheels – turn smoothly & square to beams? (pp.38-40) Carriage top-stop bolts are even & undamaged ? (p.54) All field-bolting – grade 8 bolts, tightened per spec (pp.36,40,75) a.
APPENDIX 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 11 12 13 E. ELECTRICAL Operator P/B stations undamaged & functional? (pp.63,64) (call/send from all levels, all E-stops, key switches, etc.) Operator P/B stations at least 6 ft. from Lift carriage? (pp.27,68) Main disconnect & motor control panels unaltered? (pp.27, NEC) Disconnect & motor control panel visible from Lift?(pp.
LIMITED WARRANTY The user is solely responsible for using this equipment in a safe manner and observing all of the safety guidelines provided in the Owner’s Manual and on the warning labels provided with the lift. If you are unable to locate either the manual or the warning labels, please contact Autoquip or access www.autoquip.com for replacement downloads or information.