Autoquip FREIGHTLIFT FLH User Manual

FREIGHTLIFT Model FLH P.O. Box 1058  1058 West Industrial Avenue  Guthrie, OK 73044-1058  888-811-9876  40

10 WARNING! Never operate unit when parts are broken or damaged! Do not operate this equipment when non-factory approved or damaged parts are i

100 INSPECTION CHECKLIST This checklist is intended to assist qualified maintenance and inspection personnel to inspect Freightlift installations

101 C. MECHANICAL Y N1 Lifting cables are installed properly (pp. 26,63,90-92) a. correctly fed through the reeving path &am

102 E. ELECTRICAL Y N1 Operator P/B stations undamaged & functional? (pp.63,64) (call/send from all levels, all E-stops, key

103 The user is solely responsible for using this equipment in a safe manner and observing all of the safety guidelines provided in the Owne

11 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

12 CAUTION! The hydraulic cylinder-retaining strap must be in place! A secure strap will prevent the cylinder from falling after the cable is

13 NOTICE Protect cylinder rods, hydraulic ports and lines at all times! Welding splatter and dust from grinding operations can cause severe da

14 There are several primary active safety features and devices to help protect personnel, property, and the equipment. MECHANICAL LOCKING SAFETY

15 HYDRAULIC VELOCITY FUSES Each hydraulic cylinder has a hydraulic velocity fuse (HVF) installed in the cylinder ports. These HVFs are instal

16 CONTROL TRANSFORMER SECONDARY FUSE This fuse is attached to the electrical control transformer and protects the 115 volt control circuit from

17 SAFETY INTERLOCKS/LATCHES - GATES OR DOORS (where applicable) These are electro/mechanical devices that prevent operation of the FREIGHTLIFT

18 1122344566ITEMS #1 & #2 ARELOCATED ON BOTHFRONT AND BACKSIDE OF UPRIGHTSITEMS #4 IS LOCATEDON BOT

19 Note: Labels shown here are not actual size. Figure 2 Label 36404093 Figure 3 Label 36402680 Figure 4 Label 36401560 LABEL IDENTI

2 Introduction & Company Contact Information 3 Inspection & Identification of Parts 4 Responsibility of Ow

20 Figure 5 Label 36401586 Figure 7 Label 36403720 Figure 8 Label 36405705 LABEL IDENTIFICATION

21 FLH Standard Models Model Max Travel Capacity (pounds) Platform (Min) W x L Platform (Max) W x L HP (Min) Speed (FPM) FLH-1 30’ 1000 4’

22 WARNING ! Only authorized personnel should perform inspection or maintenance and service procedures. Unauthorized personnel attempting these

23 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-

24 Proper installation of Vertical Reciprocating Conveyors (VRCs) is vital to the safety of the operators, the efficiency of the unit, and the ul

25 B. Assuming no damage has occurred to the crate, check the components against the packing list. This will provide assurance that every item sh

26 5. MECHANICAL INSTALLATION A. Most work can be done with the lift carriage fully lowered. Never work under the lift carriage unless it is

27 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 ele

28 C. Ensure proper operation and engagement of carriage brake assemblies. 9. TESTING A. Test up and down speeds. B. Test all limiting dev

29 THE TOOLS REQUIRED FOR INSTALLATION Listed below are some of the tools needed to install the FREIGHTLIFT in a professional and prompt manner.

3 CODE REQUIREMENTS VRCs are NOT elevators. This lift is designed for the transfer of material only from one level to another. Absolutely NO RI

30 MAST CROSSCHANNELMASTASSEMBLYCYLINDEROVERHEADCHANNELCARRIAGEUPRIGHTWELDMENTCARRIAGEWELDMENTHAND RAIL Figure 9 – Identification of Parts, FLH I

31 NOTE: All illustrations contained in this manual are for reference purposes only. Specific applications and site conditions may require diffe

32 Locate the center of tieopening or position andclearly MARK IT.Determine the locationor position of lift atupper level.SECOND

33 AOpening orLift PositionCenter Lineof CarriageMark ThisPointBPlumb Line Figure 13 Locating Center of Carriage Edge on the First Floor (Fro

34 CBD Figure 15 Chalking the Edge of the Carriage at the First Floor (Front View) CL Figure 16 Aligning the Carriage with the Chalk Li

35 Figure 17 Carriage Assembly INSTALLATION INSTRUCTIONS HAND RAILCARRIAGEUPRIGHTWELDMENTOVERHEAD

36 B. CARRIAGE ASSEMBLY (Reference Figures 16 through 18) Items needed: Qty Description 1 Carriage Weldment (pre-drilled), OR 2 Carriag

37 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 an

38 C. POSITIONING WHEEL GUIDE ASSEMBLIES (Reference Figures 19 and 20) Items Needed: Qty Description 2 Mast Beams – Left & Right 2

39 MAST BEAMLOCKINGCAMGUIDEANGLEWHEEL GUIDEASSEMBLY Figure 19a Upper Wheel Guide Assembly in Mast Beam (Top View) LIFTIN

4 Your FREIGHTLIFT arrives packaged as follows: The two (2) masts with cylinders/sheaves/cable, and platform come banded together, you also receiv

40 D. RAISING THE BEAMS & WHEEL GUIDES (Reference Figures 21 through 23) Items Needed: Qty Description 2 Lower Wheel Blocks (left &

41 SPLICED BEAMS (when used) 1. Set the upper mast on its respective lower mast (plates & beams are marked) in the orientation shown on Figu

42 Figure 21 Raising the Mast Beams INSTALLATION INSTRUCTIONS

43 TENSIONER MTG BOLT (METRIC THREAD)TORQUE TO 63 FT - LBS.DETAIL - BDETAIL - ABA Figure 22 Wheel Block & Spring Tensioner Mountin

44 BOTTOM MASTWELDMENTBOTTOM MASTWELDMENTTOP MASTWELDMENT1/41/4TYP1/4TYPTOP MASTWELDMENT Figure 23 Mast Splice Detail INSTALLATION INSTRUCT

45 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

46 MAST CROSSCHANNEL Figure 24 Mast Cross Channel INSTALLATION INSTRUCTIONS

47 F. BRACING THE BEAMS (Reference Figure 25) All illustrations on the GA drawing for bracing preferences are for reference only. Site conditio

48 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

49 ANCHORING TO BLOCK WALLSUSE BACKUP PLATES WRONGWELD TO CURB ANGLEANCHORING TO FACE OF FLOORRIGHT

5 CODE COMPLIANCE Ultimate responsibility for gaining state and local code approval is the responsibility of the buyer of the VRC. Please acquai

50 THROUGH A CUTOUT OROVERSIZED HOLE Figure 25 (cont’d) Approved Methods for Low

51 SEE DETAIL ADETAIL A3/4"DIAGONALMAST BRACE6" X 6" WIDE FLANGE BEAM(MAST BEAM)4" CH

52 TO A MEZZANINE Figure 25 (cont’d) Approved Methods for Lower Level & Diagonal Bracing INSTALLA

53 G. HYDRAULIC INSTALLATION DETAILS Items needed: Qty Description 1 50’ length of 3/8” low pressure rubber tubing 3 20’ lengths of 3/8”

54 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 Specificati

55 WARNING! The velocity fuse must be installedas illustrated. Never use a swivel fittingbetween velocity fuse and cylinder. The

56 3/8" X 240" HIGHPRESSURE HOSEBDETAIL - "B"3/8" PUSH-ONLOW PRESSURERUBBER HOSE3/8" FLAREFITTINGADETAIL - "A

57 3/8" X 240"HIGH PRESSUREHOSEDETAIL - "A"3/8" PUSH-ONLOW PRESSURERUBBER HOSE3/8" X 240"HIGH PRESSUREHOSE3/8&

58 ADJUSTABLE MECHANICAL STOPLOCATED ON EACH MAST BEAM Figure 28 Adjustable Mechanical Stops INSTALLATION INSTRUCTIONS

59 H. INSTALLING LEVEL/LIFT STATUS LIMIT SWITCHES Items needed: Qty Description Varies 1 N.O. – 1 N.C. Limit Switch Kits (depends on interl

6 SAFETY ALERTS (Required Reading!) The following SAFETY ALERTS are intended to create awareness of owners, operators, and maintenance personnel

60 MASTUNISTRUTCAMCARRIAGE BRACECAMCARRIAGE BRACECAMCARRIAGE BRACESIDE VIEWFRONT VIEW Figure 29 Level Status Switch Location INSTALL

61 Figure 30 Level Limit Switch Kit Assembly (Solenoid Interlocks only) INSTALLATION INSTRUCTIONS Sw

62 Figure 31 Sensing Switch Adjustments (Solenoid Interlocks only) INSTALLATION INSTRUCTIONS Loosen 8-32

63 I. TEST RUN (EMPTY) & MAKE ADJUSTMENTS DANGER! Never go under a platform! To avoid personal injury or death, be sure the platform

64 NOTICE The pressure switch is not functional with temporary power! The power unit will continue to run as long as the contact button is pre

65 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 le

66 Figure 32 Barrier Bar Installation Details (when required) INSTALLATION INSTRUCTIONS

67 Figure 33 Backstop Panel Kit (when required)INSTALLATION INSTRUCTIONS

68 DANGER! To avoid personal injury or death, do not operate this equipment with substandard, defective, or missing parts or equipment supports.

69 2. The rotating motor shaft is mechanically coupled to a positive displacement gear pump. The pump will rotate, drawing oil from the reservo

7 DANGER! High voltage! May cause personal injury or death. Repairs should only be performed by a qualified service/control technician. DA

70 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 th

71 PREVENTING DAMAGE TO THE LIFT 1. Exceeding the Capacity of the Lift The load capacity rating is stamped on a metal serial number plate atta

72 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 inst

73 DANGER! To avoid personal injury or death, all maintenance procedures described in this section should only be performed by qualified service

74 DANGER! To avoid personal injury or death, before performing any static inspections, make sure the platform carriage is fully lowered and th

75 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

76 DANGER! To avoid personal injury or death, the procedures described in this section should only be performed by qualified service personnel.

77 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

78 NOTES: 1. Industrial hydraulic oils formulated for high pressure uses and of the proper viscosity contain anti-wear, anti-foami

79 DANGER! To avoid personal injury or death, all maintenance procedures described in this section should only be performed by qualified serv

8 DANGER! Practice field safety procedures! To avoid personal injury or death, utilize all applicable precautions for steel erection and equ

80 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 fus

81 DOWN SOL.VALVEFUNCTION OF CHECK, RELIEF, ANDPUMP ASSEMBLY PROVIDES THE COMPLETEHYDRAULIC SCHEMATICOF WORK IS FAR MORE EXPENSIVE THAN INITIAL PR

82 APPLICATIONS, APPROVED LOADING TUNNEL ENCLOSURES.ALL FREIGHTLIFT INSTALLATIONS REQUIRE ENCLOSURESINTERLOCKED GATES OR, IN THE CASE OF CONVEYOR

83 PIPE THREAD SEALANT Loctite PST #567 pipe thread sealant or equivalent is recommended. Do not use Teflon tape. Tape fragments can cause

84 CYLINDER REMOVAL AND REPACKING 1. Press the “DOWN” button and lower the carriage to the fully down position. Continue to hold the button f

85 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.

86 POWER UNIT A. “Vertical” Heavy Duty Power Unit – Models FLH-4 thru FLH-6 DANGER! HIGH VOLTAGE!! Disconnect and/or lock out the

87 2. Because Autoquip "Super-Torque" motors actually deliver substantially more horsepower than their nameplate rating, they must alw

88 RESERVOIRMOTORPUMPDOWNSOLENOIDPRESSURESWITCHPRESSUREGAUGEDOWN FLOWCONTROLPRESSURE PORTS(ONLY ONE USEDFOR THE FREIGHTLITE)JOB NAME:DRAWN BY: DA

89 MOTORDOWN SOLENOIDDELTATROL VALVEPRESSUREGAUGEPRESSURESWITCHPRESSUREPORTSJOB NAME:DRAWN BY: DATE:QTY REQ'D:REV.SIZE:DRAWING TITLE:DRAWING

9 WARNING! Slack cables require factory help! Do not attempt to repair slack cable conditions alone! Always contact the local representative o

90 CABLE (WIRE ROPE) ADJUSTMENT PROCEDURE (Figures 38 & 39) DANGER!!! To avoid personal injury or death, this procedure should only b

91 TO CARRIAGETO MAST Figure 38 Cable Routing Diagram GENERAL MAINTENANCE

92 ADJUSTMENTPOSITIONS Figure 39 Cable Adjustment Bracket GENERAL MAINTENANCE

93 Specific part numbers vary from job to job, depending on the model and options chosen for the application. Call the Autoquip Service Departme

94 DANGER! To avoid personal injury, NEVER go under the lift platform until it is securely blocked (See "Blocking Instructions" section

95 PROBLEM POSSIBLE CAUSE AND SOLUTION Freightlift will not raise (motor is running or “humming”). WARNING! a safety device may have

96 PROBLEM POSSIBLE CAUSE AND SOLUTION The Freightlift will not lower (electrically). WARNING! a safety device may have been activated –

97 PROBLEM POSSIBLE CAUSE AND SOLUTION Unit operates in a “spongy” or jerky fashion.  The load may exceed the stated capacity of the unit.

98 TERM DEFINITION Anchors Bolts used to fix masts to the floor ATF Automatic transmission fluid Autotrol A seven-function valve block that p

99 TERM DEFINITION Mechanical stop A mechanical means of stopping travel at a predetermined spot or to prevent overtravel of a lift. Nonoperatin