Autoquip FLMC User Manual

INSTALLATION, OPERATION

AND SERVICE MANUAL

FREIGHTLIFT

Model FLMC

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

 405-

830FLMC Version 3.3

Dec. 2010

282-5200  FAX: [phone]  www.autoquip.com

Introduction & Company Contact Information 3
Inspection & Identification of Parts 4
Responsibility of Owners/Users 5
Safety Signal Words 6
Safety Practices 7
Safety Features 12
Label Identification 15
Specifications 18
Blocking Instructions 19
Installer Guidelines & Responsibilities 22
Installation Instructions 27
Operating Instructions 77
Routine Maintenance 82
General Maintenance 85
Replacement Parts List 87
Troubleshooting Analysis 88
Glossary of Terms 91
Appendix – Inspection Checklist 93
Warranty 96

TABLE OF CONTENTS

Please record the following information and refer to it when calling your dealer or
Autoquip.

Model Number:________________Serial Number: ___________________
Installation Date _____/_____/_____

2

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. The owner is ultimately
responsible for understanding these requirements for the specific job location, and
Autoquip will incorporate any special requirements into the order as requested and
approved by the customer.

Call Autoquip Corporation at [phone] or 1-888-811-9876 with any questions
you may have concerning VRC code requirements.

IMPORTANT

Autoquip Corporation has designed and manufactured the FREIGHTLIFT to safely and
efficiently move materials between multiple floors or levels. It has been built to provide
many years of dependable service.

INSTALLERS - Proper installation of this equipment is vital to both the efficiency of the
unit and the ultimate satisfaction of the end user. It is vital for the installers to read
and understand this manual! These instructions have been prepared and organized
to assist the installers and it is important for these individuals to carefully follow the
steps in the order they are presented!

OPERATORS - Please read and understand this manual prior to operation of this
Freightlift. Failure to do so could lead to property damage and/or serious personal
injury.

Situations may arise which are not covered in this manual. If you have questions,

please call Autoquip Customer Service at [phone] or 1-888-811-9876.

NOTE: Unless otherwise stated, mechanical installation does not include
unloading, permits, seismic calculations, or extensive acceptance testing. The
requirements of each contract should be carefully reviewed for possible conflicts
of interpretation.

PLANNED MAINTENANCE PROGRAM

A local Autoquip representative provides a Planned Maintenance Program (PMP) for
this equipment using qualified and experienced personnel. Call a local representative
or Autoquip Corporation at 1-888-811-9876 or 405-282-5200 for more information.

3

INSPECTION & IDENTIFICATION

Your FREIGHTLIFT arrives packaged as follows: The two (2) masts and platform come
on shipping skid(s), you also receive parts crate(s) which normally contain the following
items:

A. One Steel Tube Drive Base with Gear Motor, Shaft & Bearings
B. 1 or 2 Carriage Side Guards (Handrails)
C. Installation Angle (with bolts on each end)
D. Two equal lengths of Lifting Chain
E. Two Upper Guide Roller Assemblies
F. Two Lower Guide Roller Assemblies
G. Upper Level floor Brace Assemblies, includes brace plates & channels

(see Record Drawing)
H. Two Counterweights & Lifting Chain Kit with Chain Adaptors, Pins, etc
I. (1) Counterweight Sensing Switch Kit; (2) Slack Chain Sensing Switch

Kits (for lifting chains), and Level/Over-travel Limit Switch Kits (quantity

depends on number of levels)
J. Miscellaneous hardware, manuals, signs, extra structural supports etc.

(depends on order – consult Packing List)

NOTE: The “Bill of Lading” will state the number of pieces shipped. TWO ITEMS
MAY BE BANDED TOGETHER AND COUNT AS ONE PIECE.

Upon receipt of the shipment, check for exposed damage or shortages and make note
of it on the trucking company Bill of Lading or the Shipping Papers. Reports of
concealed damage to items contained in crates must be reported within 48 hours. DO
NOT destroy the crating while opening it to inspect the contents. If damage is
suspected or found, report it directly to the carrier. DO NOT contact Autoquip

Corporation!! All shipments are FOB from the Autoquip plant. Any claims for damage
must be filed with the carrier. Any parts shipped from Autoquip that are intended
to replace damaged or lost items will be invoiced to the ordering party.

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.
Everything needed for the installation should be available. If not, report any shortages to
Autoquip Corporation within 10 days. (Autoquip is not responsible for parts lost, stolen
or damaged during transportation, storage, installation, or during any other
circumstances or conditions that may be beyond Autoquip’s control.)

4

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.

REMOVAL FROM SERVICE

Any lift in service which is not in safe operating condition such as, but not limited to,
excessive leakage, missing rollers, pins, or fasteners, any bent or cracked structural
members, cut or frayed electric or hydraulic lines, damaged or malfunctioning controls
or safety devices, etc. shall be removed from service until repaired to original
manufacturer’s standards.

REPAIRS

All repairs shall be made by qualified personnel in conformance with Autoquip’s
instructions.

OPERATORS

Only trained personnel and authorized personnel shall be permitted to operate the lift.

BEFORE OPERATION

Before using the lift, the operator shall have:

 Read and/or had explained, and understood, the manufacturer’s operating

instructions and safety rules.

 Inspected the lift for proper operation and condition. Any suspect item shall be

carefully examined and a determination made by a qualified person as to
whether it constitutes a hazard. All items not in conformance with Autoquip’s
specification shall be corrected before further use of the lift.

DURING OPERATION

The lift shall only be used in accordance with this Manual.

 Do not overload the lift.
 Do not allow any portion of the load to overhang the perimeter of the carriage.
 Ensure that all safety devices are operational and in place.

MODIFICATIONS OR ALTERATIONS

Modifications or alterations to industrial lifting equipment shall be made only with written
permission of Autoquip. Autoquip does not foresee and does not anticipate
unauthorized modifications, and these changes or alterations are grounds for voiding all
warranties.

5

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. Therefore, all personnel have the
responsibility to diligently exercise safe practices whenever exposed to this equipment.

____________________________________________________________

SAFETY SIGNAL WORDS

DANGER!

Identifies a hazardous situation which, if not avoided, will result in death or
severe personal injury.
_____________________________________________________________

WARNING!

Identifies a hazardous situation which, if not avoided, could result in death
or serious personal injury.

CAUTION!

Identifies a hazardous situation which, if not avoided, may result in minor or
moderate personal injury.
_____________________________________________________________

NOTICE

Identifies a situation or practice not related to personal injury.

6

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 service

personnel should perform procedures labeled as “dangerous”.

DANGER!

Be sure of equipment stability! To avoid personal injury or

death, check for stability. If the supports seem unstable, do not operate!
Contact Autoquip immediately at 888-811-9876.

DANGER!

Turn off power! To avoid personal injury or death, be sure

the power is off and is locked out at the primary power disconnect switch
per OSHA Lock-Out, Tag-Out procedures.

7

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.

DANGER!

Secure platform and chains! Do not remove or disconnect the motor or

brake unless the platform and chains have been secured. See “Blocking
Instructions” section.

DANGER!

Secure platform when attempting to free a jammed carriage! Do not

walk out onto carriage or attempt to access or remove a jammed load
unless the carriage has been secured to prevent unexpected movement or
uncontrolled descent. (See “Blocking Instructions” section)

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.

8

SAFETY PRACTICES

WARNING!

Slack chains require factory help! Do not attempt to repair slack chain

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.

WARNING!

Never go under platform carriage! Use a long-handled broom or similar

implement to remove debris that may accumulate.

WARNING!

Secure unit before making static inspections! Make sure the platform is

fully lowered and the power is turned off (disconnected at the safety
disconnect switch) before performing static inspections. Place signs at all
gates, doors, controls, etc. indicating the system is temporarily out of
service for routine maintenance per OSHA Lock-Out, Tag-Out procedures.

WARNING!

Close all gates when not in use! Never leave the FREIGHTLIFT

unattended with gates left open.

9

SAFETY PRACTICES

WARNING!

Never operate unit when parts are damaged or broken! 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.

WARNING!

Use proper chain or chain master links! Never use chain or chain

master links which are not properly rated for the intended use.

WARNING

Do not over travel! Over travel limit switches must be in place and

operating as intended before operating the lift.

!

WARNING!

Do not weld on the guide flanges of the masts! Interfering with the free

travel of the wheel guides could cause permanent damage to the lift and
prevent safety devices from operating as intended.

10

SAFETY PRACTICES

CAUTION!

Chains must be seated before raising lift! Be sure the chains are

seated in the sprockets on top of the mast prior to raising the lift.

CAUTION!

Do not run carriage until limits are set! If the electrical is not complete,

do not run the carriage all the way to the top or all the way back down until
the limits are set.

NOTICE

Do not run the gear reducer when it is dry! Running the system in a dry

condition can result in serious damage to the equipment.

11

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

SAFETY FEATURES

LOCKING CAMS (Reference Figure 19)

Each chain 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 guide beam flange.

Should the chain become slack, the spring tension would cause the serrated teeth of
the safety cam to engage the guide beam. The teeth bite into the guide beam and a
wedging effect takes place between the safety cam and the guide beam. The result is a
positive halt to downward movement.

The only way to release the safety cam is to correct the malfunction that caused the
slack chain and exert upward tension on the chain through the chain drive. Either of the
two cams will support the loaded platform carriage at any point in the vertical travel.

WARNING!

Slack chains require factory help! Do not attempt to repair slack chain
conditions alone! Always contact the local representative or call the
Autoquip Service Department.

SLACK CHAIN SENSORS (Reference Figure 33)

The slack chain sensors are located on the drive base. The sensors are made up of a
mechanical spring tensioner with a nylon roller and an electrical sensing switch. The
lifting chains run over the sprockets on the main shaft, beside the slack chain sensors,
and then to the carriage. The carriage holds the chains in constant tension. The
sensing switch arm is adjusted to hold the sensing switch contacts closed as the
tensioner roller is running against the taut chain. Should a chain become slack or
broken, the spring tensioner would rotate and activate the sensing switch arm to open
its normally-closed electrical contacts. This would break electrical power to the drive
motor and cease movement of the carriage. The lift will not operate until each slack
chain sensor is restored to its correct operating condition. There is one (1) slack chain
sensor per lifting chain.

CARRIAGE OVER-TRAVEL LIMIT SWITCH (Reference Figure 30)

A redundant, over-travel limit switch is provided to be field located and installed on the
mast in order to stop the motor should the carriage not stop at the upper level limit
switch location (due to faulty wiring, out-of-adjustment or damaged limit switch arm,
etc.). Making of this switch would break the electrical circuits, shut off the motor, and
cease movement of the carriage. The carriage will not move until the over-travel limit
switch is restored to its correct operating condition.

12

SAFETY FEATURES

ELECTRICAL CURRENT SENSOR (ECS) (Reference Figure 35)

The ECS with trip relay is used to prevent overloading of the FREIGHTLIFT by sensing
an increase in the motor amps drawn should the carriage be overloaded or jammed.
The increase of motor amps will kick the relay out and shut off the motor circuit. This
condition will continue until the carriage overload or jam condition is removed/resolved.

CONTROL TRANSFORMER SECONDARY FUSE

This fuse is located in the control enclosure. It 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 of the FREIGHTLIFT in either direction.

DANGER!

Turn off pow er! To avoid personal injury or death, be sure the

power is off and is locked out at the primary power disconnect switch per
OSHA Lock-Out, Tag-Out procedures.

SAFETY INTERLOCKS & STATUS SWITCHES – GATES OR DOORS
(where applicable)

There are electro/mechanical devices that prevent operation of the FREIGHTLIFT when
the gates or doors at any floor level are open. They also prevent the gates or doors
from being opened at any level unless the platform carriage is in place at that floor level.

WARNING!

Close all gates when not in use! Never leave the FREIGHTLIFT unattended
with gates left open!
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.

COUNTERWEIGHT SENSING SWITCH (Reference Figure 34)

This switch is located on the top of one (1) counterweight tube as a redundant sensing
device in the event the slack chain sensors are not performing as designed and the lift
motor continues to run in an attempt to lower a jammed carriage. If the counterweights
attempt to be pulled from their tubes, this switch will activate and will cut off electrical
power to the motor.

13

SAFETY FEATURES

PERSONNEL GUARDS

Depending on the application, one or more of the following personnel protection
features is included in the design of this equipment (different states may vary on the
exact design and orientation of these features – IT IS IMPORTANT TO BECOME
FAMILIAR WHICH THE SPECIFIC CODE REQUIREMENTS OF YOUR STATE):

- GATES & ENCLOSURES: Required per ASME B20.1 to protect personnel from
inadvertent physical contact with a moving lift & moving load at all lift landings.

- CARRIAGE RAILINGS & SNAP CHAINS: Required per ASME B20.1 to protect
personnel whenever personnel walk onto the lift carriage when in the raised
position. Railings or side guards protect non-operating sides, snap chains protect
operating sides.

- CARRIAGE BACK-STOP PANELS: Additional safety feature recommended at all
upper levels to provide additional fixed guarding 2” (max.) away from & across all
unused, operating sides of the lift (typical with non-shaftway “Z” & 90 degree load
patterns).

- NOTE: If the personnel guards are not purchased from Autoquip it is the

responsibility of the Owner to make sure that the personnel guards are in
compliance with the requirements set forth in ASME B20.1.

SHAFTWAY DOOR BARRIER BARS (where applicable)

Shaft-way door barrier bars are designed to provide a secondary means of personnel
protection at the upper level landing of a 2-level shaft-way installation. When the
carriage is not present at the upper level, the two barrier bars rest in permanent
brackets attached to both sides of the door frame on the outside (shaft side) of the
upper level door. The barrier bars form rigid barriers at approximately 24” and 48”
above floor level. In the unlikely event that the upper level door is able to be opened
when the carriage is not at the upper landing, the bars provide an additional means of
personnel protection against stepping or backing into the shaft-way where the carriage
could be assumed to be present.

WARNING!

Shaft-way door barrier bars are not intended to be used as a primary
means of personnel protection. It is the responsibility of the operator to
ensure that all gate/door interlocks have been installed and are functioning
properly. Serious injury or death could result if upper level gates/doors
can be opened when the lift is not present at that level.

14

LABEL IDENTIFICATION

2

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

1

3

6

1

5

Figure 1 Label Placement Diagram for FLMC

Item # Qty. Description Part No.

1 2 Warning – No Riders 36404093
2 1 Freightlift by Autoquip Logo 36402680
3 1 Serial Number Nameplate 36401560
4 1 Capacity 36401586
6 varies Warning – Personnel Guarding 36403720
7 varies Warning – No Riders (located on ea. P/B) 36405705
8 1 Warning – Do Not Disassemble Motor/Brake 36405110

15

LABEL IDENTIFICATION

Note: Labels shown here are not actual size.

Figure 2 Label 36404093

Figure 3 Label 36402680

Figure 4 Label 36401560

16

LABEL IDENTIFICATION

Figure 5 Label 36401586

Figure 7 Label 36403720

Figure 8 Label 36405705

Figure 9 Label 36405110

17

GENERAL SPECIFICATIONS

FLMC Standard Models

Model Max

Travel

FLMC-1 100’ 1000 4’ x 3’ 8’ x 8’ 3 30
FLMC-2 100’ 2000 4’ x 3’ 8’ x 8’ 3 30
FLMC-3 100’ 3000 4’ x 3’ 8’ x 8’ 5 30
FLMC-4 100’ 4000 4’ x 3’ 8’ x 8’ 5 30
FLMC-5 100’ 5000 4’ x 3’ 8’ x 8’ 7.5 30

FLMC-6 100’ 6000 4’ x 3’ 8’ x 6’ 7.5 30
** Actual HP varies depending on the total hung weight of the loaded carriage and the
particular speed required for the application.

DO NOT EXCEED RATED CAPACITY OF THE LIFT. Loading the lift beyond its rated
capacity is unsafe, will shorten the operational life of the lift, and will void its warranty.

Capacity

(pounds)

Platform

(Min)

W x L

Platform

(Max)
W x L

HP**

(Min)

Standard

Speed

(fpm)

WARNING!

Do not make modifications to the lift without authorization from the
manufacturer! Unauthorized and unforeseen carriage, lift structure,
drive base or support bracing attachments added in the field could
create an unsafe operating condition which could result in severe
personal injury or death.

LIFT DUTY

Autoquip standard lift designs as described in the specifications are designed to “cycle”
(one complete “up” and one complete “down” lift operation) no more frequently than
every two minutes – or approximately 10,000 times (cycles) per year. This is
considered “normal” duty.

It is the responsibility of the user to notify Autoquip whenever a specific application is
likely to demand “above normal” duty from the lift - in excess of 10,000 cycles per year.
Above normal duty typically requires supplemental design features to enhance the
serviceable life of the lift & to avoid loss of warranty.

18

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

1. Remove any load from the unit.

2. Raise the platform to a convenient height.

A. Press the UP button and then press the EMERGENCY STOP button when

the desired height is reached, OR

B. Use a fork truck or other lifting device to raise the platform carriage, taking

care not to damage the carriage or cylinder.

3. Depending on the size of the platform carriage, insert 2, 3, or 4 empty 55-gallon

steel drums, which are in good condition and of equal height, under the platform
carriage to create a stable and crush-proof support. Be sure to remove any debris
that may interfere with the bottom of the drums with a long-handled broom.

4. Lower the platform carriage onto the drums (or other solid, stable, and structurally

adequate supports).

5. Lock out and tag the electrical disconnect.

(Carriage is completely lowered)

DANGER!

To avoid personal injury or death, turn off the power and
lock out the power at the primary power disconnect switch before service
or maintenance per OSHA Lock-Out, Tag-Out procedures.

19

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. BLOCKING FOR EMERGENCY REPAIR or INSPECTION

Whenever the carriage has stopped at any elevation besides the fully lowered position
and will not move using the operator pushbutton stations, the carriage must be secured
against downward movement prior to beginning any inspection or troubleshooting
activities that require the gates/doors to be open.

In particular, a carriage which has become wedged in the guide beams, or has become
jammed by interfering with surrounding structure (landings, floor opening, door headers,
backstop assemblies, etc.), may have damaged or broken the lifting chains or other
critical components that are supporting the carriage. Therefore, when a carriage
becomes wedged or jammed DO NOT walk out onto the carriage or attempt to
physically free the carriage until the carriage has been adequately supported from
beneath.

In any of these emergency conditions, safe lift blocking can be accomplished using one
of these approved alternate methods while following steps I.1 through I.5 above:

1. Use a series of adequately sized adjustable jack stands around the underside
perimeter of the lift carriage to provide a level, stable support

2. Use a fork truck with adequate travel, capacity, and fork width/length to provide a
level, stable support

NOTE: Whenever a wedged or jammed carriage condition occurs, you should call an
authorized Autoquip dealer or representative to conduct a comprehensive inspection of
the lift for structural and component damage before placing it back into service.

20

BLOCKING INSTRUCTIONS

III. BLOCKING FOR GEAR MOTOR MAINTENANCE

DANGER!

Do not remove or disconnect the motor or brake unless the platform has
been adequately blocked to prevent any downward movement, a falling
platform will cause serious injury or death.

Extreme caution must be taken anytime the gearbox or brake motor is disassembled.
All holding and braking forces on the lifting chains are removed and the chains are
allowed to “free-wheel” under their own weight or any other weight that may be on the
chains, including the weight of the carriage.

Therefore, any time maintenance to the drive assembly is performed, especially when
utilizing the lift carriage as the work platform, the carriage MUST be blocked adequately
per approved blocking methods as described in paragraph II. above.

DANGER!

Only trained and qualified technicians should operate the manual brake
release. With the brake disengaged, the carriage will fall uncontrollably
and cause serious injury or death.

21

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. Whenever possible, make a pre-installation visit or call someone at the site.

Installers must be familiar with everything relative to proper installation of this
equipment. It is the installer’s responsibility to check the site for problems and work
out solutions with the appropriate people – preferably before installation begins.

B. Check floor-to-floor dimensions on the general arrangement drawings to make sure

that they match on-site conditions. VRC’s are designed and built to individual
applications and specific customer requirements. It is difficult and expensive to
modify the lift after it arrives for installation.

C. Installation may or may not include unloading, permits, seismic calculations, or

extensive acceptance testing. The requirements of each contract should be carefully
reviewed for possible conflicts of interpretation.

D. Each state, county, or municipality may have unique codes governing the installation

and acceptance of VRC’s. Acquaint yourself with the permitting and/or licensing
requirements (and expenses) of the local regulatory agencies. Note also that some
agencies may require inspection or testing before and/or after lift start-up.

E. Make sure there is adequate ingress/egress to the installation site. Verify that the

equipment can get through the existing doorways, halls, and shaft openings. Think
through how the lift will be unloaded, carted/moved, raised into position, and
accessed for installation, operation & maintenance.

F. Verify the construction and integrity of building columns, joists, walls, or mezzanines

that will be used to help support the VRC mast guide beams.

2. SHIPMENT & INITIAL INSPECTION

A. Upon receipt of the shipment, check for exposed damage or shortages and make

note of it on receiving paperwork from the trucking company, any claims for damage
must be filed with the carrier. Unless otherwise stated, the VRC Manufacturer is not
responsible for parts lost, stolen or damaged during transportation, storage, or
installation.

22

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. Read and understand this manual thoroughly prior to starting the installation.

3. EQUIPMENT LAYOUT

A. Make sure pit and/or lift are properly squared and vertically aligned with upper

landings to ensure that the carriage will clear the upper landings by the required
distance.

B. Be sure to take into consideration any other obstructions (pipes, ductwork, ceiling

joists/beams, etc.) that may be located around the lift.

C. Inspect the installation for any overhanging floor landing or other obstruction (pipes,

ductwork, ceiling joists/beams, etc.) which could potentially jam a load that is slightly
overhanging the carriage deck as it raises to the next floor level. Any potential jam
point should have some type of slanted or beveled guarding placed beneath the
obstruction to push the overhanging load back onto the carriage.

4. STRUCTURAL INSTALLATION

A. Follow the bracing recommendations shown on the general arrangement drawings

and in the Installation & Service manual. Site conditions may also require
customization to standard anchoring and bracing. The installers are ultimately
responsible for the proper and safe anchoring and bracing of the equipment and
should consult the manufacturer if there is any doubt as to the structural integrity of
the installation.

B. When anchoring guide beams to walls, you must be sure that the walls can support

the reaction loads imparted on them.

C. If spliced masts are provided, be sure to assemble and field install them exactly to the

Manufacturer’s recommendations. Failure to do so will reduce the safety and
performance of the VRC. See Installation Section for acceptable limits.

D. Make sure guide beam pairs are plumb, parallel, and straight after you are finished

with all welding. See Installation Section for acceptable limits.

E. Do not modify any component of the lift without expressed written consent from the

Manufacturer.

23

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 “Blocking Instructions” section of this
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. This

hardware is often high grade, some hardware is metric.

D. Do not remove or disconnect the motor brake on mechanical drives unless

carriage and
Instructions” section of this manual..

E. Check gearbox fluid levels before starting up mechanical drive units. Failure to do

so will reduce the effectiveness and safety of the lift.

F. Use only the lifting chains and attachment hardware supplied by the Manufacturer.

6. ELECTRICAL INSTALLATION

A. Ensure that the supplied voltage matches the motor supplied.
B. Make sure that the customer-supplied electrical disconnect is a fused-type

disconnect and is installed within direct line of sight of the lift it is associated with.

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). All safety devices are by-passed in this mode of
operation and lift damage or severe personal injury could occur.

G. Do not operate the lift using the operator pushbuttons prior to having all safety

devices and/or gate interlocks wired and in the circuit. Never by-pass any safety
device and/or interlock.

H. Electrician should ensure that motor brake wiring is complete when wiring the

motor.

lifting chains are secured and properly supported per the “Blocking

24

.

INSTALLER GUIDELINES/RESPONSIBILITIES

I. Operator pushbutton stations must not be operable from the carriage with the gate(s)

or door(s) closed, typically located at least 6 feet away from the carriage platform.

J. Per OSHA requirements, the motor control panel must be mounted in a location that is

visible from the lift.

K. Always follow OSHA lock-out, tag-out procedures when the lift being maintained,

serviced, or inspected.

7. PERSONNEL & EQUIPMENT SAFETIES

A. ASME B20.1 requires that all VRC installations be completely guarded to prevent

injury from inadvertent contact with the lift or its load. ASME also requires that doors
or gates at all unloading stations be interlocked so that these doors can only be
opened when the lift carriage is stopped at that level & that the carriage is incapable
of being operated or moved so long as these doors or gates remain open. It is the
responsibility of the installer to ensure that the installation meet these requirements,
regardless of who (manufacturer, customer, architect, general contractor, etc.)
provides the doors/gates and means of enclosure. Consult Autoquip whenever there
is a question as to whether or not the gate & enclosure installation meets ASME
B20.1.

B. Where the application requires personnel to walk onto the carriage in the raised

position, the installer must ensure that the carriage is adequately provided with
railings, guards, and snap chains that are a minimum of 42” high.

C. Travel limit switches, slack chain sensors, and over travel sensors (for mechanical

units) must be installed and working properly. See Installation section of this
manual.

D. Ensure proper operation and engagement of motor and carriage brake assemblies.

8. TESTING

A. Test up and down speeds.
B. Test all electrical switches and sensors, gate interlocks, gate status switches, and any

other safety features or devices as described in the Installation section of this
manual. Also consult any manuals which may have been shipped separately for the
gate installation & operation.

C. Some states or municipalities may require testing of the carriage free-fall arrest

system (locking cams) – consult the local regulatory agency or the manufacturer.

25

INSTALLER GUIDELINES/RESPONSIBILITIES

9. CLEAN-UP & HAND-OFF

A. Conduct a final inspection of the lift installation using the Installation Checklist in the

Appendix of this manual. Correct any deficiencies before clean-up & hand-off.

B. Apply proper signage to all locations of the installation per the guidelines in the Label

Identification section and per any instructions shipped separately with the gate
interlock kits. Contact Autoquip at 888-811-9876 if labels appear to be missing or
damaged.

C. Train key personnel on the operation of the system and all safety features and

procedures by referencing the corresponding sections in this manual.

26

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 Hack Saw, Sawzall, or
Cutting Torch with Full Tanks Portable Band Saw
Fire Extinguisher Drill and Drill Bits
Forklift Extension Cords
Chain Fall Sledge Hammer
Come-A-Long Open or box end wrench
Cables or Hook Chains with 1,000# Cap. Drift Punch
Disk Grinder Carpenter’s Square
“C” Clamps (12” opening) Chalk Line
Socket Set (1/2” drive, sockets to 1 1/8”) Plumb Bobs
Pinch Bar 4’ Level
Hammer Drill & Bits for 1/4”, 3/8” and 25’ / 100’ Measuring Tapes
1/2” anchors Broom

The following supplies will also be needed:

*Concrete anchors (8 minimum) sized for the required minimum pullout of the base floor
channels and upper level bracing. Refer to the approval drawing since the size of the
anchors can vary for each installation.

*Concrete anchors for accessories, such as enclosures, approach ramps, etc. (Usually
1/4” diameter anchors and at least 12 anchors, minimum.)

*Shim stock for the floor channel, platform carriage corners, and/or approach ramp (if a
part of this installation)

*Paint (Autoquip Blue: available in 1 and 5 gallon cans, as well as spray cans)
*3” x 3” steel angle iron or 4” channel for additional bracing

ALSO - BEFORE YOU BEGIN :

1. Beams are too heavy to lift manually and require lifting equipment. Check for
availability of overhead attachment of chain fall or of fork truck before you start.

2. Before you will be able to complete the installation the unit must be operated,
therefore power to the motor is required. Arrange for power before starting
installation.

27

INSTALLATION INSTRUCTIONS

GEAR MOTOR

DRIVE SHAFT

4" X 10" TUBE DRIVE

BASE ASSEMBLY

6" X 25# I-BEAM

MAST ASSEMBLY

HANDRAIL

CARRIAGE

WELDMENT

Figure 10 – Identification of Parts, FLMC

28

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. Refer to Figures 11 - 16 to lay out and mark the reference lines so that the lift will

INSTALLATION INSTRUCTIONS

clear the upper landing and any obstructions that may be located around the lift (the
General Arrangement Record Drawings should indicate the necessary clearance
needed for the particular application).

a. Figure 11 - Layout the position of the lift at the second level landing/opening,

marking the center of the carriage first – then both outside edges of the carriage.

b. Figures 12 & 13 - Drop a plumb line from the center marking of the carriage

position at the second floor holding the plumb line one inch out from the edge of
the landing (one inch is a standard distance for clearance - deviations may
occur), or point A, down to the first floor and mark point B as the carriage center
(check the GA drawing for any other special considerations).

NOTE: To ensure carriage clearance between floors, remove any protrusions
from the floor, wall, etc., or move the plumb lines out beyond the protrusions.

c. Figure 14 - Drop plumb lines from the upper level to the lower level using the

two markings identifying the outside edges of the carriage platform. Again, the
plumb line must be held 1” out from the edge of the mezzanine or opening at the
second floor to provide adequate clearance.

d. Figure 15 - Using a chalk line, snap a line between C and D.

NOTE: The carriage will be aligned to this point. Also, always check the pit
and floor openings for correct dimensions and squareness.

29