Autoquip FLT User Manual
INSTALLATION, OPERATION
AND SERVICE MANUAL
FREIGHTLIFT
Model FLT
P.O. Box 1058 • 1058 West Industrial Avenue • Guthrie, OK 73044-1058 • 888-811-9876
405-
282-5200 • FAX: 405-282-3302 • www.autoquip.com
Item # 830FLT Version 2.0
March 2008
TABLE OF CONTENTS
Introduction 3
Inspection & Identification of Parts 4
Responsibility of Owners/Users 5
Safety Signal Words 6
Safety Practices 7
Safety Features 12
Label Identification 16
Specifications 19
Blocking Instructions 20
Installer Guidelines & Responsibilities 24
Installation Instructions 29
Operating Instructions 54
Routine Maintenance 56
General Maintenance 59
Replacement Parts List 69
Troubleshooting Analysis 70
Glossary of Terms 75
Warranty 77
IMPORTANT
Please read and understand this manual prior to operation of the FREIGHTLITE.
Failure to do so could lead to property damage and/or serious personal injury. If any
questions should arise, call a local representative or Autoquip Corporation at 1-888-8119876 or 405-282-5200.
PLANNED MAINTENANCE PROGRAM
A local Autoquip representative provides a Planned Maintenance Program (PMP) for
this equipment using factory-trained personnel. Call a local representative or Autoquip
Corporation at 1-888-811-9876 or 405-282-5200 for more information.
2
Autoquip Corporation has manufactured the FREIGHTLITE. It has been designed to
move lightweight materials between multiple floors or levels safely and efficiently. It has
been built to provide many years of dependable service. 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!
Situations may arise which are not covered in these installation instructions. If you have
questions, please call Autoquip Customer Service at (405) 282-5200 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.
INTRODUCTION
3
INSPECTION & IDENTIFICATION
The following items are typically shipped loose within each FREIGHTLITE order:
A. One platform/mast beam/cylinder pair assembly
B. One upper mast pair assembly (spliced masts)
C. One hydraulic power unit
D. One hydraulic connecting hose
E. Limit switch kits
F. One motor control panel
G. One operator pushbutton control per level
H. Miscellaneous Hardware, Manuals, and Signs
I. Miscellaneous Bracing & Guarding – depending on application
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(s), check the components against the
packing list. This will provide assurance that every item shipped has been received,
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 that are be beyond corporate 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
Autoquip’s operating/maintenance (O&M) manual and with other applicable safe
operating practices.
REMOVAL FROM SERVICE
Any lift 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, hydraulic, or pneumatic lines, damaged or malfunctioning controls or safety
devices, etc. shall be removed from service until it is repaired to the 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 Autoquip’s O&M manual.
• Do not overload the lift.
• 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 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. Therefore, all personnel have the
responsibility to diligently exercise safe practices whenever exposed to this equipment.
____________________________________________________________
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
Indicates a potentially hazardous situation which, if not avoided, may result in
property or equipment damage.
____________________________________________________________
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
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 unit seems unstable, do not operate! Contact Autoquip
immediately!
DANGER!
Turn off power! To avoid personal injury or death, be sure the power is
off and is locked 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 regulations for lock-out, tag-out, etc.!
DANGER!
Secure platform and cylinders! Do not remove or disconnect the power
unit unless the platform and cylinders have been secured. See “Blocking
Instructions” section.
WARNING!
No riders! The FREIGHTLITE is provided for the sole purpose of
transporting goods between floor elevations. At no time should it be used
to transport personnel!!
WARNING!
Never run the unit with the gates or doors open! Do not operate unit
with doors open or with the interlocks or other safety devices “defeated”
(bypassed)! Serious injury or death could result.
WARNING!
Velocity fuse lock-up requires factory help! Contact your local
FREIGHTLITE representative or call Autoquip Service Department if
hydraulic velocity fuses should lock up!
8
SAFETY PRACTICES
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 requirements for Lock-Out, TagOut.
WARNING!
Never operate unit when parts are defective! Do not operate this
equipment when substandard or defective parts are in use! Contact an
Autoquip Service Representative to rectify all such situations.
WARNING!
Never go under platform carriage! Use a long-handled broom or similar
implement to remove debris that may accumulate.
WARNING!
Use properly rated hoses only! Never use fittings or hoses that are not
properly rated for the intended use.
WARNING!
Attach velocity fuse with solid fitting! Do not use a swivel fitting
between the velocity fuse and cylinder. If accidentally broken at the swivel,
the velocity fuse will not prevent the carriage from falling to the floor.
9
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 up 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, which could create a very dangerous
condition!
CAUTION!
Do not run carriage until pressure switch is set! If the electrical work is
not complete, do not run the carriage all the way to the top until the limits
are set.
CAUTION!
Use appropriate fluids! Do not use automatic transmission fluid (ATF),
hydraulic jack oil, hydraulic fluids, or brake fluids in the power unit or hosing
system.
CAUTION!
Keep power unit filled! Do not run the hydraulic power unit dry. Damage
to the pump and motor may result.
10
SAFETY PRACTICES
CAUTION!
Do not operate motor at relief pressure! The motor should not be
operated for more than a few seconds when the unit is operating at relief
pressure. Longer running times could result in damage to the pump.
CAUTION!
Automatic cylinder retraction possible! Be aware that the cylinder rod
may retract into the cylinder body automatically when the hydraulic hose is
disconnected.
CAUTION!
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.)
CAUTION!
Protect cylinder rods, hydraulic ports and lines at all times! Welding
splatter and dust from grinding operations can cause severe damage to
this equipment.
CAUTION!
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. If the electrical control
system is complete, the motor will stop because of the pressure switch
setting.
11
SAFETY FEATURES
There are several active safety features and devices to help protect personnel, property,
and the equipment.
ZERO DRIFT FEATURE
A zero drift feature has been incorporated into the FREIGHTLITE lift. The zero drift
uses a limit switch mounted at the upper level and the pressure switch circuit. The limit
switch is tripped closed when the carriage is at the upper level. The electrical circuit is
transferred to the pressure switch, if the pressure switch closes due to a pressure drop
or leak. The motor will start momentarily to build pressure until the pressure switch
shuts the motor off. This keeps the platform from drifting downward from the upper
level. When the operator closes all gates and energizes the down pushbutton, the zero
drift circuit is disabled and the carriage will lower.
HYDRAULIC VELOCITY FUSES
Each hydraulic cylinder has a hydraulic velocity fuse (HVF) installed in the cylinder port.
These HVFs are installed in the predetermined hydraulic oil flow velocity as the oil
returns to the reservoir. They do not affect incoming oil. 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 with one to two
inches of downward movement of the platform carriage.
NOTE: Air in the system will also cause a lock up. Air acts like a spring when
compressed. To remove air from the system, see “Air Bleeding Procedures” in the
General Maintenance section.
NOTE: Small fitting leaks will not trigger the HVFs. In an air-free system, the breach
must be large enough to cause an uncontrolled or destructive lowering speed. Should a
triggering and loc up occur, it can only be released by applying upward hydraulic flow in
a functional system.
12
SAFETY FEATURES
SAFETY RELEASE BYPASS VALVE (SRBV)
The SRBV is a part of the hydraulic system. Should the system pressure exceed the
predetermined pressure setting, the SRBV will bypass the pump output back to the oil
reservoir. The SRBV is factory set to the proper pressure, which will prevent damage to
the mechanical, hydraulic, and electrical systems due to overloading, obstruction, or
other circumstances. This setting should be tested once installation is complete (see
Installation section).
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. Repairs should only be
performed by a qualified electrician or service technician and OSHA
requirements for Lock-Out, Tag-Out must be followed!!
MOTOR STARTER OVERLOADS (MSO)
These are current sensing devices that are located in the three legs of the electric motor
primary power circuit (208,230, or 460 volt). They protect the motor from excessive
current draw if it becomes overloaded, experiences low line voltage, or has a short
circuit. Should any leg sense an over-current situation the element will heat up and trip
the heat sensitive device housed in the motor starter coil circuit. Power is removed to
the coil and the three line power contacts are opened in the motor primary power circuit.
This will stop the motor from rotating until the overloads are reset and/or the fault is
cleared which caused the trip condition.
NOTE: The MSO will only affect the “UP” circuit. The platform carriage can be lowered
if the MSO trips.
13
SAFETY FEATURES
SAFETY INTERLOCKS/LATCHES-GATES OR DOORS
(where applicable)
These are electro/mechanical devices that prevent operation of the FREIGHTLITE
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.
WARNING!
Never run the unit with the gates or doors open! Do not operate unit with
doors open or with the interlocks “defeated” (bypassed)!
SHAFTWAY DOOR BARRIER BARS (where applicable)
Shaftway door barrier bars are designed to provide a secondary means of personnel
protection at the upper level landing of an FLT shaftway 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 shaftway where the carriage could be assumed to
be present.
When properly installed, the barrier bars are lifted up and along their tracks by the
carriage as it approaches the upper landing until it is completely above the load height
as the lift stops. As the lift moves to the lower level, it carries the bars back to their
stationary brackets attached to the outside of the door.
WARNING!
Shaftway 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
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
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).
: Additional safety feature recommended at all
15
LABEL IDENTIFICATION
3
1
6
4
2
5
1
(Actual Size 1” x 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.
Figure 1 FREIGHTLITE Label Placement
FREIGHTLITE
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 2 Capacity 36401586 5 2 Caution – Familiarize Yourself . . . 36401487
6 varies Warning: Do Not Operate Without . . . . 36403720
7 (2) per
P/B
P/B Labels – Warning Do Not Allow Riders 36405705
16
LABEL IDENTIFICATION
Note: Labels shown here are not actual size.
Figure 2 Label 36404093
Figure 3 Label 36402680
Figure 4 Label 36401560
17
LABEL IDENTIFICATION
Figure 5 Label 36401586
Figure 6 Label 36401487
Figure 7 Label 36403720
Figure 8 Label 36405705
18
SPECIFICATIONS
Model Capacity
(pounds)
FLT-15 1,500 3 x 3 6 x 6 15 15 5
FLT-30 3,000 3 x 3 6 x 6 15 15 5
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.
Minimum
Platform
(feet.)
WARNING!
Maximum
Platform
(feet)
Speed
(FPM)
Travel
(feet)
HP
19
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 blocking procedures is to risk the sudden
and uncontrolled descent of the lift during maintenance or inspection. A
falling lift can cause severe injury or death.
This procedure describes the only factory-approved method of working under a lift.
Follow these instructions EVERY time you plan to reach or crawl beneath the lift to
perform service or maintenance – no matter how momentary that might be.
If the factory-provided maintenance devices are damaged or missing, stop immediately
and consult the factory for assistance. The manufacturer is not liable for your failure to
use the approved maintenance devices and procedures that have been provided.
Lower the Lift Platform
The safest way to inspect or maintain a VRC unit is with the load removed and the lift
carriage in the fully lowered position. When the carriage is fully lowered it has no
potential to suddenly or unexpectedly shift or drop.
If the lift carriage cannot be lowered by gravity, secure the carriage at its stuck position
before attempting to walk on or under the platform.
DANGER!
Never go under an unsupported platform! To avoid personal injury or
death, always be sure the load has been removed from the platform and
that it has been blocked adequately to prevent shifting or dropping
unexpectedly !
20
When the Lift Carriage Must be Raised
1. All loads must be removed from the lift platform prior to engaging the maintenance
devices. These devices are designed to support an unloaded lift only. Failure to
remove the load from the platform prior to blocking could cause the failure of the
maintenance devices and allow the lift to fall unexpectedly.
2. Raise the carriage to the desired elevation.
If Operational: Press the UP button and then press the EMERGENCY STOP
button when the desired height is reached
If Not Operational: Use a fork truck or other lifting device to raise the VRC
carriage, taking care not to damage the carriage or lift actuator/drive.
3. Place maintenance leg across the mast channel as shown in Figure 10. Make sure
the square tubing of the maintenance leg rests against the flange of the mast-beam.
4. Position the maintenance leg so that all of the alignment tabs fit over the flange of
The mast beam as shown.
Note: You should not stand beneath the carriage while setting the maintenance
device into position.
BLOCKING INSTRUCTIONS
DANGER!
To avoid personal injury or death, check the stability of the supports. If there
is any chance of the support tipping or otherwise not providing a safe and
stable condition, do not go under the platform!
5. Lower the carriage platform onto the maintenance device.
If operational – either press the DOWN button or open the manual lowering
valve until the platform lands onto, and is fully supported by, the maintenance
device.
If NOT operational - Use a fork truck or other lifting device to lower the VRC
platform onto the maintenance devices, taking care not to damage the carriage
or lift actuator/drive. Make sure the platform is level when supported.
6. Re-check to ensure that the maintenance device is fully and properly engaged with
the underside of the platform. If the maintenance device is not fully engaged the lift
could fall unexpectedly, resulting in permanent damage to the device or the lift.
21
BLOCKING INSTRUCTIONS
I-BEAM
I-BEAM
ALIGNMENT TAB
MAST FLOOR
CHANNEL
Figure 10 Maintenance Device Placement
ALIGNMENT TAB
22
BLOCKING INSTRUCTIONS
7. After the platform is fully lowered, continue to hold the DOWN button/lowering
valve for an additional 5-10 seconds to relieve the hydraulic system of pressure.
WARNING !
Failure to relieve operating system pressure could result in the sudden
and unexpected release of high-pressure fluids during maintenance
and/or repair of the lift which may result in severe injury or death.
8. Follow OSHA electrical lock-out/tag-out procedures. Disconnect and tag all
electrical and/or other power sources to prevent an unplanned or unexpected
actuation of the lift.
9. Once inspection or work is complete, reverse the performance of the steps above
to raise the platform off the maintenance devices and return the devices to their
designated storage positions.
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.
23
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.
24
Loading...