Cargo Floor SLC Series, CF500 SLC, CF100 SLC, CF3 LP-2, CF500 Power speed Technical User's Manual
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Technical user manual SLC General
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Version 01 / July 10th, 2017
GENERAL
CARGO FLOOR USER MANUAL
We would like to introduce to you the right operation of our Cargo Floor system with the help of the
following data and we also want to point out to you the steps that you can take to solve malfunctions.
Please read and follow our instructions carefully so that the Cargo Floor system will give you reliable and
trouble free service for many years and health and safety is secured.
If the Cargo Floor system does not operate at all (or properly) after following the instructions, please do
not hesitate to contact your nearest agent, who will with no doubt assist you in solving the problem.
Please pay particular attention to the contents of the “Important recommendations and guidelines” on
page 2 and further!
The measurements given in this instruction start with the metric system after which between brackets [0]
the US/imperial measurement is mentioned.
TABLE OF CONTENTS
GENERAL ................................................................................................................................................ 1
Important recommendations and guidelines .......................................................................................................... 2
Health and safety short list ..................................................................................................................................... 5
Emergency stop ..................................................................................................................................................... 5
Start up check list before operation (unloading / loading) ...................................................................................... 5
Stickers ................................................................................................................................................................... 6
How to check the chosen loading/unloading function ............................................................................................ 8
Modular operating possibilities ............................................................................................................................... 9
Wet kit information ................................................................................................................................................ 10
Hydraulic start-up check list for the Cargo Floor system ..................................................................................... 11
Identification plate ................................................................................................................................................ 12
Cargo Floor technical specifications .................................................................................................................... 13
Maintenance instructions ...................................................................................................................................... 14
Adjustment of the threaded rod of the control valve ............................................................................................ 15
Warranty conditions .............................................................................................................................................. 16
A-CONTROL .......................................................................................................................................... 18
Control valve......................................................................................................................................................... 18
Loading – unloading function ............................................................................................................................... 18
Hydraulic circuit diagram A-control ...................................................................................................................... 19
Troubleshooting A-control valve ........................................................................................................................... 20
B-CONTROL .......................................................................................................................................... 21
Control valve......................................................................................................................................................... 21
Loading – unloading function ............................................................................................................................... 21
Function of B-control Switches ............................................................................................................................. 22
App receiver ......................................................................................................................................................... 23
Remote control (CF TX) Transmitter .................................................................................................................... 23
Manual override .................................................................................................................................................... 24
Electrical circuit diagram B-control ....................................................................................................................... 25
Hydraulic circuit diagram ...................................................................................................................................... 26
Troubleshooting B-control valve ........................................................................................................................... 27
E-CONTROL .......................................................................................................................................... 28
Control valve......................................................................................................................................................... 28
Function of E-control switches ............................................................................................................................. 28
App receiver ......................................................................................................................................................... 30
Remote control (CF TX) Transmitter .................................................................................................................... 30
Manual override .................................................................................................................................................... 31
Electrical circuit diagram E-control ....................................................................................................................... 32
Hydraulic circuit diagram ...................................................................................................................................... 33
Choke ................................................................................................................................................................... 34
Troubleshooting E-control .................................................................................................................................... 35
CONTACT DATA ................................................................................................................................ ... 36
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Version 01 / July 10th, 2017
IMPORTANT RECOMMENDATIONS AND GUIDELINES
Before putting the Cargo Floor loading and unloading system into operation, follow the recommendations
provided below and check the specified checkpoints to avoid damage to the Cargo Floor system and the
vehicle.
Please review the important instructions before operating the Cargo Floor system and loading cargo into
the vehicle. Likewise, before loading cargo, check the operation of the various control switches/valves to
familiarise yourself with how the system works. We strongly recommend that you perform these checks
when picking up the vehicle from the dealer so that your skilled supplier can answer your questions and
provide you with any necessary advice or guidance you may require.
Important:
Always check that the selected loading or unloading direction is actually activated and occurring!!
If the system fails to start, turn off the Cargo Floor system and the hydraulic pump and follow the
recommendations and guidelines provided below. Do not repeatedly try to start the system as this
may result in damage to your Cargo Floor system and/or vehicle.
After use, turn off the Cargo Floor system and hydraulic pump. Set switches to the "0" position and
the lever in neutral.
In case of doubt or uncertainty about these recommendations and guidelines, always contact your dealer
or an official workshop.
The Cargo Floor system comes standard with an operating manual, but is this has not been supplied,
please contact your dealer or download it from the official Cargo Floor website: www.cargofloor.com,
download.
A) Always open the vehicle's doors before turning on the hydraulic pump. Note! Build-up of pressure
against the doors can open them with force. Also some of the cargo can fall out of the vehicle by
itself after opening the doors, therefore KEEP CLEAR AT ALL TIMES, product could fall on top of
you! Both could result in damages and/or injuries! It is always advisable to use the pneumatic door
lock, if provided.
B) 1. Check that the vehicle's (quick-detachable) couplings are properly connected to the P (Pressure
line) and the T (tank/return line). Also check that the couplings are fully tightened or slid completely
into each other.
IMPORTANT: the pressure and return line connectors may not be reversed or exchanged to
prevent dirt or water from entering the lines when connecting them!
2. Before connecting, check that the non-return valves can open easily (check: the non-return
valves should open easily when pressed with the finger, if not, potential pressure build-up in the
hydraulic lines may be preventing the system from starting).
NOTE: Incorrectly connected or unopened hydraulic couplings will cause serious damage to the
Cargo Floor system and the vehicle.
C) The vehicle (pump) must be fitted with a pressure relief valve that is set at the maximum pressure
according to the system, see the technical specs. If fitted, check that the dual-function lever
(function: tipper/Cargo Floor) is in the Cargo Floor position. Pressure may not exceed the
maximum adjusted and allowable operating pressure of the Cargo Floor system. An incorrectly
adjusted pressure relief valve can cause damage to the Cargo Floor system and the vehicle.
D) During operation, the (hand)brake of the vehicle must always be applied. You must, however,
move the vehicle forward on time to unload it quickly in order to prevent unnecessary strain and
wear to the floor and the vehicle.
E) Use of a wireless remote control is permitted only if it is fully tested before the start of each loading
or unloading operation. Always check if the function you have selected is actually activated and
taking place. If, for example, you have accidentally pressed the load function when you actually
meant to press the unload function, irreversible damage may occur to the Cargo Floor system and
the vehicle.
F) During operation of the Cargo Floor system, all existing STOP and control knobs/levers must be
freely accessible.
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G) The pressure filter element needs to be replaced at least once a year. If the couplings between the
vehicle and the Cargo Floor system are regularly removed, it is advisable to check the pressure
filter for dirt build-up and replace the pressure filter element more often, if necessary. If provided,
also check the return filter (not supplied with the Cargo Floor). Failure to replace a filter element on
time may cause damage to or malfunctions in the Cargo Floor system and the vehicle.
H) Moving parts must be shielded. Always maintain at least 10 meter [30’] distance from the Cargo
Floor system when it is in operation.
I) In the event of malfunctions/maintenance work, you may approach the Cargo Floor system only if
all equipment, including the hydraulic pump, have been shut off, and the Cargo Floor system and
the electro-hydraulic aggregate have been disconnected from the power supply and pump.
J) Regularly check and, if necessary, tighten any loose bolts that secure the aluminium floor profiles
to the Cargo Floor system. All such checks can simply be performed inside the vehicle itself by
qualified personnel. The Cargo Floor system must, however, be turned on in unloaded condition
and the person performing the check must place his finger half on the floor profile and half on the
bolt. There should be no appreciable movement/space between the floor profile and bolt. Failure
to check these bolts may lead to damage to the Cargo Floor system. During this check, a second
person must also be present to switch off the Cargo Floor system.
K) Check that the minimum required amount of oil is present 150 liter [40 US gallon]. Too little oil in
the hydraulic tank will cause damage to both the pump and the Cargo Floor system.
L) Do not allow the number of strokes to exceed the maximum allowable 16 power strokes per
minute. Only a CF500 SLC Power Speed Cargo Floor system may deliver up to 23 beats per
minute. A higher number of power strokes can cause damage to the Cargo Floor system and the
vehicle.
M) Hydraulic lines, couplings and hoses with very small diameters will cause damage.
N) If the Cargo Floor system fails to start or operates incorrectly, the Cargo Floor system and the
hydraulic pump must be shut down immediately. Subsequently, check all the checkpoints before
switching the pump and the Cargo Floor system back on. To prevent the oil from overheating,
regularly check the oil temperature by CAREFULLY and CAUTIOUSLY touching the line and or oil
tank. If either is too hot to the touch, stop touching them right away. WARNING: TOUCHING
OVERHEATED OIL AND COMPONENTS CAN CAUSE BURNS!
O) The cause of failure or malfunctioning of the Cargo Floor system may also be due to other
hydraulic components that may or may not be connected to the same hydraulic circuit of the Cargo
Floor system.
P) Jamming of the floor profiles caused by the transport of abnormal loads and or the freezing of the
floor or of the product to the floor may result in damage to the Cargo Floor system and the vehicle.
Recommendation: in the event of freezing, stop the system and try to find a hall (heated area) to
allow the product to thaw.
Q) Because the electrical power supply of the Cargo Floor system is often connected to the lighting
circuit of the vehicle, it is advisable to turn on the lighting throughout the operation of the system.
R) Maintenance and repairs to the Cargo Floor system may be only performed by qualified personnel.
Use only original Cargo Floor components to ensure maximum reliability and long service life.
S) Maximum cargo weight is subject to the limits set by law and applicable regulations. Even if the
system can transport heavier loads, the law determines the maximum limit. Excessively heavy
cargo can cause damage to the Cargo Floor system and the vehicle.
T) Check that the correct type and quality of hydraulic oil is used. The use of incorrect oil type may
cause damage to the Cargo Floor system and the pump.
U) Check the vehicle for correct voltage. Make sure there are no open electrical connections. A faulty
electrical system can cause damage to the Cargo Floor system and the vehicle.
V) Check that the bulkhead, if present, is functioning smoothly and properly. A properly functioning
bulkhead ensures that the product is unloaded in a clean and quick fashion. A malfunctioning
bulkhead may extend the unloading time and cause damage to the vehicle.
W) Use of the Cargo Floor system by unqualified personnel can cause damage to the Cargo Floor
system and the vehicle.
X) Excessively high oil temperatures will cause damage to the Cargo Floor system and other
hydraulic components, such as the pump.
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Y) It is at all times advisable to stop the Cargo Floor system when all the piston rods are retracted.
This is usually the case when the floor profiles are positioned towards the unloading end (vehicle
doors). Unretracted piston rods may cause damage to the Cargo Floor system.
Z) To prevent damage to the floor profiles, exercise caution and limit the dump height as much as
possible. The transport of unauthorised goods, such as aggressive, corrosive, hot, hard, sharp and
viscous materials may cause damage to the Cargo Floor system and the vehicle. Avoid loading
and unloading sharp objects. Loads that are softer than the hardness of the floor profiles will
extend the service life of your system; if in doubt, use a protective cloth or consult your dealer.
AA) Forklift trafficable. In principle, the floors are completely trafficable and can be driven over by
forklifts, but always consult your dealer for advice on the maximum loads allowed on your vehicle.
Overloading will cause damage to the Cargo Floor system and the vehicle.
BB) Always return emergency control(s) to their original non-activated position after use.
CC) During the operation of the system, test the temperature of the oil by touching the side of the tank.
If the oil is so hot that you cannot continue to touch the tank, switch off the pump to allow the oil to
cool off and determine what is causing the overheating. Stop loading or unloading if the oil is too
hot, as this will irreversibly cause damage to the Cargo Floor system and the other hydraulic
components.
WARNING: TOUCHING OVERHEATED OIL AND COMPONENTS CAN CAUSE BURNS AND
INJURIES!
Option: your Cargo Floor system could be equipped with an oil temperature safety switch which will
switch off the system automatically when it starts to overheat.
DD) During loading and unloading operations, the load should be spread to give an even weight
distribution over the floor area, otherwise the load may stall. Tip: when transporting pallets, place
softwood boards of 300 x 18 x 2350 mm. [12” x 0.75” x 92.5”] to distribute the pressure more
evenly.
EE) The constant pressing of the load against the head board or the doors can lead to extra wear of
the complete system. Also the construction can be damaged. Please consult your supplier about
the optimizing possibilities or in order to prevent problems occurring.
FF) The user/operator/driver that is operating the Cargo Floor system is compelled to remain a safe
distance from the Cargo Floor system at all times, from the time of switching on the hydraulic pump
until turning it off. He should ensure that no dangerous situations can occur. When the process
malfunctions or if other people are present he should shut down the Cargo Floor system, or
hydraulic pump, immediately.
GG) No unauthorized alterations/modifications/changes/adjustments may be made to any part of the
Cargo Floor drive unit and system.
WARRANTY
Warranty is subject to prior approval by Cargo Floor B.V.! To request warranty coverage, visit
www.cargofloor.com to fill out and submit the warranty application form provided there; do not forget to
include your Cargo Floor system number on the form.
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Version 01 / July 10th, 2017
HEALTH AND SAFETY SHORT LIST
1. During operation, the (hand)brake of the vehicle must always be applied.
2. Check surroundings, at all times, that no persons, animals or objects are in the direct vicinity of the
vehicle.
3. Caution when opening the doors. There could be backpressure from the product to the doors which
could force the doors to open themselves and injure you, also product could fall on top of you!
4. Do not stand behind the trailer or in the discharge area when the floor is operating
5. Do not make adjustments to the unloading mechanism with the floor operating
6. Do not operate system when protective covers and screens are not in place
7. Do not go underneath the trailer when floor is operating
8. Do not leave the trailer unattended while the Cargo Floor system is in operation
9. Do not hold the conduits these can could be hot
10. Disengage the trailer from the PTO hydraulic power unit before service and maintenance
11. Stay away from any oil leaks when hydraulic pressure is high
12. Turn off the PTO hydraulic power unit before moving the trailer
13. Keep clear at all times.
EMERGENCY STOP
In the event of an EMERGENCY, operation of the Cargo Floor system can be halted as follows:
By pressing the red stop button on one of the control switches;
By turning all switches to position “0”;
By putting the handle of the control valve in the middle “0” position (only B and A control);
Turning off the PTO pump/engine;
Turning off the main switch of the power supply;
Turning off the motor of the electro-hydraulic aggregate.
START UP CHECK LIST BEFORE OPERATION (UNLOADING / LOADING)
1. Check surroundings, at all times, that no persons, animals or objects are in the direct vicinity of the
vehicle.
2. Open doors first.
CAUTION when opening the doors. There could be backpressure from the product to the doors
which could force the doors to open themselves and injure you, also product could fall on top of you!
3. Check if hydraulic hoses/couplings are connected correctly and firmly (pressure and return).
4. Turn on the lights of the trailer
5. Check your type of operation: A, B or E? Make sure that all operation controls are in the non-
activated 0 position.
6. Turn on the pump
7. Determine/choose your required operation: unloading or loading. CAUTION check immediately if
your required operation is working correctly. The loading / unloading direction is determined when all
the profiles move in one direction together. (Unloading: toward the doors / loading: toward the head
board/truck.)
8. During unloading it might be necessary to move the vehicle forward to achieve a faster and cleaner
unloading.
Remarks!
Make sure that your unloading / loading spot is long/large enough to move your complete vehicle its
full length forward.
The (hand)brake of the vehicle must always be applied.
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Version 01 / July 10th, 2017
STICKERS
This WARNING STICKER/DECAL has been supplied with the drive unit in two fold. It should be attached
near the control box and on the rear door in such a way that it is easy to read.
STICKERS/DECALS ON THE TRAILER
A
…………………………………………………………………………………………………………………………
B
White/transparent Black/ transparent
or
………………………………………………………………………………………………………………………..
A + C
A B D
C
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C
STICKERS/DECALS ON THE CONTROL BOX, ONLY WITH B- AND E-CONTROL
STICKERS/DECALS ON THE SWITCHES
Switch B-control Switch B-control Switch E-control Switch E-control
…………………………………………………………………………………………………………………………
D
STICKERS/DECALS ON THE SIDE OF THE TRAILER, NEAR THE DRIVE UNIT
Only A + B-control
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HOW TO CHECK THE CHOSEN LOADING/UNLOADING FUNCTION
UNLOADING
The complete surface of the floor moves simultaneously towards the open rear doors of the trailer.
The 3 individual movements go the opposite way (towards the front headboard of the trailer).
LOADING
The complete surface of the floor moves simultaneously towards the front headboard of the trailer
(direction of the truck).
The 3 individual movements go the opposite way (towards the open rear doors of the trailer).
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MODULAR OPERATING POSSIBILITIES
Thanks to its modular construction, the following operative versions of the Cargo Floor moving
floor® system are possible (also retrofittable):
A control
A-control with loading / stop / unloading over a manual handle, with unique "S" detent mechanism in
order to determine loading / stop / unloading position. (Non-electrical.)
B control
B-control with loading / stop / unloading over a manual handle, with unique "S" detent mechanism in
order to determine loading / stop / unloading position. on / off switching over a switch.
As a standard provided with a manual override by means of a unique red “Cargo” rotary switch.
(Optional: radio remote control.)
E control
E-control with loading / stop / unloading over a
switch
As a standard provided with a manual override by
means of a unique red “Cargo” rotary switch.
(Optional: radio remote control.)
Manual override by means
of a unique red “Cargo”
rotary switch.
OPTION
STANDARD
OPTION
STANDARD
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Version 01 / July 10th, 2017
WET KIT INFORMATION
This wet kit is designed to be used with most transmissions. Power Take Off (P.T.O.) specifications may
vary with some transmissions. Please check with your supplier for specific applications.
The wet kit used to power the Cargo Floor system must comply with the following specifications:
CF500
SLC
CF100
SLC
CF500
SLC
Power
Speed
CF3 LP-2
CF600 HDC
CF800
Advised pump
capacity (l/min [gpm])
110 [29]
70 [18]
180 [48]
110 [29]
110 [29]
110 [29]
Max. Pump capacity
(l/min [gpm])
130 [34]
80 [21]
200 [53]
170 [45]
190 [50]
130 [34]
Max. Pressure relieve
valve *bar [psi]
250 [3,625]
200 [2,900]
250 [3,625]
175 [2,538]
220 [3,191]
250 [3,625]
*Pressure relieve valve must have the ability to relieve the full pump flow at the maximum pressure for
the system.
PRINCIPLE WET KIT DIAGRAM
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Oil: See “hydraulic recommendations”.
Pump: All gear pumps regardless of make or model should be "run in" as per manufacturer's
recommendations before connecting to the trailer for the first time.
Return filter: Filter should be 10 to 30 micron on the return line. Filter should be mounted as close to the
reservoir as possible. Return filter elements should be changed after 6 hours initially and every 6 months
thereafter.
Hydraulic Reservoir: Should hold approximately 1 liter [1 gallon] of oil for every liter [gallon] per minute
of pump output. (110 l/min [29 gpm] pump = minimum 110 liter [29 gal] reservoir)
Suction line: Hydraulic suction line with a 50 mm [2"] inside diameter, not more than 1500 mm [5'] long
Pressure line: All pressure lines should be minimum diameter of 20x2 mm [3/4”]
Return line: all hoses and lines should be a minimum diameter of 25x2 mm [1”]
Pressure relief valve: Must be pilot operated type, and sized correctly for the system. See wet kit
specification.
Hydraulic recommendations
1. Use ISO 22 grade oil if the minimum operating temperature is between -25 and 0 °C [-13 and 32
°F].
2. Use ISO 32 grade oil if the minimum operating temperature is between -15 and 30 °C [5 and 86 °F].
3. Use ISO
46
grade oil if the operating temperature range is between
15
and
40
°C [59 and 104 °F].
Note: The suggested maximum viscosity value for start-up is
1000
cSt.
Temperature below
-25 [-13
°F] degree Celsius
Use the following warm up procedure in temperatures below -25 degrees Celsius [-13°F]:
1.
Set the operation handle for unload (1) – 0 – load (2) in the middle 0-position
2. Circulate the oil for a few minutes to preheat it and lower its viscosity.
HYDRAULIC START-UP CHECK LIST FOR THE CARGO FLOOR SYSTEM
Before starting your new Cargo Floor (un)loader, a quick start-up check should be made
1. Hydraulic: is your entire system plumbed to the plumbing diagram?
2. *Pump: Will it pump the advised flow at the maximum pressure according to the system?
3. *Relief Valve: is it set at the maximum pressure according to the system?
4. Hydraulic reservoir: Is it big enough and filled?
5. Power Take Off: Is the P.T.O. engaged?
6. Hoses: Is the pressure line on the trailer attached to the pressure line on the tractor and the return
line on the trailer attached to the return line on the tractor?
7. Quick Disconnects: are these suitable and connected the right way?
8. Controls Cargo Floor: Operation handle unload (1) - 0 - load (2) in position 0?
*If the information about your pump and relief valve is not known, a pressure/flow check will help
determine this information. Be sure that your entire wet kit system meets the requirements of the
hydraulic wet kit specifications in this manual.
Less than -25 °C [-13°F]
-25
-
0 °C [-13 – 32 °F]
-15 - 30
°C [5 – 86 °F]
15 - 40
°C [59-104 °F]
Warm up
ISO 22
ISO 32
ISO 46
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