Cargo Floor CF500 SLC User manual

Assembly instructions CF500 SLC Bulkmover
www.cargofloor.com Page 1
Version 01 / 12-12-2018
CARGO FLOOR®
ASSEMBLY INSTRUCTIONS
CF500 SLC BULKMOVER
CF500 SLC 15/156,8
Cargo Floor B.V.
World's leading manufacturer and supplier of horizontal loading- and unloading transport conveyor
systems.

Assembly instructions CF500 SLC Bulkmover
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Version 01 / 12-12-2018
INTRODUCTION
The assembly instructions outlined in this book will enable you to assemble the Cargo Floor system you
have purchased correctly. Every effort has been made, by means of diagrams and text, to ensure a clear
and simple installation. To ensure the durability and reliability of this revolutionary loading and unloading
system, it is important that you follow the assembly instructions as outlined in this book completely, and
use quality materials in accordance with the specifications. Please note that the guarantee is only valid if
the Cargo Floor system has been assembled in accordance with these assembly instructions. The latest
available version can always be found on our internet site: www.cargofloor.com
The measurements given in this instruction start with the metric system after which between brackets [0]
the imperial measurement is mentioned.
If the indications in this manual, as well as those stated in the user manual, are not followed
this could result in damages and/or injuries.
If your customer had any specific wishes we advise you to contact Cargo Floor B.V. This
especially when what is wished for differs from the so-called normal use.
(ADDITIONAL) INSTRUCTIONS
The following (additional) instructions are available:
Assembly CF3 LP-2 15-160
Assembly CF100 SLL
Assembly CF500 SLC
Assembly CF500 SLC Power Speed system
Assembly CF500 SLC Leak Resist Centre drive
Assembly CF500 SLC 15/156,8 XHDI / HD
Assembly CF800 system
Assembly Protected Seal 156,8 mm [6.17”]
Assembly Semi Leak Proof (SLP) system
The latest available version can always be found in the downloads section on our internet site:
www.cargofloor.com, downloads

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TABLE OF CONTENTS
Introduction ..............................................................................................................................................2
(Additional) instructions............................................................................................................................2
Table of contents......................................................................................................................................3
Important recommendations and guidelines.............................................................................................4
Emergency stop .......................................................................................................................................7
Identification plate ....................................................................................................................................8
Stickers ....................................................................................................................................................9
Hoisting instructions ...............................................................................................................................11
The chassis............................................................................................................................................12
Mounting the plastic bearing strip at the back side .................................................................................13
Mounting the plastic bearing strip “Cargo Bulkmover”.............................................................................16
Positioning the system............................................................................................................................17
Height adjustment and alignment of the Cargo Floor system..................................................................18
Securing the system...............................................................................................................................19
Bracing the side walls.............................................................................................................................21
Connecting the hydraulics ......................................................................................................................22
Choke.....................................................................................................................................................23
Mounting the plastic bearing “Cargo Twister WIDE 40/25” ....................................................................24
Mounting the plastic bearing and anti lifting SPECIAL WIDE bearing 40/25 ...........................................25
Cutting the floor profiles to size ..............................................................................................................26
Round off the profiles .............................................................................................................................26
Driling the holes in the floor profiles........................................................................................................28
MOUNTING THE SEAL..........................................................................................................................29
mounting the endcaps............................................................................................................................30
Securing the floor profiles to the drive unit..............................................................................................30
Securing the stationary side profiles.......................................................................................................31
Mounting the control box and the electrics..............................................................................................33
The moving headboard...........................................................................................................................35
The moving headboard tarpaulin............................................................................................................36
Adjustment of the threaded rod of the control valve................................................................................37
Technical specifications..........................................................................................................................38
Maintenance instructions........................................................................................................................39
Important instructions.............................................................................................................................40
Troubleshooting E-control.......................................................................................................................41
Warranty conditions................................................................................................................................43
Contact data...........................................................................................................................................45
TABLE OF CONTENTS OF THE ENCLOSED DRAWINGS
Attention: choose the system type that you are building in!!!
Subject........................................................................................................................................Drawing
System CF500 SLC H80-15-156,8, 12xM12................................................................................ S1-156,8
System CF500 SLC H100-15-156,8, 12xM12.............................................................................. S2-156,8
System CF500 SLC H120-15-156,8, 12xM12.............................................................................. S3-156,8
System CF500 SLC H140-15-156,8, 12xM12.............................................................................. S4-156,8
Hydraulic drawing CF500 SLC A........................................................................................................H1-A
Hydraulic drawing CF500 SLC B........................................................................................................H1-B
Hydraulic drawing CF500 SLC E........................................................................................................H1-E
Proposal drawing hydraulic connections CF500 SLC ............................................................................H2
Electric drawing E.................................................................................................................................. E1
Electric drawing B.................................................................................................................................. E2
Control valve .......................................................................................................................................BV1
Control valve B....................................................................................................................................BV2

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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.

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WARRANTY
Warranty is subject to prior approval by Cargo Floor B.V.! To request warranty coverage, visit
www.cargofloor.com, service to fill out and submit the warranty application form provided there; do not
forget to include your Cargo Floor system number on the form.
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.

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IDENTIFICATION PLATE
General extended identification plate
Next to the system number the Cargo Floor order number will be mentioned and a field with 9 digits has
been added in which we can, if required, put your identification or order number.
Numbers are automatically provided with a barcode; this makes it possible for you to scan the required
data.
Short small identification plate
An extra identification plate has been mounted near the rear bridge, above the threaded rod of the
control valve, so the system number can be read simply and swiftly at the outside of the trailer.
Paint and dirt protection
The identification plates are specially fitted with a double layer of transparent protective foil. The first
protective foil has a lip with remains visible when the Cargo Floor system has gotten painted or
exceptional dirty. This protective foil can simply be removed so the data is readable again and the
second protective foil remains intact so the data remains protected.

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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