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Installation, Maintenance and Service Manual SQ Series Forging
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1. Use care when taking off the adapter plate The gearbox is filled with oil Seal Adapter plate Figure 4 17 Output shaft seals 18 H Allied COMPANY Drain the gearbox of oil The output shaft seals may now be serviced Figure 4 17 Remove the output shaft assembly Figure 4 18 The output shaft fits tight you may need to remove the cap on the back of the gearbox and lightly tap the end of the output shaft with a rubber mallet to remove Figure 4 19 Output shaft Figure 4 18 Output shaft 0 Figure 4 19 Output shaft Cap 45 025 REV 10 13 onc REACH A Division of Allied Systems Company 10 Remove the end cap and motor adapter Make note Part Number YGC 48 YGC 49 YGC 49 LH YGC 50 of any installed shims Capscrews are installed with and YGC 50 LH Loctite use a long handle wrench to break loose Figure 4 20 1 Remove the attachment from truck See Section 4 1 2 Before removing the gearbox from the back plate Capscrew place a support overhead or under the gearbox Ds Remove the mounting capscrews from the gearbox Figure 4 22 Motor adapter Figure 4 20 End Cap Motor Adapter 11 Remove the input shaft assembly The assembly fits tight use a rubber mallet or press on the extended shaft to remove Remove the exposed key with a screwdriver allowing the bearing and worm to slide off of the shaft Figure 4 21 Figure 4 22 Gearbox Removal 12 Reassemble in rev
2. Pin mount attachment ge X capscrew Truck carriage Bracket lug Figure 3 5 Pin Mount Lug Weld the bracket lugs with either E 6011 or E 6013 welding rod or equivalent on each side of the truck carriage Use provided capscrews to secure attach ment to truck carriage Figure 3 5 3 4 3 All Mounting Types i Install the lines from the truck s hydraulics to the hydraulics of the attachment Inspect installation to ensure hoses are not kinked or pinched between the truck carriage and attachment Operate the attachment continuously for several minutes to determine that all hydraulic connections are secure with no leaks With the mast in the vertical position open the clamp arms fully After this procedure check that the truck s hydraulic reservoir oil level is at the recommended level Allied 1 COMPANY SECTION 4 SERVICE PROCEDURE 4 1 Attachment Removal 1 Position the attachment arms to the width of the unit s body Before disconnecting any hydraulic connections be sure to turn off the truck s power and activate the truck s hydraulic functions in both directions to bleed off the hydraulic pressure Disconnect the hydraulic connection for the attach ment positioning at the hydraulic valve ports Disconnect the side shift connections at ports 4 1 1 ITA Hook Type Mounting 1 12 Slightly raise the truck carriage to allow the removal of the bottom mounting hooks If the a
3. lt 1 16 to 1 8 clearance Figure 4 4 Arm Lug With Castle Nut Allied 13 COMPANY 2 Turn on the truck s power and activate the positioning cylinders several times to bleed out trapped air When hydraulic service has been performed activate the hydraulic functions several times to bleed out trapped air in the system before returning attachment to service 4 6 Cylinder Disassembly 1 Remove the cylinder from the attachment See re moval instructions 2 Clamp the cylinder lightly at the base end in a soft jawed vise Use a block or other support under the rod end of the cylinder Figure 4 5 Figure 4 5 Cylinder Vise 3 Use a spanner wrench or similar tool to unscrew the gland cap from the cylinder tube Figure 4 6 Figure 4 6 Cylinder Rebuild 14 H Allied COMPANY 4 Remove the rod assembly from the cylinder tube 5 Clamp the rod assembly in a soft jawed vise on the wrench flats not on the rod surface If the rod does not have wrench flats use two pieces of wood on both sides of the rod to prevent scaring Figure 4 7 Figure 4 7 Cylinder Shaft 6 Remove the piston retaining nut and remove the piston Figure 4 5 7 Carefully pry up on the piston seals using a blunt tip screw driver being careful not to scratch the seal grooves Cut the seals to remove from the piston Figure 4 8 Figure 4 8 Piston Seal 8 Use the same procedure as above to remove the seals from the gla
4. s material handling procedures may be somewhat different from those shown in this manual 2 3 Safety Symbols The following terms define the various precautions and notices Danger Indicates a hazardous situation which if not avoided WILL result in death or serious injury Carefully read the message to prevent serious injury or death Allied COMPANY Indicates a hazardous situation which if not avoided could result in death or serious injury Carefully read the message to prevent serious injury or death Indicates a hazardous situation which if not avoided could result in minor or moderate injury Carefully read the message to prevent minor or moderate injury Notice Describes information that is not related to personal injury but may cause equipment damage or void the warranty All possible safety hazards cannot be foreseen so as to be included in this manual Therefore the operator must always be alert to possible hazards that could endanger personnel or damage to the equipment Obey the following warnings before using your machine to avoid equipment damage personal injury or death 2 4 Operation Warnings e You must be trained to operate this equipment prior to operation Be extremely careful if you do not normally operate this machine Reorient yourself to the machine before starting then proceed slowly Always operate an attachment from the driver s seat e Always lower the attachment i
5. nut Figure 4 2 Body Arm weldment B Cotter pin Flush nut Figure 4 2 Arm Removal Tie the cylinder up to support the weight when re moved from the arm lug Activate the hydraulics and retract the cylinder from the arm lug 45 025 REV 10 13 onc REACH A Division of Allied Systems Company 3 Attach a suitable overhead hoist to the arm weldment Pull the arm assembly out of the body 4 3 Arm Installation 1 Attach a suitable overhead hoist to the arm weld ment Line up the slide bar with the proper channel and slide into body Activate the hydraulics and extend the cylinder rod out until it is at the arm lug Insert the spacer washer on the cylinder rod and extend the cylinder through the arm lug until the arm moves Apply a thin coat of bearing grease to the spherical and concaved portion of the flush nut if applicable Screw on the nut until it stops Back off the nut while lining up the cotter pin if applicable hole in the rod with the slot in the nut Clearance between the spacer washer and the arm lug should be 1 16 to 1 8 of an inch or less Do not tighten the flush castle nut tight to eliminate all clearance between spacer washer and arm lug Figure 4 3 and Figure 4 4 Insert the cotter pin and bend to lock into place 4 4 Cylinder Removal 1 Extend the arms outside of the body Remove the cylinder rod end cotter pin and flush nut Tie the cylinder u
6. 40 Output Shaft In Position C Wire brush screw threads to remove cured Loc tite and other debris Discard any capscrews that have damaged threads or rounded heads D Wash capscrews with non petroleum base sol vent Blow dry with compressed air 3 If you remove a plug or seal lubricate new seal and 45 025 REV 10 13 Allied 25 COMPANY 6 Install the exclusion seal into the mounting flange Care fully press the exclusion seal into place Figure 4 41 Visually check the seal seat in the mounting flange for scratches or other marks that might damage the pressure seal Check for cracks in the mounting flange that could cause leakage Shaft pressure seal _ Seal driver Seal tube Backup ring Mounting flange Figure 4 41 Seal Installation Lubricate the I D of the seal tube and O D of the shaft pressure seal with a light film of clean petroleum jelly Align the small I D end of the seal tube with the seal seat in the mounting flange Install the back up ring and pressure seal in the tube with lips of the seal face up Figure 4 41 Insert the seal driver in the tube and firmly push seal seat with a rotating action 9 10 26 After installing the seal in the mounting flange examine the seal condition If damaged or improperly installed you must replace it before continuing with reassembly Install the 49mm 1 937 in I D seal in the flange It
7. dangerous unless performed properly You must have the necessary skills and information proper tools and equipment Work in a method that is safe correct and meets your company s requirements Do not attempt to make adjustments or perform maintenance or service unless you are authorized and qualified to do so Include attachments in a scheduled maintenance and inspection program Tailor inspection steps to the at tachment Unless specified in service procedures never attempt maintenance or lubrication procedures while the ma chine is moving or the engine is running Always perform all maintenance and lubrication pro cedures with the machine on level ground parked away from traffic lanes Notice Local laws and regulations may require that additional safety measures be taken Never rely on the hydraulic system to support any part of the machine during maintenance or lubrication Never stand under a component that is supported only by the hydraulics Make sure it is resting on its mechanical stops or appropriate safety stands 45 025 REV 10 13 Allied 5 COMPANY Use caution when working around hot fluids Always allow lubricating and hydraulic oils to cool before draining Burns can be severe Use extreme caution when using compressed air to blow parts dry The pressure should not exceed 30 psi 208 kPa at the nozzle Never use compressed air on yourself Air pressure penetrating your skin can be fatal Engine
8. exhaust fumes can cause death If it is neces sary to run the engine in an enclosed space remove the exhaust fumes from the area with an exhaust pipe extension Use ventilation fans and open shop doors to provide adequate ventilation Before disconnecting hydraulic lines be sure to lower all loads and relieve all hydraulic pressure The load could fall on you or escaping hydraulic oil could cause severe personal injury Prevent personal injury or equipment damage by us ing a lifting device with a lifting capacity greater than twice the weight of any equipment to be lifted 2 8 Training Make sure all operators are trained in the fork and attachment adaptation operation and use limitations Retrain an operator if a new attachment is added to the forklift Consult the operator s manual for instruc tions on how to use the new equipment Know the mechanical limitations of your forklift Modifications or additions that affect capacity or safe operation must have prior written approval from the forklift truck manufacturer Capacity operation and maintenance instruction plates tags or decals shall be changed accordingly Never use free rigging for a below the forks lift It could affect the capacity and safe operation of a lift truck Allied COMPANY 2 9 Labeling Change capacity operation and maintenance instruc tion plates tags or decals when a forklift truck is equipped with an attachment If the truck is equippe
9. gears and bearings slowly rotate the ring gear 360 while greasing this will allow grease to completely coat the gear Gears must be fully greased Figure 4 11 Pinion Ring Gear Grease Figure 4 11 Grease Fitting Locations 16 z Allied COMPANY 4 10 Gearbox Lubrication Part Number YGC 29 YGC 32 YGC 43 and YGC 43 LH 1 Remove the top plug and the oil level plug from the gearbox Figure 4 12 Oil Level Plug Figure 4 12 Gearbox Oil Plugs 2 Use Mobil HD 85W140 or equivalent oil If tempera tures drop below 20 F then use a synthetic oil Mobil SHC 634 or equivalent Do not overfill gearbox with oil Doing so may cause damage to seals and create leakage 3 Fill the gearbox to the oil level plug location 4 The oil level should be checked occasionally at the oil level plug If the oil level has dropped a leak may have occurred The leak should be corrected and the oil should be leveled off to the oil level plug location 5 Reinstall plugs 45 025 REV 10 13 onc REACH A Division of Allied Systems Company Part Number YGC 48 YGC 49 YGC 49 LH YGC 50 and YGC 50 LH 1 The grease in the gearbox will not need to be filled or changed unless the gearbox itself has been serviced 2 Remove the top and back plugs from the gearbox and completely fill with Mobilux EPO or equivalent grease Figure 4 13 Figure 4 13 Gearbox Grease Plugs 3 Lay the gearbox with the pinion gear down and
10. onc REACH A Division of Allied Systems Company Installation Maintenance and Service Manual SQ Series Forging Clamps amp NSQ Series Clamps Allied www alliedsystems com COMPANY 21433 Oregon Street Sherwood OR 97140 USA Phone 800 285 7000 Fax 800 231 3273 45 084 9 2012 Section 1 Nameplate Location 3 Section 2 Safety Summary eeeeeees 4 2 1 Safety INPOPMALON vcsccccotdccisscecteessecceeees 4 2 2 Safety ASQUIAUONS iecchsinveststatsnetiiencetiices 4 2 3 Safety SYMONS ccd viccicsercncassacteciaienicenatye 4 2 4 Operation WarningS ceeeeeeeee 4 2 6 Electrical HAZOIGS sicicscessnnnseaniteierssaannnts 5 2 7 Maintenance Warnings 2 c 5 2 8 IAIN spain sascendccrentastatateorernecaenamuneees 6 es Hl 0196 Deere reper eee etree ee emer manera 6 2 10 Pre start CHECKS iirsceuusaireeissavieteonnonnenecee 6 2 11 Personnel Saleny sxctansccanssrnceceeticeecincs 6 2 12 Load Handling s 7 2 13 Load Positioning eee 7 2 14 Operators Controls cissicissseiciecvocesnner 8 Section 3 Installation Procedure 9 3 1 Truck Requirements 9 9 2 CANA S eiea eE 9 3 3 HydrauliCS xc cxsunntscesorseunnsstoosantomunanen 9 3 4 Attachment Installation ee 9 Section 4 Service Procedure 12 4 1 Attachment Removal 0cccccceeee 12 4 2 Arm REMOVAI ccccccceceesseeseseseeeeeeees 12 TABLE OF CONTENTS Allied COMPANY 4 3 Arm Installati
11. 2005 reaffirmed 2000 Make sure the truck carriage is clean conforms to ANSI recommendations and the notches are not damaged Notice The model description found on your shipped invoice states the following truck requirements flow gpm psi and minimum truck carriage width 3 3 Hydraulics 1 45 025 REV 10 13 The truck hydraulic system must supply to the at tachment hydraulic oil that meets the specifications required to operate the attachment properly 2 When the truck hydraulic system pressures exceed this maximum a relief valve is recommended in the attachment auxiliary system of the truck or on the attachment Consult the truck factory and or Long Reach for guidance 3 4 Attachment Installation 1 Prior to connecting the truck hydraulic system to the attachment the system must be purged through the filtration system This will eliminate any contamination that might exist in the auxiliary hydraulic system of the truck The capacity of the truck and attachment combination may be less than the capacity shown on the attachment alone Consult truck nameplate 2 Purging can be accomplished by installing a jumper line and operating each hydraulic function clamp rotate and side shift if equipped in each direction for a minimum of 30 seconds Figure 3 1 CO To truck Ti To clamp Figure 3 1 Jumper Line Allied COMPANY 3 4 1 ITA Hook Type Mounting 1 Remove the lower bolt on h
12. O ring Seal T L A Detail A Gland cap Wiper ring Y Nal Koa Cylinder rod ITN o q Locknut S CSI f j Cylinder rod Piston Wear ring BED Z Detail A Figure 4 10 Gland Cap Seal 15 4 Install the piston on the rod and tighten the locknut to 70 75 ft lbs 5 Spray the inside of the cylinder tube with lubricant to ease inserting the rod and piston Insert the rod and piston into the cylinder tube Tap the rod in with a rubber mallet if resistance is encountered 6 Install the gland cap on the cylinder rod being ex tremely careful not to cut the rod seal on the threads of the rod or rod shoulder If available use a sleeve to cover the rod threads or plastic electrical tape 7 Tighten the gland cap using a spanner wrench 4 9 Pinion Ring Gear and Bearing 1 Greasing of the pinion ring gear should be done every 40 hours Greasing of the ring gear bearings should be done every 100 hours See Section 5 If gears are not greased properly premature wear on gears may occur Wear on gears may affect performance or safety and result in loss of warranty 2 Grease the pinion ring gear with Mobil lubricating grease NLGI grade 2 ISO 220 or equivalent 3 Gease the ring gear bearings with Aeroshell 22 grease or equivalent 4 To ensure proper greasing of
13. Y YXE4C 307 1 2 x 1 2 x 2 00 steel supplemental locking lug 1 16 clearance Locking lug in notch Figure 3 3 Locking Lug 7 Install the bolt on lower hooks Inspect clearance to the carriage on lower hooks Adjust the lower hooks for a maximum clearance of 3 32 see Figure 3 4 Tighten the bolts to 40 50 ft lbs 3 32 E maximum clearance p Shim s if required Figure 3 4 Lower Hook Clearance 8 If quick hooks are installed simply raise the slide plate until the button clicks into place If the slide plate does not click into place because the truck carriage prevents the slide plate from being raised up high enough install shims between the attachment and the body of the quick change hooks Slide plate must click into place 45 025 REV 10 13 onc REACH A Division of Allied Systems Company 9 To ensure proper locking of the slide plate use a screwdriver to try to pry down the slide plate If the slide plate is not locked in place inspect and correct any cause that might restrict the slide plate from going up enough to allow the button to become fully engaged 3 4 2 Pin Type Mounting 1 45 025 REV 10 13 Install the pin mount attachment to the truck carriage as described in the truck manufacturer s installation instructions Using the attachment as a template weld on the bracket lugs supplied with the attach ment to lower bar on the truck carriage Figure 3 5
14. actory or Long Reach 2 14 Operator s Controls For clarity the direction of arm movement is shown on the control handle To move the arms in the direction shown pull the handle towards the operator To move the arms in the opposite direction the push the handle away from the operator Notice OSHA or state regulations may require the installation of backrests We suggest that you check your application against those requirements Fork position Push pull Rotate Sideshift Figure 2 5 8 Allied 45 025 REV 10 13 COMPANY onc REACH A Division of Allied Systems Company SECTION 3 INSTALLATION PROCEDURE 3 1 Truck Requirements Long Reach attachments have been designed to oper ate within specific limits Operating pressures above the stipulated maximum may cause structural damage to the attachment and may result in loss of warranty Hydraulic flow less than the recommended rates or the use of small D hoses may reduce operating speed Higher flow can result in excessive heat buildup erratic operation and damage to the truck attachment hydraulic system Notice The dealer and or the user are responsible for installing any valving required to meet the recommended hydraulic pressures and flow The required valving can be furnished by the dealer the truck factory or Long Reach 3 2 Carriage 1 The truck carriage must conform to the American National Standard ANSI dimensions shown in ANSI ITSDF B56 11 4
15. arge bearing cup in the gear cap will need to be removed with a bearing puller Allied COMPANY 8 Wipe as much grease out of the housing as possible with a rag and inspect for any foreign particles The oil seals may now be serviced Note the orienta tion of the seals Figure 4 25 Figure 4 25 Pinion Shaft Seals Remove the worm cap and motor adapter Make note of any installed shims Capscrews are installed with Loctite use a long handle wrench to break loose Use a large screwdriver and hammer to separate the worm cap from the housing Note any installed shims Figure 4 26 Do not damage the machined surfaces of the worm cap and housing ee Motor adapter Figure 4 26 Worm Cap Motor Adapter 45 025 REV 10 13 onc REACH A Division of Allied Systems Company 11 The seal in the motor adapter can now be replaced 4 42 Gearbox Assembly Figure 4 27 Part Number YGC 48 YGC 49 YGC 49 LH YGC 50 12 Using a rubber mallet lightly tap on the extended and YGC 50 LH housing lowing suggestions to insure leak free operation and long seal life A Cover the keyway and any other surface discon Motor Adapter tinuity with smooth tape to protect the seal lip from being damaged B A sealant should be used between the O D Of the seal and the I D Of the bore into which the seal is installed The seal bore should also be free of any burrs nicks or scratches C Be sure that the seal is not
16. cocked in the seal bore The outer face of the seal should be flush with the surface into which it is mounted 2 Press on the bearing cup for the worm gear shaft into the housing on the worm cap side 3 Install the worm cap and shims if applicable Figure 4 27 Motor Adapter Seal Notice Use Loctite blue on all capscrews See Notice Section 4 15 for Torque Specifications The bearing cup on the motor adapter side of the housing will need to be 4 Place the bearing cones on both ends of the worm removed with a bearing puller gear shaft and install into the housing 13 Wipe as much grease out of the housing as possible 5 Press on the bearing cup for the worm gear shaft with a rag and inspect for any foreign particles into the housing on the motor adapter side 6 Install the motor adapter and shims if applicable 7 Press on the small bearing cup for the pinion shaft into the housing 8 Press on the large bearing cup for the pinion shaft into the gear cap 9 Slide the gear cap onto the pinion shaft 10 Slide on the large bearing cone onto the pinion shaft 11 Press the gear onto the pinion shaft to the large bearing 12 Slide on the small bearing cone onto the pinion shaft and secure with the snap ring 45 025 REV 10 13 Allied 21 COMPANY 13 Install the pinion shaft assembly and shims if ap plicable Figure 4 28 14 Remove grease plugs and completly fill with grease See section 4 10 F
17. d with front end attachments other than factory installed attachments truck must be marked to identify the attachments and show the approximate weight of the truck and attachment combination at maximum elevation with load laterally centered 2 10 Pre start Checks Check your equipment before you operate it If any thing looks wrong unusual or different report it before using the attachment Do not operate this machine if you know of malfunc tions missing parts and or mis adjustments These situations can cause or contribute to an accident or damage to the machine Stop the machine immedi ately if problems arise after starting Check to make sure the attachment on your truck is the same as on the truck capacity plate Check for hydraulic leaks and cracked hoses or fittings Check the hydraulic oil level in the lift truck hydraulic reservoir All electrical cables and connectors must be in good condition Use caution in wet weather to avoid danger from electrical shock Always check the attachment for proper fit and en gagement of the truck carriage 2 11 Personnel Safety When removing or installing dismountable at tachments always keep hands and feet free from dangerous positions or pinch points Never leave a dismounted attachment in a dangerous position Keep hands feet long hair and clothing away from power driven parts Do not wear loose fitting clothing or jewelry while performing maintenance and lubrica tio
18. d Systems Company N MODEL N SERIAL NO MAXIMUM HYD PRESS PSI WEIGHT LBS CAPACITY LBS inch LG SEE TRUCK NAMEPLATE FOR COMBINED TRUCK amp ATTACHMENT NET CAPACITY LOST pe inches fae inches LOAL inches Ne CG AND AET SPECIFICATIONS ARE APPROXIMATE ET SD Manufactured By Allied Systems Company 21422 Oregon Street Sherwood OR 97140 USA O www alliedsystems com 2500005 R Oj 45 025 REV 10 13 Allied COMPANY SECTION 2 SAFETY SUMMARY 2 1 Safety Information Safety is Everyone s Responsibility Whether you are new on the job or a seasoned veteran these safety tips may prevent injury to you to others or to the materials you are handling Always be alert watch out for others and follow these suggestions A Attachments handle material not people Safety starts with common sense good judgement properly maintained equipment careful operation and properly trained operators The safety instructions and warnings as documented in this manual and shipped with the machine provide the most reliable procedures for the safe operation and maintenance of your Long Reach attachment It s your responsibility to see that they are carried out 2 2 Safety Regulations Know your company s safety rules Some companies have site specific directions and procedures The meth ods outlined in your operator s manual provide a basis for safe operation of the machine Because of special condi tions your company
19. e load positioned as close as possible to the horizontal center of the lift truck Always back down ramps or inclines Driving forward down a ramp or incline with a clamped load will lessen the stability of the truck Figure 4 Figure 4 Do not cross dock boards or dock levelers with the attachment or carriage fully lowered Ramming the front or rear of the attachment against a dock board can cause severe damage Limit lift truck movement to a minimum when high stacking Limit sideshift movement to a minimum when high stacking Always be observant when high stacking Look for poorly stacked loads overhead obstacles broken cartons or damaged products in the stack Travel slowly around corners Sound horn on blind corners Be careful of tail swing and overhead clear ances Watch in all directions Avoid sudden stops Allied COMPANY 2 13 Truck Requirements Prior to connecting the truck hydraulic system to the at tachment the truck hydraulic system must be cleaned through the filtration system This will eliminate any contamination that may exist in the auxiliary hydraulic system of the truck The capacity of the truck and attachment combined may be less than the attachment capacity Consult truck nameplate Notice The dealer and or the user are responsible for installing any valving required to meet the recommended hydraulic pressures and flow The required valving can be furnished by the dealer the truck f
20. erse order Use Loctite blue on all Capa CTAN tee SENGA NS Or Torque paci 3 Place the gearbox on a flat surface and remove the eanons motor mounting capscrews Figure 4 23 Notice 4 Remove the capscrews from the gear cap The gear It is important to get oil to the worm and cap capscrews are installed with Loctite use a long worm bearings Before reinstalling dip handle wrench to break loose Using a large screw the worm and worm bearings in oil for driver and hammer separate the gear cap from the proper lubrication of these elements See housing Figure 4 23 Section 4 10 Screwdriver Figure 4 23 Motor Gear Cap Removal Figure 4 21 Input shaft 45 025 REV 10 13 Allied 19 COMPANY Do not use an impact wrench on the screws that have been secured with Loctite this could result in rounded heads or broken sockets Do not damage machined surfaces of the gear cap and housing Figure 4 24 Pinion Shaft Remove the pinion shaft assembly Figure 4 24 Remove the snap ring from the end of the pinion shaft Figure 4 24 Place the assembly in a press supporting the gear cap not the pinion shaft Press the pinion shaft through the small bearing and the worm gear At this point the small bearing worm gear and large bearing are loose and can be lifted out of the housing Figure 4 24 20 Do not drop the pinion shaft onto a hard surface or it may chip Notice The small bearing cup in the housing and the l
21. f the capscrew and the threaded hole Reapply Loctite 242 on the capscrew threads and in the threaded hole Re torque the capscrew 2 000 Hour or 12 Month Maintenance Replace oil in the gearbox YGC 29 YGC 32 YGC 43 and YGC 43 LH Allied 29 COMPANY
22. f you need to leave the lift truck A lift truck supporting a load requires your full attention 45 025 REV 10 13 ONG REACH A Division of Allied Systems Company 2 5 Hydraulic Hazards Danger Small hydraulic hose leaks are extremely dangerous and can inject hydraulic oil under the skin even through gloves Infection and gangrene are possible when hydraulic oil penetrates the skin See a doctor immediately to prevent loss of limb or death e Wear personal protective equipment such as gloves and safety glasses whenever servicing or checking a hydraulic system e Assume that all hydraulic hoses and components are pressurized Relieve all hydraulic pressure before disconnecting any hydraulic line e Never try to stop or check for a hydraulic leak with any part of your body use a piece of cardboard to check for hydraulic leaks 2 6 Electrical Hazards Remain at least 25 feet from high voltage electrical wires Failure to do so may result in injury or death and will damage equipment All electrical cables and connectors must be in good condition free of corrosion damage etc Use cau tion in wet weather to avoid danger from electrical shock Never attempt electrical testing or repair while standing in water Do not wear electrically conductive jewelry clothing or other items while working on the electrical system 2 7 Maintenance Warnings Maintenance lubrication and repair of this machine can be
23. fill the gearbox from the top plug hole allowing traped air to escape through the back plug hole until grease is present in the back plug hole 4 To fill gearbox mounted to back plate fill gearbox from the back plug hole allowing traped air to escape through the top plug hole until grease is present in the top plug hole 5 Reinstall the plugs 4 11 Gearbox Disassembly Part Number YGC 29 YGC 32 YGC 43 and YGC 43 LH 1 Remove the attachment from truck See Section 4 1 2 Before removing the gearbox from the back plate place a support overhead or under the gearbox Remove the mounting capscrews from the gearbox Figure 4 14 Back Plate Capscrew Figure 4 14 Gearbox Removal 3 Place the gearbox on a flat surface and remove the motor mounting capscrews Note coupling fits loose and may slide out Figure 4 15 Figure 4 15 Motor Removal 4 Remove the pinion gear and key from the output shaft Use a screwdriver to knock loose the key 45 025 REV 10 13 Allied 17 COMPANY Do not use a impact wrench on the screws that have been secured with Loctite this could result in rounded heads or broken sockets 5 Remove the capscrews from the adapter plate The adapter plate capscrews are installed with Loctite use a long handle wrench to break loose Lightly tap the back of the adapter plate with a rubber mallet to remove Figure 4 16 Capscrew Figure 4 16 Adapter Plate Removal
24. igure 4 28 Pinion Shaft Assembly 4 13 Motor Disassembly 1 Remove the motor from gearbox 2 Place the motor in a vice and clamp across the edge of the flange with output shaft down When clamping use a protective device on the vise such as special soft jaws pieces of hard rubber or board Figure 4 29 Figure 4 29 Motor Clamping 22 Allied COMPANY 3 Remove the capscrews and seal washers if ap plicable from the end cap The seal on the end cap can now be serviced Figure 4 30 4 Remove the gerotor and the drive spacer if appli cable The seal on the gerotor can now be serviced Figure 4 31 N Capscrew ol Washer Figure 4 30 End Cap Drive men DN Figure 4 31 Gerotor 5 Remove the drive and the spacer plate The seal in the housing can now be serviced Figure 4 32 Seal Spacer plate Figure 4 32 Drive 45 025 REV 10 13 onc REACH A Division of Allied Systems Company 6 Remove the output shaft and the needle thrust bear ing from the housing 7 Reposition the motor in the vise Clamp the motor across the ports as shown in Figure 4 33 Do not clamp on the side of the housing Excessive clamping pressure on the side of the housing causes distortion 13mm 1 2 in 13mm 1 2 in Figure 4 33 Motor Port Clamping 8 Remove capscrews from the mounting flange These capscrews are installed with Loctite and will require 300 400 Ib in of torque to brea
25. ing flange Figure 4 35 Use a seal removal tool Figure 4 36 and 4 37 to remove the exclusion and pressure seals Notice Be careful not to scratch the seal cavity O D This could create a leak path Work from the outer side for both either seals A metal plug with seal plugs a machining hole in the housing It is not necessary to remove the plug and replace seal unless leakage occurs around the plug To remove the plug insert a 5 mm 187 in hex key through the port opening and push it out Figure 4 38 Allied COMPANY Pressure Seal Seal N 9 L Back Up Ring C Mounting Flange Exclusion Seal Figure 4 35 Mounting Flange Seals Bend tip Radius Modify i Modify screwdriver i screwdriver as shown AJ Radius as shown Remove on end Remove all burrs all burrs Figure 4 36 seal Removal Tool Mounting k Pressure Seal Back up Ring Exclusion Seal Removal Tool Seal Figure 4 37 Seal Removal Figure 4 38 Housing Plug 45 025 REV 10 13 onc REACH A Division of Allied Systems Company 4 14 Motor Assembly install on plug Some plugs have two O ring grooves 1 Check all mating surfaces Replace any parts with but require only one O ring Install O ring in groove scratches or burrs that could cause leakage or dam closest to the end of the plug Push the plug into the age Clean all metal parts in clean solvent Blow dry housing so the plug and housing are flush Be careful w
26. is recommended to apply a light coat of Loctite Primer NF in tapped holes of housing Allow primer to air dry for at least 1 minute Do not force dry with air jet the primer will blow away Allied COMPANY 11 l2 Notice The use of primer is optional With primer Loctite curing time is approximately 15 minutes Without primer curing time is approximately 6 hours Apply 3 or 4 drops of Loctite sealant at the top of the threads for each of the four holes in the housing Do not allow parts with Loctite applied to come in contact with any metal parts other than those for assembly Wipe off excess Loctite from the housing face using a non petroleum base solvent Notice Do not apply Loctite to threads more than 15 minutes before installing capscrews If the housing stands for more than 15 minutes repeat application No additional cleaning or removal of previously applied Loctite is necessary Before installing the mounting flange and seal as sembly over the shaft place a protective sleeve or bullet over the shaft Then lubicate the space be tween the exclusion seal and pressure seal as well as the lips of both seals Figure 4 42 Apply petroleum jelly across this area Output Shaft Dust Seal This lip to face inward Pressure Seal Seal l Bearing Interior of Race motor Figure 4 42 Output shaft Lubrication 45 025 REV 10 13 ONG REACH A Division of Allied Systems Company 13 Install
27. ith air not to damage the seal 4 Lubricate the output shaft with hydraulic oil then install Do not wipe parts with a cloth or paper sae ae eitia hydraul systemi Do not permit oil to get into the four ge tapped holes 2 Check around the key slot and chamfered area of the shaft for burrs nicks or sharp edges that could damage seals during reassembly Remove nicks or burrs with a hard smooth stone such as an Arkansas stone Do not file or grind motor parts 5 Install the needle thrust bearing then the bearing Notice Lubricate all seals with petroleum jelly Use new seals when reassembling motor Refer to parts coverage Do not stretch seals before installing Figure 4 39 Output Shaft them Lubricate these areas Needle thrust bearing race onto the output shaft Pull the output shaft Notice partially out of the housing Push all three parts into Fully cured Loctite resists most solvents the housing together Figure 4 40 The bearing race oils gasoline and kerosene and is not must rotate freely when in position affected by cleaning operations It is not necessary to remove cured Loctite that is securely bonded in tapped holes however any loose particles of cured Loctite should be removed A Wash the housing with solvent to remove oil grease and debris Pay particular attention to four tapped holes on the flange end B Blow dry with compressed air Clean and dry tapped holes re Figure 4
28. k loose and 100 Ib in of torque to remove Do not use a impact wrench on the screws that have been secured with Loctite This could result in rounded heads or broken sockets Notice If more torque than recommended above is required to break capscrews loose apply heat according to the following instructions A Loctite partially melts when heated This reduces torque required to remove the capscrew Use a small flame propane torch to heat a small area of the housing where the capscrew enters Figure 4 34 Be careful not to overheat the housing and damage the motor Gradually apply torque to the capscrew with a socket wrench as heat is applied for 8 to 10 seconds As soon as the capscrew breaks loose remove heat from the housing Continue turning the capscrew until it is completely removed 9 Carefully remove the mounting flange from the housing Heat with a propane torch to melt Loctite ca 7 Mounting Flange Figure 4 34 Capscrew Loctite 45 025 REV 10 13 Allied 23 COMPANY Notice Some motors may have a quad seal and back up ring instead of the pressure seal The quad seal and back up ring are no longer available and are replaced by the pressure seal They are interchangeable but some precautions must be taken to insure proper installation Follow the reassembly instructions in Section 4 24 10 The exclusion seal back up ring pressure seal and 11 12 24 seal will come off with the mount
29. l into the gerotor seal groove Carefully place the gerotor onto the spacer plate seal side toward the spacer plate For standard rotation align any star point with the marked tooth on the drive Figure 4 44 Gerotor Gerotor Seal lt 1h opr Spacer Plate Dot Housing Forward Valving Slot Figure 4 44 Standard Rotation 45 025 REV 10 13 Allied 27 COMPANY 22 For reverse rotation align any star valley with the marked tooth on the drive Figure 4 45 Bey Z Oo 23 Rotate the gerotor to line up the bolt holes Be careful MO T a not to disengage the star from the drive or disturb Gerotor seal a the gerotor seal 24 Install the drive spacer if applicable ee plate 25 Install 73 mm 2 875 in seal into the end cap Care l fully place the end cap on gerotor Housing 26 Install the capscrews and seal washers if applicable into the end cap Pretighten the capscrews to 40 Ib in Make sure the seal washers are properly seated Then torque the capscrews to 235 250 Ib in Figure 4 45 Reverse Rotation 4 15 Torque Specifications The following torque values are to be used on all fasteners unless otherwise specified Lubricated refers to fasteners in the As Received condition which is normally a light preservative oil coating on unplated fasteners and no oil coating on plated fasteners No special steps are taken to add further lubrication prior to assembly Dry refers t
30. n in these areas Never jump on or off the machine Never stand on top of material being raised lowered or transported Figure 1 45 025 REV 10 13 45 025 REV 10 13 ONG REACH A Division of Allied Systems Company Figure 3 Never use the attachment or its load to support a man carrying device Never allow anyone under a load or under the car riage Figure 2 Never stand in front of or beside an attachment that is being operated Never allow another person to ap proach an attachment that is being operated Figure 3 Never leave an attachment or load in an elevated position Never reach through the mast of the truck Keep all parts of the body within the drivers compartment Always operate an attachment from the operators seat never while standing next to the lift truck Do not allow riders on the truck at any time Always use reverse when carrying a load that impedes full vision Watch for pedestrians when transporting Always use personal protective equipment PPE appropriate to the situation 2 12 Load Positioning Be accurate in load placement It s important to know what the load will do when it s released Always carry loads as close to the floor as possible consistent with the surface being traversed Scraping or bumping the floor surface with the load or the at tachment can severely damage the attachment and cause product damage The mast should be tilted back Always keep th
31. nd cap 45 025 REV 10 13 onc REACH A Division of Allied Systems Company 4 7 Cylinder Inspection Inspect the cylinder tube bore for 1 Deep scratches or nicks 2 Signs of galling or excessive wear 3 Out of roundness or deformities of the barrel Inspect the piston for 1 Scratches or nicks on seal grooves 2 Wear on O D Inspect the cylinder rod for 1 Scratches or nicks on the rod surface 2 Straightness of the rod 3 Damaged threads Inspect the gland cap for 1 Scratches or nicks in seal grooves 2 Damaged threads or spanner wrench holes 3 Excessive wear in bore Replace any component found to be defective 4 8 Cylinder Assembly 1 Spray the piston gland cap and seals with WD40 or other similar product to ease slipping of the seals in place 2 Note the direction of the seal on the piston Improper installation will result in poor performance The cupped side or O ring side of the seal should be facing the gland cap Figure 4 9 3 Install the seals and wipers in the gland cap Note the direction of the seals The cupped side or O ring side of the seal should be facing the piston Figure 4 10 45 025 REV 10 13 Allied COMPANY a Sy DETAIL A i Nae eG 4A ace X EAL L Cylinder Rod E i Z Piston Wear Ring Figure 4 9 Piston Seal Backup ring
32. o parts that have been degreased both mating parts GRADE 8 COURSE THREAD GRADE 5 COURSE THREAD SOCKET HEAD COURSE THREAD 1 4 129 in Ibs 1 4 1 4 150 in Ibs 5 16 23 ft lbs 5 16 5 16 26 ft lbs 3 8 40 3 8 3 8 46 7 16 63 7 16 7 16 74 1 2 96 1 2 1 2 9 16 9 16 9 16 5 8 5 8 5 8 3 4 3 4 3 4 7 8 7 8 7 8 1 1 1 1 1 8 1 1 8 1 1 8 1 1 4 1 1 4 1 1 4 1 3 8 1 3 8 1 3 8 1 1 2 1 1 2 1 1 2 28 Allied 45 025 REV 10 13 COMPANY onc REACH A Division of Allied Systems Company SECTION 5 MAINTENANCE SCHEDULE Daily Maintenance 1 Check level of hydraulic oil in the truck reservoir and add oil if necessary Visually inspect all hoses and fittings for signs of hydraulic leaks Visually inspect for external damage or cracks Inspect lower hooks for proper clearance Maximum clearance is 3 32 of an inch If the attachment is equipped with quick change hooks check the slide plate latch for engagement Weekly 40 Hour Maintenance 1 45 025 REV 10 13 Inspect all hoses and fittings for wear or damage Inspect for hydraulic leaks Check for loose or missing bolts Grease the pinion ring gear See Section 4 9 Check for foreign matter between the arm slides and the bocy Foreign matter may lead to uneven arm movement or galling of the slides or body On NSQ models Do NOT grease plastic wear strips Notice In wet or humid conditi
33. on 13 4 4 Cylinder Removal cceeeeeeees 13 4 5 Cylinder Installation 13 4 6 Cylinder Disassembly eee 14 4 7 Cylinder Inspection ceeeeeeees 15 4 8 Cylinder ASSemDIy ceeeeeeeees 15 4 9 Pinion Ring Gear and Bearing 16 4 10 Gearbox Lubrication sic cseerecctsieccees 16 4 11 Gearbox Disassembly 17 4 12 Gearbox Assembly ceeeeeeees 21 4 13 Motor Disassembly ccceeee 22 4 14 Motor Assembly soseen 25 4 15 Torque Specifications 28 Section 5 Maintenance Schedule 29 Daily Maintenance ccceeeeeeceeees 29 Weekly 40 Hour Maintenance 29 100 Hour Maintenance s 29 500 Hour Maintenance n 29 2 000 Hour or 12 Month Maintenance 29 45 025 REV 10 13 ONG REACH A Division of Allied Systems Company SECTION 1 NAMEPLATE LOCATION Notice When you receive your attachment locate the Long Reach nameplate upper left corner on the body Record the information from the nameplate along with the date received at the bottom of this page If the nameplate is missing look for the serial number stamped directly into the metal at the nameplate location and consult the factory for details Date received ONE Rah prtson ot Allie
34. ons inspect slides for corrosion build up Remove rust or corrosion and regularly apply a dry anti corrosion spray such as marine molycoat or equivalent On SQ models Check that arm and slides are clean and lubricated Keeping the arm slides greased with a multi purpose polymer fortified grease such as DuBois Chemical MPG 2 will prevent excess wear For high temperature applications use Alpha 2000 high temp grease Gun barrel grease the insides of the body sections and wipe off excess 100 Hour Maintenance Grease the ring gear bearing assembly See Section 4 9 500 Hour Maintenance 1 Inspect base and lower retainer for hairline cracks or signs of structural failure particularly at the welds If welding is required to make a structural repair consult Long Reach before proceeding 2 Visually inspect ring gear bearing seals to ensure they are properly inserted into their grooves and that they are fully intact preventing contaminants from entering the bearing 3 Re torque the fork bars front plate and ring gear bearing capscrews Earlier models used 5 8 UNF capscrews that should be torqued to 185 ft lbs Later models use 5 8 UNC capscrews that should be torqued to 155 ft lbs Check the parts section of this manual to determine if you use Y74G 1032 5 8 UNF or Y73G 1032 5 8 UNC capscrews 1 2 UNC capscrews should be torqued to 77 ft lbs 4 facapscrew moves during re torque remove it and clean the Loctite of
35. ooks and if applicable make a note of any factory installed shims Shims are used to create clearance between the hook and car riage If the attachment is equipped with quick change hooks simply depress the button on the back of the hooks allowing the slide plate to drop Removal of the quick change hooks is not recommended Figure 3 2 Raise slide to secure attachment to truck Push button y to lower slide Figure 3 2 Quick Change Hook 2 Center the truck behind the attachment and drive toward the attachment with the mast tilted forward approximately 4 degrees 3 Line up the locking lug under the hanger plate if applicable with the appropriate notch on the truck s carriage Check that the bronze side shifting wear strips are in the proper place if applicable 4 Slowly raise the truck carriage completely to engage the top hooks with the truck carriage Tilt carriage back until the unit is against the carriage bottom fork bar 0 degrees 5 Inspect for proper engagement of the locking lug in the corresponding notch of the truck s carriage Inspect any wear strips if applicable to insure they are properly aligned in the top hooks 6 Weld on the supplemental locking lug that is sup plied with the attachment two pieces of 1 2 x 1 2 x 2 00 steel included with the attachment with either E 6011 or E 6013 welding rod or equivalent on each side of the truck carriage Figure 3 3 10 z Allied COMPAN
36. p to support the weight when re moved from the arm lug Activate the hydraulics and retract the cylinder to the fully closed position 45 025 REV 10 13 Before disconnecting any hydraulic connections be sure to turn off the truck s power and activate the truck s hydraulic functions in both direction to bleed off the hydraulic pressure Turn off the truck s power and activate the hydraulic functions in both directions several times to relieve built up hydraulic pressure Disconnect the hydraulic connections Remove the cylinder base end pin and cotter pin The cylinder now can be removed from the attachment 4 5 Cylinder Installation 1 Install the cylinder base end pin to the body and in sert the cotter pin if applicable Bend out the cotter pin ends to lock Apply a thin coat of bearing grease to the spherical and concaved portion of the flush nut if applicable Screw on the flush nuts or castle nuts until they stop Back the nut off while lining up the cotter pin hole in the rod end stud with the slot in the flush nut Do not tighten the flush castle nut tight to eliminate all clearance between washer and arm lug Adjust to allow 1 16 to 1 8 of an inch clearance between the rod end washer and the arm lug Figure 4 3 and Figure 4 4 Cylinder fad gt lt 1 16 To 1 8 clearance Figure 4 3 Arm Lug with Flush Nut Lug Cylinder rod L oa nut y
37. the mounting flange Rotate the mounting flange slowly while pushing down over the shaft Be careful not to invert or damage the seals 14 After removing the bullet clamp the motor in a vise Make sure the shaft cannot fall out Install dry cap screws and alternately torque them immediately to 250 Ib in If you use a primer allow to cure for 10 to 15 minutes Without primer allow 6 hours for cur ing time before subjecting the motor to high torque reversals On all other applications you can run the motor immediately Figure 4 43 1 Figure 4 43 Motor Clamping Notice If you use new capscrews make sure they are the correct length 22mm 875 in under head length See parts coverage for correct part number 15 Reposition the motor with the geroter end up then clamp the motor across the ports 19 20 21 To aid the installation of seals apply a light coat of clean petroleum jelly to seals Do not stretch the seals before installing them in groove Pour approximately 35 CC of clean hydraulic oil into the output shaft cavity Install 73 mm 2 875 in I D seal into the housing seal groove Avoid twisting the seal Install the drive Use a felt tip marker to mark one drive tooth Align this tooth with the timing dot on the shaft Notice If the drive is not symmetrical install the larger splined end into the shaft Install the spacer plate Install 73 mm 2 875 in I D sea
38. ttachment is equipped with quick change hooks simply press the slide plate release button and drop the slide plate down Figure 4 1 m Raise slide to secure attachment to truck Push button y to lower slide Figure 4 1 Quick Change Hook Position the attachment on the edge of a pallet Lower the attachment so that the lower carriage bar misses the pallet when lowered Tilt the mast forward to allow the carriage to disengage from the upper mounting hooks and back away If lowering onto a floor blocks of wood can be place under the body of the attach ment to raise the rear To reinstall follow the installation procedure in this manual Allied COMPANY 4 1 2 Pin Type Mounting i 2 Remove the two lower retaining bolts Position the attachment on the edge of a pallet Lower the attachment so that the lower carriage bar misses the pallet when lowered Remove the retaining pins from the the carriage to disengage the attachment from the truck and back away If lowering onto a floor blocks of wood can be place under the body of the attachment to raise the rear To reinstall follow the installation procedure in this manual When hydraulic service has been performed activate the hydraulic functions several times to bleed out trapped air in the system before returning attachment to service 4 2 Arm Removal i Extend the arms outside of the body Remove the cotter pin retaining the flush nut Remove the flush
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