MAINTENANCE AND SERVICE MANUAL PHA
Contents
1. RG adh of ied Systems Company e UN MODEL NO SERIAL NO MAXIMUM HYD PRESS PSI WEIGHT LBS CAPACITY LBS inch LC SEE TRUCK NAMEPLATE FOR COMBINED TRUCK amp ATTACHMENT NET CAPACITY LOST HOR inches VERT inches LOAL inches CG CG CG AND SPECIFICATIONS ARE APPROXIMATE J Manufactured By Allied Systems Company o 2142 Oregon Street Sherwood 97140 USA Date Received www alliedsystems com 2500005 gt L Class Il Mounting Perry Hook 45 046 REV 3 08 Allied COMPANY SECTION 2 SAFETY SUMMARY 2 1 General 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 Attachments Handle Material Not People SAFETY STARTS WITH COMMON SENSE GOOD JUDGEMENT PROPERLY MAINTAINED EQUIPMENT CAREFUL OPERATION AND PROPERLY TRAINED OPERATORS 1 Check your equipment before you operate it 2 Checkto make sure the attachment on your truck is the same as on the truck capacity plate 3 Check for hydraulic leaks and cracked hoses or fittings 4 Check the hydraulic oil level in the lift truck hydrau lic reservoir 5 Check for p2. onc Reach MAINTENANCE AND SERVICE MANUAL PHA 45 046 REV 3 08 Allied COMPANY TABLE OF CONTENTS SECTION 1 MODEL IDENTIFICATION 2 SAFETY SUMMARY 2 1 GENERAL INFORMATION 2 2 LOAD 2 3 LOAD 2 4 OPERATION CONTROLS SECTION PAGE 3 SERVICE PROCEDURE 3 1 ATTACHMENT REMONVAL 7 3 2 CYLINDER REMOWYAL 7 3 3 CYLINDER INSTALLATION 7 3 4 CYLINDER DISASSEMBLY 7 3 5 CYLINDER INSPECTION 8 3 6 CYLINDER 9 4 MAINTENANCE 4 1 MAINTENANCE SCHEDULE 10 4 2 TORQUE SPECIFICATIONS 10 4 3 22 2 000001 11 Allied 45 046 REV 3 08 COMPANY onc Reach SECTION 1 MODEL IDENTIFICATION Each clamp is identified by a model number and a serial number located on the attachment nameplate which is attached to the top of the unit prior to shipment Before ordering replacement parts for any unit be sure to use the correct parts list for your model number Both model number and serial number must be given to ensure that the correct parts are ordered NOTE The serial number is also metal stamped onto the plate under the identification plate O
3. 3 Extend the cylinder until the rod end hole lines up with the mounting hole Install the clevis pin and hair pin into the rod end of the cylinder 4 Turn on the trucks power and activate the positioning cylinders several times to bleed out trapped air WHEN HYDRAULIC SERVICE HAS BEEN PERFORMED BEFORE RETURNING AT TACHMENT TO SERVICE BE SURE TO ACTIVATE THE HYDRAULIC FUNCTIONS SEVERAL TIMES TO BLEED OUT TRAPPED AIR IN THE SYSTEM 3 4 Cylinder Disassembly 1 Remove the cylinder from the attachment See removal 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 3 1 b Figure 3 1 Cylinder Vise Allied COMPANY 3 Spread and remove the retaining ring from the gland cap 4 Push gland inward 1 inch and pry out lock ring 5 Remove the rod assembly from the cylinder tube 6 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 3 2 Figure 3 2 Cylinder Shaft 7 Remove the piston retaining nut and remove the piston Figure 3 3 Figure 3 3 Rod Assembly Allied COMPANY 8 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 3 4 Figure 3
4. 4 Piston Seal 9 Use the same procedure as above to remove the seals from the gland cap 3 5 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 bad 45 046 REV 3 08 onc Reach 3 6 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 Im proper installation will result in poor performance The cupped side or O Ring side of the seal should be fac ing the gland cap Figure 3 5 Piston Seal Piston Nut O Ring Cylinder Rod Figure 3 5 Piston Seal 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 3 6 Figure 3 6 Gland Cap Seal 45 046 REV 3 08 Allied COMPANY 4 Install the gland cap on the cylinder rod being ex tr
5. VICE PROCEDURE 3 1 Attachment Removal 1 Position the attachment forks to the width of the unit s body BEFORE DISCONNECTING ANY HYDRAU LIC CONNECTIONS BE SURE TO TURN OFF THE TRUCKS POWER AND ACTIVATE THE TRUCKS HYDRAULIC FUNCTIONS IN BOTH DIRECTIONS TO BLEED OFF THE HYDRAULIC PRESSURE 2 Disconnect the hydraulic connection for the attach ment positioning at the side shift cylinder 3 Slightly raise the truck carriage to allow the removal of the lower retainer hooks 4 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 attachment to raise the rear 5 To reinstall follow the installation procedure in this manual WHEN HYDRAULIC SERVICING HAS BEEN PERFORMED BEFORE RETURNING AT TACHMENT TO SERVICE BE SURE TO ACTIVATE THE HYDRAULIC FUNCTIONS SEVERAL TIMES TO BLEED OUT TRAPPED AIR IN THE SYSTEM 3 2 Cylinder Removal 1 Disconnect the hydraulic connections 2 Remove the cylinder rod end hair pin and clevis pin 3 Remove hair pin and clevis pin at the base end of the cylinder 45 046 REV 3 08 3 3 Cylinder Installation 1 Install the clevis pin and hair pin into the base end of the cylinder 2 Attach the hydraulic connections to the cylinder
6. arrying a load that impedes full vision 18 Watch for pedestrians when transporting Sudden stops can dislodge all or part of a load 2 2 Load Handling 1 All operators must be trained and qualified 2 Never overload the attachment Refer to the attachment nameplate for the rated capacity of the attachment Refer to the nameplate of the truck for the net working capacity of the truck and attachment Observe the lower of the two capacities The attachment capacity is the structural rating of the attachment and should not be exceeded Net work ing capacity is the truck manufacturer s rating of the truck attachment combination 3 Never use a load to support or move another object Do ing so can easily exceed the holding capacity of the attach ment causing loss of the load 4 Never lift lower side shift pivot rotate or tilt loads while traveling Repositioning loads while traveling affects the stability of the truck and may impede vision or clearances 5 Never speed or race a lift truck High speed adversely af 45 046 REV 3 08 Allied COMPANY fects the stability and steering of the lift truck 6 Do not use an attachment to open or close boxcar doors Doing so can severely damage the attachment and cause loss of warranty Damage to clamp arms may result in product damage 7 Do not carry loose items or unsupported loads on top of a clamped load 8 Never allow anyone under a load or under the carriage 9 N
7. emely 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 5 Install the piston on the rod and tighten the locknut to 90 ft lbs 0 56 UNF 22 ft lbs 0 75 UNF 6 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 rub ber mallet if resistance is encountered 7 Press on the lock ring and spread retaining ring to install onto the gland cap SECTION 4 MAINTENANCE 4 1 Maintenance Schedule 4 2 Torque Specifications Unless otherwise specified Daily 1 Visually inspect all hoses fittings and cylinder for signs of hydraulic leaks Nominal Size 2 Visually inspect for external damage or cracks 100 Hour Maintenance 1 Complete the above daily checks 2 Check all hoses and fittings for wear or damage Inspect for hydraulic leaks 3 Check for loose or missing bolts 4 On the forks and top hooks check grease fittings to ensure that they are clean and properly working 5 Check wearstrips on the top hooks Wearstrips should be replaced before top hooks contact carriage 200 Hour Maintenance 1 Re Torque top hook bolts per chart Notes Nominal Size 10 H Allied COMPANY SAE Grade 5 Capscrews Torque Ft Lbs K 0 20 K 0 15 8 6 10 7 Thread Series SAE Grade 8 Capscrews To
8. ever use chains cables or other devices in conjunction with an attachment for load handling 10 Never clamp loads other than what the attach ment was designed to handle 11 Travel slowly around corners Sound horn on blind corners Be careful of tail swing and over head clearances Watch in all directions Avoid sudden stops 12 Do not exceed the specified maximum operat ing pressure or flow for the attachment To do so can severely damage the attachment and cause loss of warranty 2 3 Load Positioning 1 Always operate an attachment from the driver s seat 2 Always lower the attachment if you need to leave the lift truck Remember a lift truck support ing a load requires your full attention 3 Never use the attachment or its load to support or move other loads or equipment 4 Always carry loads as close to the floor as pos sible consistent with the surface being traversed Scraping or bumping the floor surface with the load or the attachment can severely damage the attachment and cause product damage The mast should be tilted back 5 Always keep the load positioned as close as possible to the horizontal center of the lift truck 6 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 2 4 Figure 2 4 7 Do not cross dock boards or dock levelers with the attachment or carriage fully lowered Ramming the front or
9. hysical damage to the attachment If anything looks wrong unusual or different report it before using the attachment 6 When removing installing dismountable attach ments always keep hands and feet free from danger ous positions or pinch points Never leave a dismount ed attachment in a dangerous position 7 Checkto make sure that the dismountable attach ment is properly secured to the truck carriage before using the lift truck and attachment 8 Never stand on top of material being raised low ered or transported Figure 2 1 Allied COMPANY e 9 Never use the attachment or its load to support a man carrying device Figure 2 1 10 Never position an attachment or load over people Figure 2 2 Figure 2 2 11 Never leave an attachment or load in an elevated position 12 Never reach through the mast of the truck Keep all parts of the body within the driver s compartment 13 Never leave a lift truck unattended without lowering the load to the floor setting the brake and turning the truck off 45 046 REV 3 08 onc Reach 14 Always operate an attachment from the operators seat never while standing next to the lift truck 15 Never stand in front of or beside an attachment that is being operated Never allow another person to approach an attachment that is being operated Figure 2 3 16 Do not allow riders on the truck at any time Figure 2 3 17 Always use reverse when c
10. rear of the attachment against a dock board can cause severe damage 8 Always check loads to be handled If they are bro ken unbalanced loose or too heavy advise a supervi Sor or properly correct the situation prior to handling 9 Limit lift truck movement to a minimum when high stacking Limit sideshift movement to a minimum when high stacking 10 Always be observant when high stacking Look for poorly stacked loads overhead obstacles broken cartons or damaged products in the stack 11 Always carry cylindrically shaped loads in the verti cal position not the horizontal 12 Always clamp loads with the contact pads if ap plicable not the arm or arm base 13 Never rotate a load that is off center to the center line of rotation Severe damage to the rotator could result 14 Always check the attachment for proper fit and engagement of the truck carriage 2 4 Operator s Controls 1 For clarity the direction of arm movement is shown on the control handle To move the arms in the direc tion shown pull the handle towards the operator To move the arms in the opposite direction the push the handle away from the operator Clamp Fork Positioner Push Pull Rotate Side Shift Figure 2 5 NOTE OSHA OR STATE REGULATIONS MAY REQUIRE THE INSTALLATION OF BACKRESTS WE SUGGEST THAT YOU CHECK YOUR APPLI CATION AGAINST THOSE REQUIREMENTS 6 H 45 046 REV 3 08 Allied COMPANY onc Reach SECTION 3 SER
11. rque Ft Lbs Metis Dry Lubed K 0 20 K 0 15 Thread Series 45 046 REV 3 08 onc Reach 4 3 Lubrication Grease Fitting Locations Grease Fitting Locations Use NLGI Grade No 2 Multi Purpose Lithium Extreme Pressure Grease Figure 4 1 Grease Fitting Locations COMPANY
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