INSTALLATION, MAINTENANCE AND SERVICE MANUAL FMP
Contents
1. a SERIES USEABLE FMP Fork Mount PLATEN Push Pull LENGTH PLATEN 40 40 CAPACITY THICKNESS 44 44 30 3000 Ib capacity G 0 375 48 48 35 3500 Ib capacity H 0 500 45 4500 Ib capacity OPTIONS PLATEN ONO None WIDTH H55 LH Termination OPTIONAL Iaa FUNCTION dnd N Non Side Shift adi PLATEN MOUNTING MOVEMENT Fork Mounted N Fixed HOOK TYPE N A MOUNTING ANGLE N A 4 of 16 Allied stems 45 033 REV 05 10 PLP Series Model Number 3 5 5 4 R N O A Q 0 USEABLE SEHE a PLATEN PLP Quick Mount S Solid LENGTH Push Pull PLATEN 40 40 CAPACITY THICKNESS 44 44 30 3000 Ib capacity B 1 48 48 35 3500 Ib capacity G 0 38 45 4500 Ib capacity OPTIONS PLATEN RNO None WIDTH ONO None OPTIONAL 9 15 FUNCTION 8 18 N Non Side Shift S Side Shift PLATEN MOUNTING MOVEMENT CLASS ITA Class Il N Fixed HOOK TYPE Q Quick Change MOUNTING ANGLE 0 0 deg 45 033 REV 05 10 i 5 of 16 Allied COMPANY PSR Series Model Number P S R 5 0 F P D 1 4 82. Reach INSTALLATION MAINTENANCE AND SERVICE MANUAL FMP PLP and PSR SERIES 45 033 REV 05 10 lllied 1 of 16 COMPANY TABLE OF CONTENTS SECTION PAGE SECTION PAGE 1 NAME PLATE LOCATION 3 5 SERVICE PROCEDURE 2 MODEL NO DESCRIPTION 5 1 ATTACHMENT REMOWVAL 14 5 2 CYLINDER 14 FMP MODEL 4 5 3 CYLINDER INSTALLATION 14 PLP MODEL 5 PSR MODEL NUMBER 6 6 MAINTENANCE SCHEDULE 3 SAFETY SUMMARY 6 1 QUICK ATTACHMENT REMOVAL 15 6 1 SUHEBULDE 2 ee 16 3 1 GENERAL INFORMATION 7 6 2 TORQUE SPECIFICATIONS 16 3 2 LOAD 8 3 3 LOAD 8 3 4 HYDRAULIGS 9 9 5 OPERATION CONTROLS 9 4 INSTALLATION PROCEDURE 4 1 TRUCK REQUIREMENT S 10 4 2 HYDRAULIC 10 4 3 ATTACHMENT INSTALLATION 10 4 3a QUICK HOOK INSTALLATION 11 4 3b QUICK HOOK PIN STYLE CLASS 12 4 4 HYDRAULIC CONNECTIONS 13 2 of 16 Allied stems 45 033 REV 05 10 SECTION 1 NAMEPLATE LOCATION NOTE WHEN YOU RECEIVE YOUR ATTA
3. Figure 4 3 Fork Installation 4 3a Quick Hook 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 AT TACHMENT 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 4 1 45 033 REV 05 10 Allied COMPANY Figure 4 1 Jumper Line 3 Remove the lower bolt on hooks and if applicable make a note of any factory installed shims Shims are used to create clearance between the hook and car riage Ifthe 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 4 2 Figure 4 2 Quick Change Hook 11 of 16 4 Center the truck behind the attachment and drive toward the attachment with the mast tilted forward ap proximately 4 degrees 5 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 prope
4. Figure 4 5 ANY ALTERATIONS TO THE ORIGINAL AT TACHMENT MAY AFFECT PERFORMANCE OR SAFETY AND RESULT IN LOSS OF WARRANTY Figure 4 5 Truck Connection 2 Inspect installation to ensure hoses not kinked or pinched between the truck carriage and attachment 3 Operate the attachment continuously for several minutes to determine that all hydraulic connections are secure with no leaks 4 Activate cylinders fully and check that the truck s hy draulic reservoir oil level is at the recommended level 5 Before placing the attachment in operation check the following 45 033 REV 05 10 Allied 13 of 16 COMPANY SECTION 5 SERVICE PROCEDURE 5 1 Attachment Removal 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 1 Disconnect the hydraulic connection at the attach ment from the truck 2 Slide out the Fork Latch Assembly and remove forks Figure 5 1 _ Figure 5 1 Fork Removal 5 2 Cylinder Removal 1 Disconnect the hydraulic connections 2 Remove the cylinder rod end cotter pin and clevis pin BEFORE DISCONNECTING ANY HYDRAU LIC CONNECTIONS BE SURE TO TURN OFF THE TRUCKS POWER AND ACTIVATE THE TRUCKS HYDRAULIC FUNCTIONS IN BOTH DIRECTION TO BLEED OFF THE HYDRAULIC PRESSURE 14 of 16 Allied COMPANY 3 Remove cotter pin and clevis pin at the base end of
5. the cylinder 5 3 Cylinder Installation 1 Install the clevis pin and cotter pin into the base end of the cylinder 2 Attach the hydraulic connections to the cylinder 3 Extend the cylinder until the rod end hole lines up with the mounting hole Install the clevis pin and cotter pin into the rod end of the cylinder 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 INTHE SYSTEM 45 033 REV 05 10 SECTION 6 MAINTENANCE 6 1 Quick 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 HYDRAU LIC PRESSURE 2 Disconnect the hydraulic connection for the attach ment positioning at the hydraulic valve Figure 4 5 3 Disconnect the side shift connections 4 Slightly raise the truck carriage to allow the removal of the bottom mounting hooks If the attachment is equipped with Quick Change Hooks simply press the slide plate release button and drop the slide plate down Figure 6 1 Figure 6 1 Quick Change Hook 45 033 REV 05 10 Allied COMPANY 5 Position the attachment on the edge of a pallet Low er the attachment so that the lower carriage bar misses the pallet when lowere
6. B 1 Q 0 PLATEN USEABLE SERIES TYPE PLATEN PSR Quick Mount S Solid LENGTH Push Pull P Platen D148 1 25 x11 x48 PUSH STROKE 50 CUSTOMER DESIGNATION CB Coors Brewery OPTIONAL FUNCTION NF Non Side Shifting MODEL SPECIFICATION 1 Standard MOUNTING CLASS AQ ITA Class 11 W Quick Release Mounting Hooks MOUNTING ANGLE 0 2 0 deg 6 of 16 Allied stems 45 033 REV 05 10 SECTION 3 SAFETY SUMMARY 3 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 Check to 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 physical 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 Neve
7. CHMENT LOCATE THE LONG REACH NAMEPLATE UPPER LEFT CORNER ON THE BODY OR FRONT OF BASE UNIT AND RECORD THE INFORMATION TO THE BLANK NAMEPLATE TAG WITH THE DATE RECEIVED IN THE SPACE PROVIDED ON THE BOTTOM OF THIS PAGE IF THE NAME PLATE IS MISSING LOOK FOR THE SERIAL NUMBER STAMPED DIRECTLY INTO THE METAL AT THE ORIGINAL LOCATION AND CONSULT FACTORY Date Received NM 21433 SW Oregon Street 2500005 rF O ONG RE AACHE A Division of Sherwood OR 97140 USA O Allied Systems Company www alliedsystems com MODEL SERIAL NO NO CAPACITY KG AT LOAD CENTER LBS BAR L min MAXIMUM PRESSURE PSI GPM SEE TRUCK NAMEPLATE DATE FOR COMBINED TRUCK amp O ATTACHMENT CAPACITY 45 033 REV 05 10 ie d 3 of 16 Z1 COMPANY HYDRAULIC FLOW mH HCG SECTION 2 MODEL NUMBER DESCRIPTION Each clamp is identified by a model number and a serial number located on the name plate attached to the unit prior to shipment Long Reach s model numbers are designed to describe how an attachment is equipped The guide below illustrates the information that is represented in a model number Always include model and serial number when ordering parts or requesting service information FMP Series Model Number 3 5 8 4 8
8. d 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 6 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 INTHE SYSTEM 15 of 16 6 3 Torque Specifications SAE Grade 5 Capscrews Nominal Thread Torque Ft Lbs Ft Torque Ft Lbs Size Series Dry Lubed K 2 20 15 6 2 Schedule Daily 1 Visually inspect all hoses fittings cylinders and valves for signs of hydraulic leaks 2 Inspect hoses for wear pinching and replace as required 3 Inspect platens for nicks dents rough spots and repair as required 4 Visually inspect for external damage or cracks 5 Check Fork Latch Assembly for proper engagement 40 Hour Maintenance 1 Complete the above daily checks 2 Inspect retaining pins and replace as required 3 Tighten retaining pin bolts as required 4 Clean and wax platens 5 Lube bronze top hooks if needed 6 Lube mechanism if desired Use Light Oil Nominal Size 500 Hour Maintenance 1 Perform 40 hour inspection 2 Check gripper pad for tears or excessive wear and replace as required 3 Inspect bushings for excessive cleara
9. d 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 3 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 it s 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 3 4 45 033 REV 05 10 7 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 8 Always check loads to be handled If they are broken Figure 3 4 unbalanced loose or too heavy advise a supervisor or properly correct the situation prior to handling 9 Limit lift
10. eplate 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 aversely af fects the stability and steering of the lift truck 8 of 16 Allied COMPANY 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 Never 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 hea
11. lic 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 at tachment 3 Consult the truck factory and or Long Reach for guidance 4 3 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 10 of 16 Allied COMPANY THE CAPACITY OF THE TRUCK AND AT TACHMENT 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 4 1 Figure 4 1 Jumper Line 3 Slide out the Fork Latch Assembly to install attach ment to forks The Retainer Pin needs to be lifted up to allow the Fork Latch Assembly to slide out Figure 4 2 Figure 4 2 Fork Latch Assembly 45 033 REV 05 10 4 Center the truck behind the attachment and drive toward the attachment until the forks are completely inserted into the attachment 5 When forks are flush against the attachment lock the attachment to the forks by sliding the Fork Latch
12. nce at all pivots and replace as required 4 Tighten and torque all bolts 5 Check lower hook clearance and adjust as required Nominal Size Allied COMPANY SAE Thread Series Grade 8 Capscrews Torque Ft Lbs Inches Dry 0 20 K 0 15 Class 5 8 Class 8 8 Class 10 9 Dry Lubed Dry Lubed Dry Lubed 0 20 0 15 0 20 0 15 0 20 0 15 165 0 300 0 Ft Lbs N m 1 356 45 033 REV 05 10
13. r 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 3 1 45 033 REV 05 10 Allied COMPANY Figure 3 1 9 Never use the attachment or its load to support a man carrying device 10 Never position an attachment or load over people Figure 3 2 Figure 3 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 drivers compartment 13 Never leave a lift truck unattended without lowering the load to the floor setting the brake and turning the truck off 7 of 16 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 3 3 16 Do not allow riders on the truck at any time Figure 3 3 17 Always use reverse when carrying a load that impedes full vision 18 Watch for pedestrians when transporting Sudden stops can dislodge all or part of a load 3 2 Load Handling 1 All operators must be trained and qualified 2 Never overload the attachment Refer to the attachment nam
14. r place if applicable 6 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 7 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 prop erly aligned in the top hooks 8 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 4 3 Tight en the bolts to 40 50 ft lbs 9 f Quick Hooks are installed simply raise the slide plate until the button clicks into place Figure 4 3 Lower Hook Clearance 12 of 16 Allied COMPANY THIS SLIDE PLATE MUST CLICK INTO PLACE TO ENSURE THE ATTACHMENT IS SECURED TO THE CARRIAGE IF THE SLIDE PLATE DOES NOT CLICK INTO PLACE BECAUSE THE TRUCK CARRIAGE PREVENTS THE SLIDE PLATE FROM BEING RAISED UP HIGH ENOUGH SHIMS MUST BE INSTALLED BE TWEEN THE ATTACHMENT AND THE BODY OF THE QUICK CHANGE HOOKS 10 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 11 If Pin Style Quick Hooks are installed slowly raise the truck carriage comple
15. tely to engage the top hooks with the truck carriage Tilt carriage back until the unit is against the carriage bottom fork bar 0 degrees 12 Remove detent pin and slide hook snugly against carriage Reinstall the detent pin 4 3b Quick Hook Pin Style Class Conversion 1 Remove mounting bolts and slide off Quick Hook Assembly 2 Select the correct class Quick Hook Assembly for your application and install assembled as shown in Figure 4 4 Note that the hook assemblies for Class and Class have different length bolts Slide lower hook against carriage install mounting bolts and insert detent pin into the lower hole up position 45 033 REV 05 10 a Inspect all hoses and fittings for leaks and routing p uit clearance Be sure to include clearance for jumper CLASS I e ef IN CLASS ILAND Ill hoses to the mast Check the valve and cylinder for leaks HARDWARE c Check cotter pins at each end of the cylinder for security 6 After completing the installation operate the attach i A ment without a load for several cycles to remove any d i air in the hydraulic system Test the attachment with a a DIFFERENT IN LENGTHS load to make sure the attachment operates correctly WEAR PAD AND HON SAME FOR CLASS 11 AND Figure 4 4 Quick Change Pin Style Hook 4 4 Hydraulic Connections 1 Install the lines from the truck s hydraulics to the hydraulics of the attachment
16. 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 A A Push Pull Rotate Side Shift Figure 3 5 NOTE OSHA OR STATE REGULATIONS MAY REQUIRE THE INSTALLATION OF BACKRESTS WE SUGGEST THAT YOU CHECK YOUR APPLI CATION AGAINST THOSE REQUIREMENTS 9 of 16 SECTION 4 INSTALLATION PROCEDURE 4 1 Truck Requirements Long Reach attachments have been designed to operate 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 I D hoses may reduce oper ating speed Higher flow can result in excessive heat buildup erratic operation and damage to the truck attachment hydraulic system NOTE IT ISTHE RESPONSIBILITY OF THE DEALER AND OR THE USER EITHER TO FUR NISH AND INSTALL THE REQUIRED VALVING TO MEET THE RECOMMENDED HYDRAULIC PRESSURES AND FLOW OR TO ARRANGE INSTALLATION OF THE REQUIRED VALVING AT THE TRUCK FACTORY OR AT LONG REACH THE MODEL DESCRIPTION FOUND ON YOUR SHIPPED INVOICE WILL STATE THE FOLLOW ING TRUCK REQUIREMENTS FLOW GPM PSI AND MIN TRUCK CARRIAGE WIDTH 4 2 Hydraulics 1 The truck hydraulic system must supply to the at tachment hydrau
17. 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 3 4 Hydraulics 1 Be aware of the hazards of pressurized hydraulics 2 Wear personal protective equipment such as gloves and safety glasses whenever servicing or checking a hydraulic system 45 033 REV 05 10 Allied COMPANY 3 Assume that all hydraulic hoses and components are pressurized Relieve all hydraulic pressure before disconnecting any hydraulic line 4 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 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 3 5 Operator s Controls 1 For clarity
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