Boxcar Door Assist - Cascade Corporation
Contents
1. Wireless Remote Pickup Guides Control EN Roll or Bale Clamp Pad Grips SN Sliding NS Boom Sheaves Power Cable Winch Harness Guards Cable M Release E DA0013 il O T oe O 0 iid Frame with Cable amp Hook Fork Slots Front View Fully Optioned Base Unit PERATOR S GUIDE Safety Rules Boxcar Door Assist Assure Door Assist is centered and secure prior to lifting and traveling Safety Chains Hooks Use gloves when handling and rigging cable Assure cable guards are in place and cable is covered Do not operate winch with cover removed 2 g h CO Er E We Do not operate Door Assist when tilted Assure fork safety locks are engaged Assure carriage is equipped With fork stops Assure five 5 wraps of cable minimum on drum at all times Do not operate Door Assist more than 2 ft 60 cm above floor CAUTION Electrical interlocks prevent unsafe operation with unit tilted raised too high or overloaded Faults reset automatically in 2 10 sec DAOOS ill 6019803 Rev 1 PERATOR S GUIDE Safety Rules Industrial Lift Trucks No riders No reaching through mast No standing under load GA0172 ill With M Sirm E T T Traveling RAMP2. 5 NN NAN vs x Control z NO STAND ZONE defined by door size RN movement range Picking up securing unit Adjust forks to Position roll clamp pads Position bale clamp slot width OR on towers ABOVE fork slots OR pads ontowers pads EVEN with bottom of unit DAO042 ill RC1217 ill CL1958 ill Short Arm on RH side Connect Pick up or clamp power unit and attach ur 10 safely chains ruc DAO0023 ill DAO0018 ill DAO019 ill 4 6019803 Rev 1 PERATOR S GUIDE Opening closing doors on open docks A Tilt mast vertical C Position unit as low as possible DAOO065 ill B Bale Clamp Pads aligned with bottom of unit C Connect hook to lowest anchor point on door A Release winch 3 B Manually __ pull cable from winch DAOO22 ill USING WIRELESS REMOTE Winch Operating e Operate winch by pressing both IN buttons simultaneously Use OUT button to release cable tension only Wait for motor to stop before reversing direction LED will blink when winch operates Replace Remote s IN batteries if LED does not light Programming receiver for new 41 Remote Assure Door Assist Unit is level Press and hold right side pes IN button until winch pulses or
3. jumps Test by pressing OUT DAOOS 1 ill 6019803 Rev 1 2 4 A Drive forward touch bumper just beyond door open or close point B Set parking brake truck in neutral DAO002 1 ill A Engage winch use IN buttons on remote to pull door partially open B Assure no loose or falling loads open door fully C Press OUT button to release tension use IN 0 00261 buttons to rewind cable WARNING Do not continue pulling if overload sensor deactivates winch Check for damaged door or load fouling door Heposition unit or cable connection point on door before trying again __ 0 PERATOR S GUIDE Opening closing doors in close quarters using narrow doorway boom A Tilt mast vertical C Position unit as low as possible 2 ft 60 cm Max DAO044 ill B Roll Clamp Pads positioned above fork pockets A Release winch D Manually pull cable from winch connect hook to lowest anchor point on door C Insert locking pin thread cable on unit H B Slide boom for increased ull range DAOOAO ill THREADING CABLE Loop aro
4. 3 Connect the new power cable harness on top of the other cables and wires as shown CAUTION Assure correct polarity and that all wires are properly reattached See illustration and schematics Truck Refer to the Electrical Installation Section in this Manual to replace the power cable harness on the truck Contactor 1 wean Cover 6019803 Rev 1 Positive Battery Cables Winch Contactor Fusebox Base Power Cable Capscrews Washers NO NOTE Install power cable on top of winch motor cables Go Power cable to truck Red stripe positive lead 13 Winch Contactor Motor Power Cables 3 3 14 CAUTION Before working on the contactor and cabling disconnect the positive battery cable at the truck battery 1 Remove the cover from the contactor CAUTION Both covers contain electrical compo nents and wiring handle carefully to avoid damage Disconnect the main power cable harness from the and terminals on the winch contactor For reassembly the main power cable is installed on top of the other cables and exits along the RH side driver s view of the contactor see illustration below Disconnect the remaining cables and wire harnesses ERVICE ELECTRICAL SCHEMATIC Sensor Winch Winch Contactor DA0072 ill from the contactor Remove the contactor from the frame For reassembly tighten
5. North America South America Europe Cascade Corporation Cascade N V U S Headquarters European Headquarters 2201 NE 201st P O Box 3009 Fairview OR 97024 9718 1300 Almere Tel 800 CASCADE 227 2233 Damsluisweg 56 503 669 6300 1332 ED Almere Fax 888 329 8207 The Netherlands Tel 31 36 5492911 Lift Truck Dealers To order parts service literature or videos 9X 91 96 5492964 Cascade Parts Sales 2501 Sheridan Ave opringfield OH 45505 Tel 888 CASCADE 227 2233 FAX 888 329 0234 cascade om Cm3 TM Cascade Corporation 2003 7 2003 Part Number 6019803 R2
6. U SER MANUAL Boxcar Door Assist Manual Number 6019803 R2 cascade corporation ascade is a Registered Trademark of Cascade Corporation C ONTENTS Page INTRODUCTION opecial Definitions 1 OPERATOR S GUIDE oafety Rules 1 Boxcar Door Assist 2 Industrial Lift Trucks 3 General Setup for Opening Doors 4 Picking Up Securing Unit 4 Opening Closing Doors 5 Open Docks 5 Close Quarters 6 Disengaging and Stowing 7 Troubleshooting 7 safe Operation and Maintenance 8 OSHA Regulations 8 INSTALLATION Truck Requirements 9 Electrical Installation 10 INSPECTION amp MAINTENANCE Daily 11 100 Hour Maintenance 11 500 Hour Maintenance 11 1000 Hour Maintenance 11 SERVICE Winch Drive Assembly Cable Replacement 12 Sheaves Cable Guards Guide Block 12 Electrical 13 PARTS Product Identification 16 Base Unit 16 Multi Clamp Tower Assembly 18 Narrow Doorway Boom Sheave Assembly 19 Hecommended Spare Parts back cover Publications back cover Contact Cascade back cover i 6019803 Rev 1 0 NTRODUCTION This User Manual for the Cascade Boxcar Door Assist contains an Operator s Guide Installation Instructions Inspection amp Maintenance Service and Parts All specifica tions are shown in U S and Metric units where applicable Special Definitions The statements shown appear throughout this Manual where special emphasis is required Read all WARNINGS and CAUTIONS before proceeding with any work Statements lab
7. and other locations where vision is obstructed If the load being carried obstructs forward view the driver shall be required to travel with the load trailing 7i When ascending or descending grades in excess of 10 percent loaded trucks shall be driven with the load upgrade 711 On all grades the load and load engaging means shall be tilted back if applicable and raised only as far as necessary to clear the road surface o Loading 1 Only stable or safely arranged loads shall be handled Caution shall be exercised when handling off center loads which cannot be centered 2 Only loads within the rated capacity of the truck shall be handled 3 The long or high including multiple tiered loads which may affect capacity shall be adjusted 4 Trucks equipped with attachments shall be operated as partially loaded trucks when not handling a load 5 Aload engaging means shall be placed under the load as far as possible the mast shall be carefully tilted backward to stabilize the load 6 Extreme care shall be used when tilting the load forward or backward particularly when high tiering Tilting forward with load engaging means elevated shall be prohibited except to pick up a load An elevated load shall not be tilted forward except when the load is in a deposit position over a rack or stack When stacking or tiering only enough backward tilt to stabilize the load shall be used p Operation of the Truck 1 If at
8. buildup if possible a e Mount connector securely using hex capscrews and nuts provided Fuse 12V 200A Connect power cable to truck battery terminals e Route power cable directly to truck battery terminals e Assure cables are connected correctly with positive to positive and negative to negative Use cable ties as necessary to secure cable Connect power cable from winch to cowl e Mount fuesbox solidly to truck if possible or connector for test secure with cable ties to prevent movement WARNING Power cable on truck is always hot and will carry very high current Assure cable is connected correctly and protected against pinch points or chafing that could cause accidental grounding 6019803 Rev 1 NSPECTION amp MAINTENANCE WARNING After completing any service procedure always test the Boxcar Door Assist Unit through a complete cycle First test with no load then test with a load to make sure the unit operates correctly before returning it to the job Daily Check items shown each day Report problems to your supervisor 100 Hour Complete the following inspection and maintenance on the Boxcar Door Assist Unit Check safety chains hooks and chain anchors for damage Replace damaged or missing parts Check for loose or missing fasteners Tighten or replace if neces
9. illustration Assure current overload sensor is installed on negative cable between contactor and motor with arrow pointing toward motor connection Secure sensor to large cable with wire tie IMPORTANT If current sensor is installed back wards motor will start briefly and stop and all LEDs will illuminate To correct rotate sensor 180 degrees and reinstall Contactor Cover 1 2 3 Pin Connector Height Sensors Emergency Back Up Winch Cover IN 1 Wire Harness Wire Color Bom mS Black Red White 6019803 Rev 2 Current Sensor WIRING HARNESS SCHEMATIC Current Sensor White Emergency Back Up Switch PC Board Controller DAOO73 ill PC Board Controller 1 Controller Wire Harness DAOO70O ill Winch Contactor Current Sensor IMPORTANT Arrow must point toward negative connection to motor 15 16 ARTS Base Unit Product Identification This Section shows replace ment parts for the Boxcar Door Assist Unit Product model number and serial number can be found on the nameplate or stamped underneath and must be provided when ordering replacement parts Nameplate with model number serial number specifications phone numbers for service Front View Fully Optioned Unit WARNING For the s
10. l i l nS AA i tl i 1 ISA E N i 1 25 1 1 in Bale Clamp E AT qi ii i Ly rir in Pi uc J 1 l Ep OW 4l ez C HE BER LLL PULL S Paper Roll Clamp 1 ET us 1 INA 1 pt 39 Tag 1 l i wd prd 1 AMI roy Fo m Hn prd poa l d pg d um Ph i NT R UN sh d il l 1 ETE l l 1 Fu adiTT Y m Td 1 ET I _ oa j n I Lad 12 YON Tu ui ad AF S Sy E L 1 yt x5 eT LY ir ro wl Fio N jj I nj Egg ys er Mi ig lih ten vo wy Why sz Ig po Jede rui wet We ii Li yl A iA VAAS dj NN l x E LO Pee NR P4 DAOOO8 ill Electrical Power e A 12V 200 Amp electrical source is required to operate the internal winch Electrical power cabling and connector plugs are supplied with the unit see Page 12 for electrical cable installation 6019803 Rev 1 9 10 NSTALLATION Electrical Installation The Boxcar Door Assist Unit requires DC power from the truck electrical system Use the No 2 gauge twin cable Determine location on truck and connectors supplied with the unit cowl for power connector e Position connector for easy accessibility and to avoid interference with truck or Inline Fusebox BN mast components e e Orient connector to avoid water and dirt e
11. operate correctly if cable is spooled from top See safety decal on brake Retaining Wedge 37 22 PKI lt DA0074 ill Cable against drum flange N RS 2 O Cable between center sheaves CAUTION Use gloves when handling and rigging cable Serious injuries may result from frayed ends or broken strands Sheave Capscrew Spring Cover Return Spring Cable Guard X Roll Pin M 5 Sheave 55 Stop Pin QM o Base LH RH Boom 7 Capscrews 2 Eyepin Capscrew Fairlead Sheave DAOO66 ill 6019803 Rev 1 30 Electrical s1 Main Power Fuse 1 Locate the main power cable fusebox Recommended location is near the truck battery 2 Remove the cover and replace the fuse as shown Assure that the stud terminals are reassembled as shown CAUTION Assure that the replacement fuse is the correct ampere rating for the winch 12V system 200 Amp Part No 6017353 32 Power Cable Harness CAUTION Before working on the contactor and cabling disconnect the positive battery cable at the truck battery Boxcar Door Assist Unit 1 Remove the cover from the back of the winch contactor CAUTION Cover contains electrical components and wiring handle carefully to avoid damage 2 Disconnect the power cable harness from the terminals on the winch contactor by removing the capscrews
12. 020120 Sheave Assembly LH Driver s View o 6020181 heave Assembly RH 601800 20520 Capscrew M12 x 90 683822 Lockwasher M12 763025 Nut M12 5021532 Sheave Assembly 6021655 BARRE 202251 Washer M12 6020120 Sheave Assembly LH 683821 Capscrew M12 x 20 _ 6020181 Sheave Assembly RH 6020116 Base LH See parts breakdown T 6020180 2 3 4 5 7 10 11 12 3 Torsion Spring Capscrew M20 x 75 6014809 Rev 1 ARTS P Recommended Spare Parts 6016660 Sheave w Bearing 6021668 Cable Guide Block A HAH t 6021811 Cable Hook Assembly 6028481 Cable Wedge Anchor 6026661 Wireless Remote 6019450 Truck Power Harness Fuse Block 6017353 200A Fuse 12V 6026661 Wireless Remote Battery Panasonic ECR2032 st clc la qx PH Publications Boxcar Door Assist PART NO DESCRIPTION cascade Service Literature Index and Order Form 6019803 User Manual Operation Installation Service Parts 679929 Tool Catalog 673964 Literature Index Order Form 6024073 Promotional CD Phone Cascade Corporation 360 io 45501 A CE GAO0098 ill Contacting Cascade Users Cascade product literature service literature parts and videos are available through authorized lift truck dealers To find the dealer nearest you contact
13. S Ves emply Watch clearances No parking on ramp GA0173 ill TRAFFIC r RE te cc Slow for Sound horn slow Sound horn Wet floors Bumps two way traffic at intersection slow at corner 6019803 Rev 1 3 u 0 PERATOR S GUIDE General setup for opening boxcar doors WABNNNGOBEmON PINO stay clear of No Stand Zone when opening or closing boxcar door Assure cable is rigged parallel to door and floor do not pull with cable at an angle Cable under tension is hazardous and may result in equipment damage or bodily injury Boxcar Door Assist Unit SN fit 2 D NS 7 N 64 x 2 ty oN 4 NN ut c NN f M 2 4 ple FO 2 Pd NUN 23 42 I 2 L 1 1 D 7 2 AM E 2 Mw id 2 rt I f A yf 2 1 d d 2 e a i WF S dE d 47 x 2224 I X 4 227 1 2 I 21 2 2 4 7 1 4 O l 1 y uw p o4 uw 7 Y 1 1 r WE eS 1 1 1 Y MN 2 d I 2 da 1 4 25 1 1 1 i pod e T ud 2 S 4 2 2 2 e AE 2 2 y l 1 e EN BE p du INS 1 2 Y 1 V ES d ii Mp Je 1 2 AL T bad 0 MS l s p s gt E x S Cum NS E NN N Ur di SS X OS wc Rr Vou 08 SN yy oN Nay TQ oM SS MAS CAN roue
14. afety of yourself and others DO NOT install the parts shown in this Manual unless you have thoroughly reviewed the appropriate service procedures DAO067 ill 6019803 Rev 1 5 Base Unit 15A REF QTY PART NO DESCRIPTION 024568 015241 025812 020248 6001 O D D 4 629516 024660 6019902 768538 O 209043 Washer M10 767614 Capscrew M10 x 20 3550 Capscrew 25 x 375 O 020238 206321 202346 8020229 202348 76855 020689 6024331 787385 76738 016660 683162 6020106 Pin 682990 787308 76796 6021248 Fairlead Weldment 021751 6021355 Safety Chain Assembly 019453 6019450 206322 021112 6389 021752 6028481 A Included with Winch Included in Center Sheave Assembly 6021908 e Included in Cable Assembly 6025812 Heference SK 7152 E EF E3 E N O i O Co C5 Co Co CO CoO NI O O AIIN I OO CO 0 6014809 Rev 1 17 18 ARTS Multi Clamp Tower Assembly PART 60945 Tower Assembly 6 2549 WashenM2O 6 679082 Capscrew M20xG5 2 00657 Whip Spring 6014809 Rev 1 ARTS Narrow Doorway Boom Sheave Assembly Boom Assembly NE 6021930 heave Boom Assembly 6016659 Tube Slide 2 5 S 767614 apscrew M10 x 20 LH Shown
15. any time a powered industrial truck is found to be in need of repair defective or in any way unsafe the truck shall be taken out of service until it has been restored to safe operating condition Maintenance of Industrial Trucks 1 Any power operated industrial truck not in safe operating condition shall be removed from service All repairs shall be made by authorized personnel 5 All parts of any such industrial truck requiring replacement shall be replaced only by parts equivalent as to safety with those used in the original design 6 Industrial trucks shall not be altered so that the relative positions of the various parts are different from what they were when originally received from the manufacturer nor shall they be altered either by the addition of extra parts not provided by the manufacturer or by the elimination of any parts Additional counter weighting of fork trucks shall not be done unless approved by the truck manufacturer 7 Industrial trucks shall be examined before being placed in service and shall not be placed in service if the examination shows any condition adversely affecting the safety of the vehicle Such examina tions shall be made at least daily When industrial trucks are used on a round the clock basis they shall be examined after each shift Defects when found shall be immediately reported and corrected Railroad Facilities Ref 1917 17 h Before being opened fully doors shall be opened s
16. der the elevated portion of any truck whether loaded or empty 3 Unauthorized personnel shall not be permitted to ride on powered industrial trucks A safe place to ride shall be provided where riding of trucks is authorized 4 The employer shall prohibit arms or legs from being placed between the uprights of the mast or outside the running lines of the truck 51 When a powered industrial truck is left unattended load engaging means shall be fully lowered controls shall be neutralized power shall be shut off and brakes set Wheels shall be blocked if the truck is parked on an incline 5il A powered industrial truck is unattended when the operator is 25 feet or more away from the vehicle which remains in his view or whenever the operator leaves the vehicle and it is not in his view 51 When the operator of an industrial truck is dismounted and within 25 feet of the truck still in his view the load engaging means shall be fully lowered controls neutralized and the brakes set to prevent movement 6 A safe distance shall be maintained from the edge of ramps or platforms while on any elevated dock or platform or freight car Trucks shall not be used for opening or closing freight doors 10 A load backrest extension shall be used whenever necessary to minimize the possibility of the load or part of it from falling rearward n Traveling 4 The driver shall be required to slow down and sound the horn at cross isles
17. e cable and tap into the slot IMPORTANT Assure wedge and cable are flush with drum surface when fully seated 4 Reinstall leaf spring brake and use IN buttons on remote to wind the cable under tension onto the drum IMPORTANT Assure cable is under tension and spools onto drum from underside see illustration Sheaves Cable Guards Guide Block sheave bearings are permanently sealed and require no periodic lubrication Replace worn or damaged parts as described below 1 Remove the capscrews and eyepins and remove the center sheeves Note location of shims Replace with new parts as shown 2 Remove damaged cable guard spring or complete sheave assembly Replace with new parts as shown To obtain proper rotational force on the cable guard loosen the sheave capscrew and turn the knurled spring cover until the spring tab contacts the roll pin Rotate the spring cover 1 2 turn more and tighten the sheave capscrew Cable guard handle should rotate freely 180 degrees handle outward and snap back into the safety position against the stop pin handle inward Tighten the capscrews as follows Sheave Capscrew 175 ft lbs 240 Nm Base Capscrews 50 ft lbs 66 Nm Fairlead Eyepin Capscrews 5 ft lbs 8 Nm 4 Remove and replace worn or damaged guide block Install the metal cap and tighten the capscrews to 30 ft Ibs 40 Nm WARNING Cable must be spooled onto winch drum from underside Winch will not
18. eled IMPORTANT and NOTE are provided as additional information of special significance or to make the job easier WARNING A statement preceded by WARNING is information that should be acted upon to prevent bodily injury A WARNING is always inside a ruled box CAUTION A statement preceded by CAUTION is information that should be acted upon to prevent machine damage IMPORTANT A statement preceded by IMPORTANT is information that possesses special significance NOTE A statement preceded by NOTE is information that is handy to know and may make the job easier PERATOR S GUIDE This Section contains operating instructions for the Cascade Boxcar Door Assist It will help you avoid common errors which can often cause damage to the equipment or personnel injury This information is intended to simplify operator under standing about effective and safe Boxcar Door Assist use and operation Read this information thoroughly before operating the unit Be sure you know and understand all operating procedures and safety precau tions If you have any questions or don t understand a procedure ask your supervisor Emphasize Safety Most accidents are caused by operator carelessness or misjudgement You must watch for poorly maintained equipment and hazardous situations and correct them 6019803 Rev 1 WARNING Do not operate this unit with an attachment unless you are a trained and authorized lift truck driver
19. ge battery condition replace if required Check fuse replace if required LI NOTE If winch runs in wrong direction assure cable spools from underside of drum Reprogram code from remote see Check power cable connectors replace worn or damaged parts Check LEDs Green Signal OK Red Overload Fault NOTE Fault conditions reset 1 Yellow Orange all on automatically in 2 10 sec 6019803 Rev 1 Tilt Fault Height Fault Overload sensor installed backwards OPERATION AND MAINTENANCE OSHA Regulations Industrial Trucks and Attachments Specific Regulations from OSHA 1910 178 and 1917 17 WARNING The safe operation and maintenance of industrial trucks is regulated by Occupational Safety and Health OSHA regulations 1910 178 and American National Standards Institute ANSI Safety Standard for Powered Industrial Trucks ANSI B56 1 When operating and maintaining industrial trucks equipped with attachments you should pay particular attention to the following sections of these regulations You should be familiar with all sections of these regulations Ask your employer for the complete regulations a General Requirement 4 Modifications and additions which affect capacity and safe operation shall not be performed by the customer or u
20. lightly to ensure that the load has not shifted during transit Special precautions shall be taken if the doors being opened are visibly damaged i lf powered industrial trucks are used to open railcar doors the trucks or the railcar doors shall be equipped with door opening attachments Employees shall stand clear of the railcar doors while they are being opened and closed Only railcar door openers or powered industrial trucks equipped with door opening attachments shall be used to open jammed doors 019803 Rev 1 __ NSTALLATION Truck Requirements An IC lift truck with forks or clamp attachment is required to pick up the Boxcar Door Assist Unit Electrical power from the truck battery is required to operate the unit WARNING Lift truck must weigh 8000 los 3630 Kg minimum when using Boxcar Door Assist Use of lighter truck not recommended Forks or Clamp Attachment e Forks 2x 5 x 48 in L maximum e Paper Roll Clamp SUN ll pop pe RATE _ Bale Clamp TEMPEL EE MN M Pour tid lay pro 2222 17 pH Ti N D poH T E ee rU pog fone I 1 ae Via ly nay d TER I TE nm i I rie HU j i T pd l prag Why pl yg pos ILU ay 1 TER itid Lg p pos i ty ly i pol l 1 l a pd 31 Lech pd HD EAE a I 1 NON Forks l
21. sary Check cable sheaves and cable guards for freedom and proper operation Replace damaged or worn parts Check electrical power cable and connectors for damage Replace damaged or worn parts Check winch cable hook by pulling out to full length and assuring there are no frayed or broken strands or kinks in the cable Replace cable if it does not meet the above inspection criteria 500 Hour Replace winch cable 1000 Hour Replace cable sheeves 6019803 Rev 1 Remote Control Operation SN Fasteners i NS Power Cable Harness Sheaves Guards DAOO 16 ill Safety Cable amp Hook Chains 11 S 1 0 1 1 2 0 12 ERVICE Winch Drive Assembly There are no field servicable items on the winch drive assembly except for the cable wire rope Winch Cable Replacement The winch cable must be replaced properly to prevent damage Follow the procedure below 1 Remove the large safety cover and the leaf spring brake on the rear of the cable drum Free spool the cable out fully and remove cable NOTE To disen gage cable loosen retaining wedge by tapping from side to side 2 Route the free end of a new cable through the center sheaves to the underside of the drum Insert the cable through the slot in the drum so the free end extends slightly above the drum surface IMPORTANT Assure cable is against drum flange 3 Insert the retaining wedge alongside th
22. ser without manufactur ers prior written approval Capacity operation and maintenance instruction plates tags or decals shall be changed accordingly 5 If the truck is equipped with front end attachments other than factory installed attachments the user shall request that the truck be marked to identify the attachments and show the appropriate weight of the truck and attachment combination at maximum elevation with load laterally centered 6 The user shall see that all nameplates and markings are in place and maintained in a legible condition e Safety Guards 2 If the type of load presents a hazard the user shall equip fork trucks with a vertical load backrest extension in accordance with a2 All new powered industrial trucks acquired and used by an employer after February 15 1972 shall meet the design and construction requirements for powered industrial trucks established in the American National Standard for Powered Industrial Trucks Part Il ANSI B56 1 except for vehicles intended primarily for earth moving or over the road hauling Operator Training Only trained and authorized operators shall be permitted to operate a powered industrial truck Methods shall be devised to train operators in the safe operation of powered industrial trucks m Truck Operations 1 Trucks shall not be driven up to anyone standing in front of a bench or other fixed object 2 No person shall be allowed to stand or pass un
23. the capscrews to 5 ft Ibs 8 Nm For reassembly reverse the above procedures with exco IMPORTANT F1 and F2 cable g l connections between motor and 1 e Install a new winch contactor e F1is 15 CAUTION Assure all cables and wires are connected to F1 FOOTER reconnected properly and with the correct polarity Serious damage may result with the cables misconnected Refer to illustrations and schematics for correct hookup Winch Motor Power Cables Winch Current Sensor Contactor Es IMPORTANT Arrow over must point toward d A negative connection M s to motor Rx Winch Motor Mounting Capscrews DAOOT1 ill Power cable to truck Red stripe positive lead 6019803 Rev 1 ERVICE PC Board Controller and Wiring Harnesses The PC board controller is located inside the small plastic cover on the rear of the Boxcar Door Assist No field serviceable components are located on the PC board Heplace as a complete unit as described below 3 4 1 Remove the cover from the winch contactor on the backside of the Boxcar Door Assist Disconnect the two 2 wire harness connectors from the PC board 2 Remove the PC Board by removing the four 4 screws that fasten it to the inside of the cover 3 For reassembly reverse the above procedures with the following exceptions e Assure both wiring harnesses are properly connected see schematic and
24. und sheave under cable guard Pull cable through DA0054 ill guide except when boom is extended A Drive forward allow clearance for door to open B Set parking brake truck in neutral l1 ICT Pod DAOOS9 ill buttons on remote to pull door partially open EHI B Assure no loose or falling loads open door fully 4 A Engage winch use IN __ Press OUT button to release tension use IN buttons to rewind cable DA00861 ill WARNING Do not continue pulling If overload sensor deactivates winch Check for damaged door or load fouling door Reposition unit or cable connection point on door before trying again 6019803 Rev 1 0 PERATOR S GUIDE Disengaging and Stowing CAUTION All cables and chains must be disconnected and properly stowed before disengaging unit from truck Follow the procedure shown 2 Lower unit lo floor Disengage unit Disconnect and DA0025 ill 4 Disconnect and stow 4 safely chains or hooks Assure cable is 7 1 rewound with hook stowed ec T Lr s Y B AEST Ai S 3 SS DA ICI p NN eL Check wireless remote for dama
Download Pdf Manuals
Related Search