USE AND MAINTENANCE MANUAL
Contents
1. 2 Use a 5 mm DIN 6450 punch to remove the elastic pins In this step the cylinder block and support drop down 3 Disconnect the cylinder from the support 4 Use a 5 mm DIN 6450 punch to extract the upper guide slide blocks 3 Disconnect the flexible hoses from the truck Eyebolt 4 Disconnect the attachment from the truck and rest it on the ground Lifting cable Fixing bracket S 5 Disconnect the lower slide blocks using an ISO 2380 screwdriver D To disassemble the lower hooks loosen the screws avoiding the detachment of Lower hook the fastening brackets and moving downwards UM SSFGA 10 2010 R0 D TO PUT BACK THE DISASSEMBLED PARTS PERFORM THE PROCEDURE DESCRIBED ABOVE IN REVERSE Cylinder support Lower slide FEM slide 9 USE AND MAINTENANCE MANUAL 10 7 3 SLIDE BLOCK CHECK 10 7 4 GASKET REPLACEMENT Replace the slide blocks if there is breakage or permanent deformation or if their thickness at Turn the plug until it is S1 is less than 2 mm S2 3 mm and S3 3 mm Lock ring 11 TROUBLESHOOTING completely out of the lock ring P i The jaws close or open slowly Insufficient oil pressure and or flow Check and or adjust the hydraulic pump and oil level in the tank of th2. USE AND MAINTENANCE MANUAL 5 HYDRAULIC POWER PLANT YOU MUST APPLY A PROTECTION OR DEVICE TO THE JAW OPEN CONTROL LEVEL TO AVOID ACCIDENTALLY PUSHING IT AND LOSING THE LOAD THE MANUFACTURER OF THE TRUCK OR THE INSTALLER IS RESPONSIBLE FOR APPLYING THIS DEVICE Before connecting the hoses eliminate the pressure in the Oil can spill out of the hoses Prepare a container to truck s circuit following the manufacturer s instructions collect the fluid 5 1 CONNECTION WITHOUT SHIFTING 5 1 1 DIAGRAM WITHOUT CUT OFF 5 1 2 DIAGRAM WITH CUT OFF CLOSED 5 3 MOVEMENT CHECK gt l 2nd lever tilting Existing power plant on the truck Existing power plant on the truck 1st lever lifting 5 2 CONNECTION WITH SHIFTING T 5 2 1 DIAGRAM WITHOUT CUT OFF 5 2 2 DIAGRAM WITH CUT OFF CLOSED To check the connections perform 5 complete movements without and with a load Existing power plant on the truck 5 Si EAEE ya N 1 m ing power plant on the truck UM SSFGA 10 2010 R0 USE AND MAINTENANCE MANUAL 6 MOUNTING THE FORKS 6 1 130 mm FORKS Be careful during handling the fork is precariously balanced For narrower forks you must use a 12 mm ISO 2936 wrench to reposition the push bolts located in the lower part of the fork support Use a 6 mm ISO 2936 wrench to insert the replacement plugs to protect the remaining free holes 1 Use a 17 mm IS
3. Apply no 2 eyebolts and hook with cable Valve unit Bellevue spring 2 Dismount the lower hooks with an ISO 2936 3 Disconnect the flexible hoses from Eyebolt Internal spacer 4 Disconnect the attachment from the truck and rest it on the ground Check that the shock absorber is 5 Disconnect no 4 flexible hoses from the valve unit f ower hook Check that the internal spacer is perfectly inserted in its seat and tighten until the cylinder is locked positioned correctly Tighten the nut until the Bellevue spring is locked and 6 Use a 6 mm ISO 2936 wrench to disconnect or replace the valve unit tighten 90 REVERSE 10 7 SIDE MOVEMENT MAINTENANCE D TO PUT BACK THE DISASSEMBLED PARTS PERFORM THE PROCEDURE DESCRIBED ABOVE IN the manufacturer s instructions D Before connecting disconnecting m Qil can spill out of the hoses Prepare a container to collect the fluid 10 7 1 UNHOOKING FROM THE TRUCK 1 Apply no 2 eyebolts and hook with cable 2 Dismount the lower hooks with an ISO 3318 wrench the hoses eliminate the pressure in the truck circuit following 10 7 2 CYLINDER AND SLIDE BLOCK DISASSEMBLY 1 Disconnect no 2 flexible hoses from the distribution block Flexible hoses
4. min 380 max 381 Class I min 474 5 max 476 Class IV min 595 5 max 597 DO NOT USE THE ATTACHMENT FOR ANY PURPOSE OR MOVEMENT OTHER THAN INDICATED Avoiding lifting the load with just the point of the forks Avoid locking the pallet by opening or closing the forks If this manoeuvre is necessary do not tighten at full power THE EFFECTIVE CAPACITY OF THE COMBINATION OF THE TRUCK AND THE ATTACHMENT IS THE RESPONSIBILITY OF THE MANUFACTURER OF THE TRUCK AND MAY NOT CORRESPOND TO WHAT IS SPECIFIED ON THE IDENTIFICATION PLATE CONTACT THE MANUFACTURER OF THE TRUCK FOR ITS DEFINITIVE CAPACITY Handle loads whose height does not interfere with visibility during the manoeuvre The points of the forks must support the last crossbeam of the pallet without projecting beyond it UM SSFGA 10 2010 R0 2 USE AND MAINTENANCE MANUAL 3 ATTACHMENT DESCRIPTION CO Serene o 3 1 SHIPPING CONFIGURATION 3 2 FRONT DESCRIPTION Ron TYPE TYPE Belt fixing the attachment to the pallet MATRICOLA FABRIK NR Envelope with documentation PORTATA STRUTT TRAGKRAFT KG STR CAPACITY CAPACITE STRUCT Sr CON BARIC A MIT L SP MM WITHC OG AT AVEC CD G A SPESSORE VORBAUMASS MM THICKNESS EPAISSEUR MASSA EIGENGEWICHT O KG WEIGHT MASSE BARICENTRO SCHWERPUNKT MM C 0 G AT C D G A PRESSIONE MAX ESERCIZIO MAX BETRIEBSDRUCK MAX WORKING BAR
5. CONFORMITY Dichiarazione CE di Conformit The manufacturer warrants all its products for 12 months or 2 000 working hours which ever comes first from the date of shipment Seen re If used for more than 8 hours per day the warranty period will be x reduced proportionally The warranty is limited to the replacement FOB the manufacturer s plant of those parts it acknowledges to be defective in materials or workmanship it does not include labour or travel to replace the parts In addition it is understood that the warranty is void if the problem is due to inappropriate use of the product if it was not put into service following the manufacturer s instructions or if other than original replacement parts were used for modifications and or repairs The attachment is not warranted for uses that exceed the capacities shown on the plate and in the documentation All attachments are covered by insurance against any damage to third parties caused by defective pieces or their incorrect functioning damage caused by incorrect or improper use is excluded UM SSFGA 10 2010 RO 11
6. Check the integrity of the guides and remove any deformations Check and or replace the slide blocks IN THE CASE OF PROBLEMS NOT DESCRIBED ABOVE CONTACT OUR SERVICE DEPARTMENT UM SSFGA 10 2010 R0 10 USE AND MAINTENANCE MANUAL 12 NOISE 13 RECYCLING THE SPECIFICATIONS THAT FOLLOW APPLY TO THE If replaced pieces are scrapped TRUCK ATTACHMENT UNIT their disposal must be differentiated depending on the nature of the material and in conformity with the law governing the disposal of solid industrial waste Acoustic pressure level of the weighted emission A in the work place if it of solid industrial waste exceeds 70 dB A if this level does not exceed 70 dB A it must be NOTE Pieces not listed in the table to the side are steel indicated Pallet for transport Wood f f Belts for fixing and protective Polyester and heat shrink The maximum value of the instantaneous weighted acoustic pressure C in covering for shipping the work place if it exceeds 63 Pa 130 dB with respect to 20 uPa Cylinder plugs Gaxtiron l SE ide slide block Nyl Weighted acoustic power level A emitted by the machine if the weighted nu S ge Blocks yon acoustic pressure level A in the work place exceeds 80 dB A T pee tings Polyestevsteel Gaskets Polyurethane and NBR Paint Polyester epoxy Gearmotor and grease Dispose of in conformity with local law 14 WARRANTY 15 FACSIMILE OF CERTIFICATE OF CE
7. DATIONS FOR USING THE EQUIPMENT 1 1 PROHIBITED MOVEMENTS 1 2 CORRECT MOVEMENTS 2 CHECKS OF THE TRUCK The load must be stable with crossed layers or tied with straps Transporting an unstable or uncentred load of weight greater than the indicated capacity moving an already deposited load using the load to be deposited using the attachment when it presents structural deformations or operating anomalies When checked at the distributor the truck s hydraulic pump must have a maximum pressure of 25 MPa and a flow capacity of 18 20 I m The recommended diameter for any additional power plant is 9 5 mm Distributor with no 4 levers for controlling movement The fork placement notches must be in good condition and not clogged The fork holder plate must be flat and without front projections When moving with the truck keep the mast tilted the point of the forks high the load lifted slightly from the ground and centred adjusting the speed based on the road surface and any obstacles or presence of Proceeding at high speed on a rough persons on the route surface or climbing ramps Transporting persons or performing manoeuvres with persons in the radius of action of the truck Parking the truck with motor running and or load lifted on a rough surface or on climbing ramps ISO 2228 Dimension A mm Class I min 304 max 305 Class II
8. FF Page 5 10 4 REPLACING GASKETS Page 8 2 FORKLIFT CHECKS Page 2 5 1 2 DIAGRAM WITH CUT OFF CLOSED Page 5 10 5 FASTENING CYLINDERS Page 9 3 ATTACHMENT DESCRIPTION Page 3 5 2 CONNECTION WITH SHIFTING Page 5 10 5 1 ROD SIDE Page 9 3 1 SHIPPING CONFIGURATION Page 3 5 2 1 DIAGRAM WITHOUT CUT OFF Page 5 10 5 2 BOX SIDE Page 9 3 2 FRONT DESCRIPTION Page 3 5 2 2 DIAGRAM WITH CUT OFF CLOSED Page 5 10 6 VALVE DISASSEMBLY Page 9 3 2 1 REAR DESCRIPTION WITHOUT SHIFTER Page 3 5 3 MOVEMENT CHECKS Page 5 10 7 SIDE MOVEMENT MAINTENANCE Page 9 3 2 2 REAR DESCRIPTION WITH SHIFTER Page 3 6 MOUNTING THE FORKS Page 6 10 7 1 UNHOOKING FROM THE TRUCK Page 9 4 FIXING TO THE TRUCK Page 4 6 1 130 mm FORKS Page 6 10 7 2 CYLINDER AND SLIDE BLOCK DISASSEMBLY Page 9 4 1 HOOKING Page 4 6 2 100 mm FORKS Page 6 10 7 3 SLIDE BLOCK CHECK Page 10 4 2 FASTENING LOWER HOOKS Page 4 6 3 80 mm FORKS Page 6 10 7 4 GASKET REPLACEMENT Page 10 4 2 1 WITH SHIFTING Page 4 7A CHECKS AND ADJUSTMENTS Page 6 11 TROUBLESHOOTING Page 10 4 2 2 WITHOUT SHIFTING Page 4 8 DAILY CHECKS Page 7 12 NOISE Page 11 4 3 CONNECTING HOSES Page 4 9 REGULAR MAINTENANCE Page 7 13 RECYCLING Page 11 43 1 WITHOUT SHIFTING Page 4 10 EXTRAORDINARY MAINTENANCE Page 8 14 WARRANTY Page 11 43 2 WITH SEMI INCORPORATED SHIFTING Page 4 10 1 FORK SUPPORT DISASSEMBLY Page 8 15 FACSIMILE OF CERTIFICATE OF CE CONFORMITY Page 11 UM SSFGA 10 2010 R0 USE AND MAINTENANCE MANUAL 1 RECOMMEN
9. O 3318 Use straps for handling the fork 6 2 100 mm FORKS 6 3 100 mm FORKS wrench to slide out the stop pin holding the lower jaw 2 Use a 16 mm ISO 3318 wrench and a 5 mm ISO 2936 wrench to open the side fork 3 Hook the fork to the upper ISO 2328 profile of the fork support and rest it on the lower part 4 Slide the lower jaw stop pin and lock with the screw EE E need ena side fastening screws OM a SO Pin Stop pin screw 7 CHECKS AND ADJUSTMENTS The attachment does not have a pressure limiter valve Using a manometer at the distributor or consult the specifications of the truck to check that the pressure does not exceed 23 MPa In the case of problems contact our post sales support The forks are synchronised by a closed circuit between the linear hydraulic actuators The synchronism restore valves are preset and checked during final acceptance testing with in house controllers With the application of the manometer you only check record the pressure in the hydraulic circuit for the automatic restoration of fork synchronism Before connecting the hoses eliminate the pressure in the truck s circuit following the manufacturer s instructions UM SSFGA 10 2010 R0 Position the side push bolts with 130 mm fork CI 1 Position the screws as shown above 1 Mount the forks as shown in point 6 1 MOUNTING THE FORKS Synchronism restore valves Fitting for
10. PRESSURE PRESSION MAX SERVICE RISPETTARE LA PORTATA COMPLESSIVA DEL CARRELLO E DELLA ATTREZZATURA TRAGFAHIGKEIT VON STAPLER UND ANBAUGERAT g BEACHTEN RESPECT CAPACITY OF TRUCK AND Fork support with E ATTACHMENT ASSEMBLY RESPECTER LA CAPACITE DE L ENSEMBLE CHARIOT ACCESSOIRE ISO 2328 profile Identification plate Linear actuator fastening Fork side fastening screw Fixed guide for fork support slide blocks Pusher bolts for forks with different dimensions Fork assembly pin 3 2 1 REAR DESCRIPTION WITHOUT SHIFTING 3 2 2 REAR DESCRIPTION WITH SHIFTING The attachment is protected by a heat shrink covering Upper slide block support hooks hooked to the truck s ISO 2328 profile Shifter hydraulic power plant ixed frame Upper ISO 2328 hooks Valve block Power input for opening and closing jaws Central reference and stop for side sliding Hydraulic power Fork support linear actuator Lower ISO 2328 locking hooks Lubricatable lower slide blocks Lower ISO 2328 hooks with vertical guide slide blocks UM SSFGA 10 2010 R0 3 USE AND MAINTENANCE MANUAL 4 FIXING TO THE TRUCK 4 1 HOOKING 4 2 FASTENING LOWER HOOKS eS 1 Remove the Nylon protection and the fastening belts Use ISO 3318 hexagonal wrench mm N m Class 2 22 120 Class 3 24 200 Class 4 24 200 2 Fasten the evebolts to the ends of the frame 3 Disas
11. USE AND MAINTENANCE MANUAL WIDE OPENING FORK POSITIONER INTRODUCTION SPECIFICATIONS AND USE OF THE ATTACHMENT This manual contains instructions for assembly periodic and extraordinary maintenance and troubleshooting The instructions in this manual supplement and do not replace the obligation to obey occupational safety and accident prevention laws which is the user company s responsibility The user company is likewise required to follow all the instructions in this manual including training its personnel to use and maintain the attachment ORIGINAL INSTRUCTIONS Attachment to be hooked to forklift trucks for positioning the forks when handling medium and wide loads It consists of a guide frame to support the forks complete with hooks with ISO 2328 profiles for fastening to the truck without or without side shifting hydraulic power plant with synchronisation of the jaws by differentiated diameter linear actuators and closed circuit valves with automatic zeroing FEM forks with ISO 2328 profiles hooked to supports driven by opposing actuators weer CEE C2 e operator s safety performed INDEX 1 RECOMMENDATIONS FOR USING THE EQUIPMENT Page 2 5 HYDRAULIC POWER PLANT Page 5 10 2 SLIDE BLOCK DISASSEMBLY AND REPLACEMENT Page 8 1 1 PROHIBITED MOVEMENTS Page 2 5 1 CONNECTION WITHOUT SHIFTING Page 5 10 3 CYLINDER DISASSEMBLY Page 8 1 2 CORRECT MOVEMENTS Page 2 5 1 1 DIAGRAM WITHOUT CUT O
12. e truck or irregularly Residual air in the hydraulic circuit Check the oil level in the forklift s tank Remove the residual air in the circuit Hydraulic pump worn Replace the truck s hydraulic pump Obstruction or leaks in the hydraulic circuit Check the hoses and connections of the hydraulic power plant of the truck attachment remove the obstructions or leaks replacing damaged hoses Oil oozing in cylinders or valve Replace the cylinder gaskets or replace the valve Excessive friction between the slide block guides Clean and grease Check the integrity of the guides and remove any deformations Check and or replace the slide blocks Side shifting slow irregular or Insufficient oil pressure and or flow blocked Check and or adjust the hydraulic pump and oil level in the tank of the truck Check and adjust the attachments valve Residual air in the hydraulic circuit Check the oil level in the forklift s tank Remove the residual air in the circuit Hydraulic pump worn Replace the truck s hydraulic pump Obstructions or breakage in the hydraulic circuit Check the hoses and connections of the hydraulic power plant of the truck attachment remove the obstructions or leaks replacing damaged hoses Oil oozing in cylinders or valve Replace the cylinder gaskets or replace the valve Excessive friction between the slide block guides Clean and grease
13. hydraulic connections 200 Check that the nameplates and accident prevention stickers in c are intact and easy to read In addition to the operations for every 200 working hours do the following Check slide blocks b and replace if necessary Check the synchronism of the jaws Check the condition of the flexible hoses and fittings 1 000 Check hydraulic actuators d check for oil leaking from the plug and the condition of the chromed surface of the rod In addition to the operations for every 200 and 1000 working hours do the following In zone f check for wear on the parts sliding on the ground Ched Position al ball head greasers UNI 7763 AM6 5 8 2000 Look for deformations or breakage in the structure or welds IF THE EQUIPMENT IS USED IN DUSTY HUMID OR CORROSIVE ENVIRONMENTS WE RECOMMEND HALVING THE HOURS OF WORK Recommended Lubricants For insides ISO X M2 SHELL ALVANIA GREASE R2 Outsides ISO CB 32 ESSO NUTO32 m Check the wear of the forks per the ISO 5057 standard UM SSFGA 10 2010 R0 USE AND MAINTENANCE MANUAL 10 EXTRAORDINARY MAINTENANCE 10 1 FORK SUPPORT DISASSEMBLY 10 2 SLIDE BLOCK DISASSEMBLY AND REPLACEMENT Attachment fixed to the truck or positioned so that you A The balance of the support fork beco 1 Use a 4 mm ISO 3926 1 can move the fork supports hydraulically unstable when not guided by the fram wrench to remove the
14. repare a container to for the hydraulic seal collect the fluid 1 Attachment fixed to the truck or positioned so that ou_can move the jaws hydraulically 1 Dismount the forks 2 Position the jaws at their minimum opening 1000 Cylinder plug Use a 12 60 mm spanner wrench and 4 mm diameter pin to remove the cylinder plug 3 Disconnect the cylinder rods using a 19 mm ISO 3318 wrench to clamp the rod and a 30 mm ISO 1174 socket wrench to unscrew the nut pA 4 Bring the cylinders to their minimum ZZ Lower cylinder closure supporting the upper cylinder 5 Disconnect the flexible hoses with a 19 mm ISO 3318 6 Use a 30 mm socket wrench to unscrew the bottom side nut and remove the cylinder TO PUT BACK THE DISASSEMBLED PARTS PERFORM THE PROCEDURE DESCRIBED ABOVE IN REVERSE When replacing the gaskets taken care to match the mounting direction and work in an area protected from dust UM SSFGA 10 2010 R0 USE AND MAINTENANCE MANUAL 10 5 CYLINDER FASTENING 10 5 1 ROD SIDE 10 5 2 BOX SIDE Vibration damper o 10 6 VALVE DISASSEMBLY ou must disconnect the attachment from the truck to remove the valve in the truck circuit following the manufacturer s instructions Oil can spill out of the hoses Prepare a container to collect the fluid 1
15. screws mes e Stop fastening A and remove the slide block stop 7 2 Using an 8 mm DIN 6450 1 Dismount the forks punch unlock the slide blocks Handling straps 2 Bring the jaws to their maximum and slide them off of the guide Replace the slide blocks if there is breakage or permanent deformation or if their thickness at S1 is less than 4 mm at S2 5 3 To disconnect the cylinder roads use a 19 mm ISO 3318 wrench to clamp the shaft and a 30 mm ISO 1174 30 wrench to In the absence of holes for unlocking the slide blocks use an ISO 2380 mm A With the rod released the screwdriver cylinders can tilt downwards a Position the stop 4 Bring the cylinders to their minimum D correctly when closure mounting the new slide 5 Using straps slide the fork support blocks sideways and rest it on the ground D TO PUT BACK THE DISASSEMBLED PARTS PERFORM THE PROCEDURE DESCRIBED ABOVE IN REVERSE 10 3 CYLINDER DISASSEMBLY 10 4 REPLACING GASKETS Use a 19 mm ISO 3318 wrench to replace the copper seal washer Before connecting disconnecting the hoses eliminate the pressure in the truck circuit following the manufacturer s instructions Lower cylinder Plug with copper washer Oil can spill out of the hoses P
16. semble the lower hooks Wrench ISO 2936 22 WITHOUT SHIETING 4 Use cables with UNI ISO 4479 hooks to lift the attachment 5 Hook the attachment to the truck so that the central stop engages the entral notch of the fork holder plate he lower hooks must lock the attachment to the fork holder plate Fixing bracket Jh Lower hook __ 0 To disassemble the lower hooks loosen the Lower hook 4 2 1 WITH SHIFTING Horizontal slide o Check that the slide blocks and fastening bracket are positioned perfectly screws avoiding the detachment of the fastening brackets and moving downwards JavHnal slide KiKa Lower hook Lower hook When positioning the lower hooks maintain a distance of 1 2 mm YOU MUST APPLY A PROTECTION OR DEVICE TO THE JAW OPEN CONTROL LEVEL TO AVOID ACCIDENTALLY PUSHING IT AND LOSING THE LOAD THE MANUFACTURER OF THE TRUCK OR THE INSTALLER IS RESPONSIBLE FOR APPLYING 4 3 CONNECTING HOSES 4 3 1 WITHOUT SHIFTING 4 3 2 WITH SEMI INCORPORATED SHIFTING Before connecting the hoses eliminate the pressure in the truck s circuit following the manufacturer s i LR F hoN Closing forks Opening forks Closing jaws I Openineiaws H aAa 2 Oil can spill out of the hoses Prepare a container to collect the fluid a 1 The connection hoses between valve Shifting right and truck power plant are options UM SSFGA 10 2010 R0 4
17. the removal of any residual air in the closed circuit between linear hydraulic actuators Possible spilling of oil under pressure A during the removal of residual air The protection of the valves is an anti tampering safety feature The manufacturer will not be liable for damage or breakage if not contacted before any adjustments Centre tooth 0 USE AND MAINTENANCE MANUAL 8 DAILY CHECKS At the start of every work shift check the points to the side and inform maintenance personnel of any problems Check the tightness of the nuts The attachment s centre tooth must fastening the rod and bottom of engage the centre notch of the truck s 7 the fork movement cylinders fork holder plate 5 Check for any oil leaks from the Lower hooks correctly cylinders or hydraulic power plant ositioned see point 4 2 gt y y P P P P r i oot The forks must be hooked in the upper part and the lower pin correctly positioned and fastened Soe all 7 Check the cleanliness of the guides or slide block tracks and lubricate Cylinder rod fastening Cylinder rod fastening 9 REGULAR MAINTENANCE o Before connecting disconnecting the hoses eliminate the pressure in the truck circuit following the manufacturer s instructions PERIODIC MAINTENANCE DIAGRAM Hours of OPERATIONS work 6699 Clean and grease slide block guides a Grease points al Check screw tightness and oil leaks from the
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