Installation, Maintenance and Service Manual TNNA
Contents
1. 3 1 Schedule Daily 1 Visually inspect all hoses fittings cylinders and valves for signs of hydraulic leaks 2 Visually inspect for external damage cracks or loose hardware 40 Hour Maintenance 1 Apply grease to the fork pin as needed 100 Hour Maintenance 1 Complete the above daily checks 2 Check all hoses and fittings for wear or damage In spect for hydraulic leaks GRADE 8 COARSE THREAD GRADE 5 COARSE THREAD Check for loose or missing bolts 4 Check fork shaft for damage or wear Replace bent fork shafts consult factory about other damage or wear issues 3 2 Torque Specifications The following torque values are to be used on all fasten ers unless otherwise specified Lubricated refers to fasteners in the As Received condi tion 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 SOCKET HEAD COARSE THREAD Bolt Size Lubricated Torque Bolt Size Lubricated Torque Capscrew Size Lubricated Torque 1 4 129 in Ibs 1 4 91 in Ibs 1 4 150 in Ibs 5 16 23 ft lbs 5 16 16 ft lbs 5 16 26 ft lbs 3 8 40 3 8 28 3 8 46 7 16 63 7 16 45 7 16 74 1 2 96 1 2 68 1 2 9 16 9 16 98 9 16 5 8 5 8 5 8 3 4 3 4 3 4 7 8 7 8 7 8 1 1 1 S 1 1 8 1 1 8 1 1 4 1 1 4 12. 1 4 1 3 8 1 3 8 1 3 8 1 1 2 4 4 2 1 1 2 Figure 3 1 Torque Specifications 10 H Allied COMPANY 45 082 REV 8 14
3. 3 10 Electrical Hazards Electrocution hazard Contact with energized equipment may result in injury or death and will damage equipment Remain at least 25 feet from high voltage electrical wires 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 3 11 Maintenance Warnings Maintenance lubrication and repair of this machine can be 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 Allied COMPANY e Do not attempt to make adjustments or perform maintenance or service unless you are authorized and qualified to do so e Include attachments a scheduled maintenance and inspection program Tailor inspection steps to the attachment e Unless specified in service procedures never attempt maintenance or lubrication procedures while the ma chine is moving or the engine is running e 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 measu
4. 3 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 s material handling procedures may be somewhat different from those shown in this manual 3 3 Safety Symbols The following terms define the various precautions and notices Indicates a hazardous situation which if not avoided will result in death or serious injury Carefully read the message that follows to prevent serious injury or death Indicates a hazardous situation which if not avoided could result in death or serious injury Carefully read the message that follows to prevent serious injury or death A Allied COMPANY Indicates a hazardous situation which if not avoided could result in minor or moderate injury or equipment damage or void the machine warranty Carefully read the message that follows to prevent minor or moderate injury NOTICE Describes information that is useful but not safety related Multiple hazards Ignoring safety warnings may cause equipment damage personal injury or death All possible safety hazards cannot be foreseen and included in this manual The operator must always be alert to possible hazards that could endanger personnel or damage the equipment 3 4 Labeling Change capacity operation and mainten
5. a single lever to control both hoist and tilt functions others have separate levers for each function Refer to your lift truck manual for more information 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 Figure 3 5 7 Fork position Sideshift Push pull Rotate Figure 3 5 Operator controls Lifting speed is controlled by the speed of the engine and the position of the control lever Engine speed has no effect on lowering speed Before going on the job shift the truck control levers one way and then the other to determine which direction the attachment moves when the levers are shifted Make sure the attachment moves smoothly throughout its travel without binding or pinching hoses Equipment damage hazard Injury or equipment damage may result if the attachment does NOT operate smoothly Do not take malfunctioning equipment on the job Check with your supervisor about needed repairs 3 15 Industry Standards ANSI ITSDF B56 1 2009 is the published sequence and direction standard for lever and hand type controls NOTICE The chart on the following page shows industry standards Your equipment may be different If you do not routinely operate this equipment refresher training is recommended You must reacquaint yours
6. damage to the rotator could result Always ensure that the load is the same width as the pallet and neatly stacked when using a carton clamp 3 13 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 the 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 3 4 Figure 3 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 3 14 Operator s Controls Some lift trucks are equipped with
7. or jewelry while performing maintenance and lubrica tion in these areas Never jump on or off the machine Never stand on top of material being raised lowered or transported Figure 3 1 Figure 3 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 3 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 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 driver s 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 3 7 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 o
8. ONG REACH A Division of Allied Systems Company Installation Maintenance and Service Manual TNNA Integral Carriages 45 082 REV 8 14 Alti d Systems COMPANY TABLE OF CONTENTS SECTION 1 NAMEPLATE LOCATION SECTION 2 SAFETY SUMMARY 2 1 Safety Information 2 2 Safety Regulations 2 3 Safety Symbols 2 4 Labeling 2 5 Training cs ceceesecioscnce 2 6 Personnel Safety 2 7 Pre start Checks 2 8 Operation rotten erbe 2 9 Hydraulic Hazards 2 10 Electrical Hazards 2 11 Maintenance Warnings 6 2 12 Load Ee 7 2 13 Load Positioning 7 2 14 Operators Controls 7 2 15 Industry Standards 8 2 16 Clamp Open Control 8 SECTION MAINTENANCE 10 NS ssoi 10 10 40 Hour Maintenance 10 100 Hour Maintenance uites 10 3 2 Torque Specifications 10 Allied 45 082 REV 8 14 COMPANY ONG REACH A Division of Allied Systems Company this page If the nameplate is missing look for the serial number stamped directly into the metal at the nameplate location and 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
9. ance instruc tion plates tags or decals when a forklift truck is equipped with an attachment If the truck is equipped 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 3 5 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 operators manual for instruc tions on how to use the new equipment e Know the mechanical limitations of your forklift 45 082 REV 8 14 REACH A Division of Allied Systems Company 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 3 6 Personnel Safety 45 082 REV 8 14 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
10. elf with this manual and the equipment before starting and then proceed slowly Allied COMPANY Special controls such as automatic devices should be identified preferably according to the recommendations in Figure 3 6 When a function is controlled by a pair of push buttons they should operate in the same sense as the lever con trols For example pushing a button located to the rear relative to the operator s position should serve the same function as moving a control lever to the rear 3 16 Clamp Open Control For all lift trucks with a load bearing clamp paper roll clamp carton clamp ANSI ITSDF B56 1 Section 7 25 7 requires the driver to make two distinct motions before opening or releasing the clamp For example you must press a switch and then move a lever to unclamp the load This requirement applies to new and used attachments being mounted on new trucks shipping from the factory after October 7 2010 and is a recommended feature to be installed on dealer orders and existing applications Load loss hazard Injury or equipment load damage result if a fork positioner attachment is used to clamp a load The fork positioner does not have enough clamping force to safely hold a load Always support the load with the forks Do not use fork positioning attachments as clamps Figure 3 6 Do Not Clamp 45 082 REV 8 14 REACH A Division of Allied Systems Company Direction of mo
11. n your truck is the same as on the truck capacity plate Check for hydraulic leaks and cracked hoses or fit tings 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 3 8 Operation Warnings 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 Always lower the attachment if you need to leave the lift truck A lift truck supporting a load requires your full attention 5 3 9 Hydraulic Hazards Injection hazard Infection and gangrene will result when hydraulic oil penetrates the skin See a doctor immediately to prevent loss of limb or death Use a piece of cardboard to check for hydraulic leaks Wear personal protective equipment such as gloves and safety glasses whenever servicing or checking a hydraulic system 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
12. pacity of the truck and attachment combined are less than the attachment capacity Consult truck nameplate for truck capacity with an attachment installed Never overload the attachment Refer to the attach ment nameplate for the rated capacity of the attach ment Refer to the truck nameplate for the maximum net working capacity of the truck attachment combi nation Never use a load to support or move another object Doing so can easily exceed the holding capac ity of the attachment Always check loads to be handled Correct loads that are broken unbalanced loose or too heavy Never lift lower side shift pivot rotate or tilt loads while traveling Repositioning loads while traveling af fects the stability of the truck and may impede vision or clearances 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 Do not carry loose items or unsupported loads on top of a clamped load Never use chains cables or other devices in conjunc tion with an attachment for load handling Never clamp loads other than what the attachment was designed to handle Always carry cylindrically shaped loads in the vertical position not the horizontal Always clamp loads with the contact pads if appli cable not the arm or arm base Never rotate a load that is off center to the centerline of rotation Severe
13. res be taken e 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 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 Suffocation hazard Engine exhaust fumes can cause death Remove the exhaust fumes from the area with an exhaust pipe extension or use ventilation fans and open shop doors to provide adequate ventilation e 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 e 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 45 082 REV 8 14 REACH A Division of Allied Systems Company 3 12 Load Handling Treat an unloaded forklift with an attachment as par tially loaded 45 082 REV 8 14 Equipment overload hazard Injury or equipment damage may result if the ca
14. tion Operator s hand on control handle facing the load Up Rearward or up Hoist Down Forward or down Reach Retract Rearward or up Extend Forward or down Tilt Rearward Rearward or up Forward Forward or down Right Rearward or up hift Left Forward or down Rearward Rearward or up Push pull RPM Forward or down Clockwise Rearward or up Rotate lateral Counter Forward or down clockwise fotata lenditude Rearward Rearward or up PME Forward Forward or down aparece Down Rearward or up Up Forward or down ight Rearward or up Left Forward or down Clockwise Rearward or up Slope Counter Forward or down clockwise Together Rearward or u Fork position iig P Apart Forward or down Engage Rearward or up Release Forward or down Gri Engage Rearward or up Release Forward or down Rai R d Truck stabilizer nl dedo Lower Forward or down Clamp Rearward or up Figure 3 7 ANSI ITSDF Sequence of location and direction of motion for lever hand type controls For high lift order picker trucks and center control pallet trucks predominant motion of the operator s hand when actuating the control handle while facing away from the load The sense of rotation of the control handle is intended to be in the same direction as the desired motion of the mast or load 45 082 REV 8 14 Alti d Systems 9 COMPANY
15. with the date received at the bottom of consult the factory for details Date Received CAPACITY AT LOAD CENTER MAXIMUM HYDRAULIC PRESSURE DATE O long REACH A Division of Allied Systems Company www alliedsystems com 21433 SW Oregon Street Sherwood OR 97140 USA 2500005 rF O APPROX S N PLATE LOCATION KG Il BAR PSI aU 45 082 REV 8 14 LBS MM KG MM MASS AET IN LBS IN L min MM MM MM HCG VCG LCG GPM IN IN IN SEE TRUCK NAMEPLATE FOR COMBINED TRUCK amp ATTACHMENT CAPACITY Q SERIAL NO SECTION 2 SAFETY SUMMARY 3 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 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
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