Installation, Maintenance and Service Manual CPR, NPR, KPR and
Contents
1. i i ii bn o e E n n E ja E H ip r A N OZ iN Om U Jj JU U m G nore tf 1 l ri Bi l el mo i ease F Fy Mice LSO dt l S D D P og Grease here e o Grease here F kp _ le i 4 m a OD Cp Q fe l E o ael o o Ee as 45 027 REV 8 15 Figure 6 1 Grease Zerk Locations Allied COMPANY 37 6 2 Torque Specifications yin a The following torque values are to be used on all fasten Ray H 4 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 c2. Gearbox Back Plate N OTI C E Equipment damage hazard Impact wrenches could damage screws or sockets if screws have been secured with Loctite Use care when working with the gear assembly Do not use a impact wrench on the screws that have been secured with Loctite NOTICE Figure 5 4 Gearbox Removal Oil Leak Hazard 3 Place the gearbox on a flat surface and remove the motor mounting capscrews Note Coupling fits loosely and may slide out Figure 5 5 Capscrew Removing the adapter plate without draining the oil can result in a large oil spill FB Capscrew Drain oil from the gearbox before removing aN Housing Cover the adapter plate 5 Remove the capscrews from the adapter plate The adapter plate capscrews are installed with Loctite use a long handle wrench to them break loose Lightly tap the back of the adapter plate with a rubber mallet to remove Figure 5 6 Pinion Gear Figure 5 5 Motor Removal 4 Remove the pinion gear and key from the output shaft Use a screwdriver to knock the key loose Figure 5 6 Capscrew Figure 5 6 Adapter Plate Removal 18 H 45 027 REV 8 15 Allied COMPANY onc REACH A Division of Allied Systems Company 6 The output shaft seals may now be serviced Figure Seal Adapter Plate Figure 5 7 Output Shaft Seals 7 Remove the output shaft assembly Figure 5 8 Bearing Output Shaft Bearing Snap Ring Figure 5 8 Out
3. ANSI ITSDF B56 11 4 2013 2 Make sure the truck carriage is clean conforms to ANSI recommendations and the notches are not damaged 3 The truck hydraulic system must supply to the attach ment with hydraulic oil that meets the specifications required to operate the attachment properly Find specifications for your attachment on the attachment nameplate Section 1 4 When the truck s hydraulic system pressures exceed the attachment s maximum add a relief valve to the truck s auxiliary system or on the attachment 12 H Allied COMPANY 4 2 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 Equipment overload hazard Overloading the truck may cause equipment damage Consult truck nameplate to determine the capacity of the truck and attachment combination as it may be less than the capacity shown on the attachment alone 2 Purging can be accomplished by installing a jumper line and operating each hydraulic function clamp rotate and side shift if equipped in each direc tion for a minimum of 30 seconds Figure 4 1 Hoses should be 2300 psi working pressure rated for all attachment functions O v To truck v Q a Y To clamp Figure 4 1 Jumper Line 45 027 REV 8 15 onc REACH A Division of Allied S
4. Figure 5 25 Seal Removal Tool Mounting Flange Pressure Seal Back up Ring Exclusion Seal Seal Removal Tool Figure 5 26 Seal Removal NOTICE Equipment damage hazard Any scratch on the surface of the seal cavity outer diameter could create a leak path Be careful not to scratch the seal cavity OD Work from the outer side for both either seals A metal plug with seal plugs a machining hole in the housing It is not necessary to remove the plug and replace seal unless leakage occurs around the plug To remove the plug insert a 5 mm 187 in hex key through the port opening and push it out Figure 5 27 Figure 5 27 Housing Plug 45 027 REV 8 15 Allied 25 COMPANY 5 7 Motor Assembly 1 Check all mating surfaces Replace any parts with scratches or burrs that could cause leakage or dam age Clean all metal parts in clean solvent Blow dry with air NOTICE Equipment damage hazard Any scratch or foreign material on the surface of the seal cavity outer diameter could create a leak path Be careful not to scratch the seal cavity OD Use lint free towels to wipe parts 2 Check around the key slot and chamfered area of the shaft for burrs nicks or sharp edges that could damage seals during reassembly Remove nicks or burrs with a hard smooth stone such as an Arkansas stone Do not file or grind motor parts NOTICE Lubricate all seals with petroleum jelly Use new
5. P3 P4 P5 P6 P7 and P8 Cap hose ends with metal plugs and caps Tag for reassembly Disconnect the motor hydraulic hoses at the swivel assembly ports A and B Cap hose ends with metal plugs and caps Tag for reassembly Remove the swivel assembly mounting bolts and remove the swivel assembly gt m Pho T oei me gt P5 P7 x A B P2 P4 o o Xx eo x MEL P6 Ps a j P3 PZ rote o lt e ele Vo Idhons L d pe 8 l 1 XXX PSI E Sor pay See model description aloe ae for relief setting C1 C2 on 0i e o V1 V2 Figure 5 43 Hydraulics Allied COMPANY 33 5 14 Swivel Assembly Installation 1 Reinstall in the reverse order of removal Section 5 13 Turn on the truck s power and activate the hydraulic functions several times to bleed out trapped air 5 15 Stop Link Adjustment Test stop link adjustment i 2 Flex pad out Each pad has two stop link assemblies Only one stop link on each pad is adjustable Wiggle both stop links to assess how tight they are Both stop links should feel snug and allow for a small amount 1 16 of movement Adjust the adjustable stop link as necessary to achieve equal tension on both links Adjust stop link 1 10 34
6. Remove cotter pin from clevis pin and remove clevis pin Figure 5 44 Turn and remove stop link assembly from notch Loosen the nut three turns then tighten or loosen the link Reinstall and test Repeat adjustment as necessary to equal the tension on the non adjustable link When tension is acceptable remove the adjustable stop link from the notch Mark the correct link position by turning the nut up against the link Unscrew the link Apply Loctite 242 Blue to the threads and reinstall the link just as far as the nut Tighten nut and link together Return stop link to notch Reinstall clevis pin Rein stall cotter pin keeper Adjustable Stop Link Cotter Pino Clevis PS oe Figure 5 44 Stop Link Adjustment Allied 45 027 REV 8 15 COMPANY fone REACH A Division of Allied Systems Company 5 16 Attachment Removal 1 Position the attachment arms to the width of the unit s body Turn off lift truck Relieve pressure in the hydraulic circuit to the attachment by cycling the lever back and forth several times Crush hazard Serious injury could result if residual hydraulic pressure causes equipment to drift during service procedures Cycle the hydraulic circuit as described above to relieve all system pressure 2 Slightly raise the truck carriage to remove the bottom 45 027 REV 8 15 mounting hooks If the attachment is equipped with quick
7. 3 Excessive wear in bore Replace any component found to be defective 45 027 REV 8 15 5 11 Cylinder Assembly 1 Spray the piston gland cap and seals with WD40 or other similar product to ease slipping of the seals in place Note the direction of the seal on the piston Improper installation will result in poor performance The cupped side or O ring side of the seal should be facing the gland cap Figure 5 41 Seal Locknut Piston Wear Ring Figure 5 41 Piston Seal Use a spanner wrench or similar tool to unscrew the gland cap from the cylinder tube 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 5 42 T Ring ay ES NLL LY eZ 1 x EE S Cylinder Rod Wiper Ring Figure 5 42 Gland Cap Seal Alied D COMPANY fee 32 Install the piston on the rod and tighten the locknut to 70 75 ft lbs 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 rubber mallet if resistance is encountered Install the gland cap on the cylinder rod being ex tremely careful not to cut the rod seal on the threads of the rod or rod shoulder If available use a sleeve or plastic electrical tape to cover the rod threads Tighten the gland cap usin
8. 5 30 Seal Installation If the housing stands for more than 15 minutes repeat application No additional 11 Visually check the seal seat in the mounting flange cleaning or removal of previously applied for scratches or other marks that might damage the Loctite is necessary pressure seal Check for cracks in the mounting flange that could cause leakage 16 Before installing the mounting flange and seal as sembly over the shaft place a protective sleeve or 12 Lubricate the ID of the seal tube and OD of the shaft bullet over the shaft Then lubricate the space be pressure seal with a light film of clean petroleum jelly tween the exclusion seal and pressure seal as well Align the small ID end of the seal tube with the seal as the lips of both seals Figure 5 31 seat in the mounting flange Install the back up ring and pressure seal in the tube with lips of the seal face up Figure 5 34 Insert the seal driver in the tube and firmly push seal seat with a rotating action 45 027 REV 8 15 Allied 27 COMPANY 17 18 28 Apply petroleum jelly across this area Output Shaft Dust Seal Back Up This lip to Ring face inward Pressure Interior of motor Figure 5 31 Output Shaft Lubrication Install the mounting flange Rotate the mounting flange slowly while pushing down over the shaft Be careful not to invert or damage the seals After removing the protective sleeve clamp the motor in a vise Make sure the
9. Figure 5 22 Allied COMPANY Be careful not to overheat the housing and damage the motor Apply heat for 8 to 10 seconds while gradu ally applying torque to the capscrew with a socket wrench As soon as the capscrew breaks loose remove heat from the housing Continue turning the capscrew until it is completely removed Heat with a propane torch to melt Loctite ae Mounting Flange Figure 5 22 Capscrew Loctite Remove the shaft key Mark the flange for proper orientation at reassembly Press down on the end of the shaft while lifting the flange Figure 5 23 Do not disturb the shaft Figure 5 23 Motor Flange Removal 45 027 REV 8 15 fone REACH A Division of Allied Systems Company NOTICE Some motors may have a quad seal and back up ring in place of the pressure seal The quad seal and back up ring are no longer available and are replaced by the pressure seal They are interchangeable but some precautions must be taken to ensure proper installation Follow the reassembly instructions Section 5 8 7 The exclusion seal back up ring pressure seal and seal will come off with the mounting flange Figure 5 24 Pressure Seal Seal J AN gt Back Up Ring Mounting Flange a Exclusion Seal Figure 5 24 Mounting Flange Seals Use a seal removal tool Figure 5 25 and 5 26 to remove the exclusion and pressure seals Bend tip Radius Modify screwdriver as shown Remove all burrs
10. KG MM AT LOAD MASS CENTER LBS IN HYDRAULIC FLOW HCG PRESSURE PSI GPM IN SEE TRUCK NAMEPLATE DATE FOR COMBINED TRUCK amp ATTACHMENT CAPACITY O 21433 SW Oregon Street Sherwood OR 97140 USA www alliedsystems com 2500005 rF is fp VCG IN KG AET MM SERIAL NO LBS IN 45 027 REV 8 15 Allied COMPANY SECTION 2 MODEL NUMBER DESCRIPTION Each clamp is identified by a model number and a serial number located on the nameplate 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 an multi digit model number Always include model and serial number when ordering parts or requesting service information Series Model Number A P T 2 5 R N F 1 2 4 2 O N O A N 0 CAPACITY ARM TYPE MAX ROLL MOUNTING 20 2 000 Ib F Fixed DIA CLASS 24 2 400 Ib short arm 42 42 A ITA Il 25 2 500 Ib P Positionable 45 45 B ITA III 35 3 500 Ib short arm 51 51 C ITA IV 40 4 000 Ib 54 54 D ITA III 45 4 500 Ib 60 60 E ITA IIV 48 4 800 Ib 65 65 P Pin mount 50 5 000 Ib 72 72 60 6 000 Ib 84 84 66 6 60
11. adjoining end Place a drop of super glue on the end already in the bearing so that the two ends will be joined Allow ten minutes for the glue to cure Re grease the bearing until grease squeezes out from under the seal to remove any foreign matter that might have become lodged in the bearing separation line 5 4 Oil Filled Gearboxes 5 4 1 Lubrication for Part Numbers YGC 29 YGC 32 YGC 43 and YGC 43 LH 1 45 027 REV 8 15 Remove the top plug and the oil level plug from the gearbox Figure 5 3 2 Oil Level Plug Figure 5 3 Gearbox Oil Plugs Use Mobil HD 85W140 or equivalent oil For tempera tures below 20 F use Mobil SHC 634 or equivalent synthetic oil NOTICE Equipment damage hazard Overfilling the gearbox may damage the gearbox causing a leak Do not overfill gearbox with oil 3 Fill the gearbox to the oil level plug location 4 The oil level should be checked occasionally at the oil level plug If the oil level has dropped a leak may have occurred The leak should be corrected and the oil should be leveled off to the oil level plug location 5 Reinstall plugs 5 4 2 Disassembly for Part Numbers YGC 29 YGC 32 YGC 43 and YGC 43 LH 1 2 Remove the attachment from truck See Section 5 16 Before removing the gearbox from the back plate place a support overhead or under the gearbox Remove the mounting capscrews from the gearbox Figure 5 4 Alied COMPANY
12. hooks simply press the slide plate release button and drop the slide plate down Figure 5 1 Raise slide to secure attachment to truck Slide plate Body Push button to lower slide Figure 5 1 Quick hook 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 attach ment to raise the rear To reinstall follow the installation procedure in this manual See Section 4 2 Equipment damage hazard Equipment damage and loss of performance could result if air is trapped in the hydraulic system Activate the hydraulic functions several times after hydraulic service has been performed to bleed trapped air out of the system before returning attachment to service Alied i COMPANY SECTION 6 MAINTENANCE 6 1 Schedule Daily Maintenance The attachment can stay mounted on the truck for all daily maintenance 1 Check level of hydraulic oil in the truck reservoir and add oil if necessary 2 Visually inspect all hoses and fittings for signs of hydraulic leaks 3 Visually inspect for external damage or cracks 4 Inspect lower hooks for proper clearance Maximum clearance is 3 32 of an inch 5 Ifthe attachment is equipped with quick hooks check the s
13. 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 yourself with this manual and the equipment before starting and then proceed slowly 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 Allied COMPANY i 3 16 Clamp Open Control For all lift trucks with a load bearing clamp paper roll clamp carton clamp etc 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 may result if a fork positioner attachment is used to clamp a load The fork
14. onc REACH A Division of Allied Systems Company Installation Maintenance and Service Manual CPR NPR KPR and KTR Paper Roll Clamps 45 027 REV 8 15 Allied COMPANY TABLE OF CONTENTS 4 1 Truck Requirements eeeee 12 4 2 Attachment Installation cee 12 4 3 Hydraulic Connections cccccceeees 15 4 4 Arm Movement 15 Allied COMPANY SECTION 1 NAMEPLATE LOCATION 3 SECTION 5 SERVICE PROCEDUREG 16 SECTION 2 MODEL NUMBER DESCRIPTION 4 5 1 General ssrdsn 16 SECTION 3 SAFETY SUMMARY ssssannesnnnnns 5 5 2 Pinion Ring Gear and Bearing 16 3 1 Safety Information scesccaniiicannnsaninccaenadeaneans 5 5 3 Bearing Seal Replacement 16 3 2 Safety Regulations eseseeeeeee eeen 5 5 4 Oil Filled Gearboxes cceeeeeees 17 3 3 Safety Symbols nicesas ccesenncsavnnianahearaieanpians 5 5 5 Grease Filled Gearboxes ceeeee 20 3 4 Labelin siiani iens 6 5 6 Motor Disassembly 23 3 5 MANINO erinin eel at EES 6 5 7 Motor Assembly scsicsiieicvcscdenstdecstereontvaeiss 26 3 6 Personnel Safety ceeeeeceeeeeseeeeeeees 6 5 8 Cylinder ASniOVal tcciicticnteeainins 29 3 7 Pre start Checks secciscccniassccsatatiesesetensiennecs 7 5 9 Cylinder Disassemblly eeeeee 29 3 8 Operation Warnings wiciccsiecsesavcteivedntootene 7 5 10 Cylinder Inspection ccceeeeeee 31 3 9 Hydraulic Hazards wsiscie
15. 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 10 H Allied COMPANY Figure 3 6 Do Not Clamp 45 027 REV 8 15 fone REACH A Division of Allied Systems Company p Direction of motion Function Operator s hand on control handle facing the load Up Rearward or up Hoist Down Forward or down Retract Rearward or up Reach Extend Forward or down Rearward Rearward or up Tilt Forward Forward or down Right Rearward or up Sideshift Left Forward or down Rearward Rearward or up Push pull Forward Forward or down Clockwise Rearward or up Rotate lateral Counterclockwise Forward or down Rearward Rearward or up Rotate longitude Forward Forward or down Down Rearward or up Load stabilizer Up Forward or down Right Rearward or up Swing Left Forward or down Clockwise Rearward or up Slope Counterclockwise Forward or down Together Rearward or up Fork position Apart Forward or down Engage Rearward or up Trip Release Forward or down Engage Rearward or up Grip Release Forward or down Raise Rearward or up Truck stabilizer Lower Forward or down Clamp Rearward or up Clamp Release Forward or down Figure 6 ANSI ITSDF Sequence of location and direction of motion for lever or hand type controls For high lift order picker trucks and center co
16. screwdriver and hammer separate the housing cover from the housing Figure 5 15 NOTICE Equipment damage hazard Impact wrenches could damage screws or sockets if screws have been secured with Loctite Use care when working with the gear assembly Do not use an impact wrench on the screws that have been secured with Loctite NOTICE Equipment damage hazard The equipment could fail if machined surfaces of the housing cover and housing are damaged during disassembly Use care when working with the gear assembly 5 Remove the pinion shaft assembly Figure 5 15 6 Remove the snap ring from the end of the pinion shaft Figure 5 15 Figure 5 15 Pinion Shaft 7 Place the assembly in a press supporting the housing cover not the pinion shaft Press the pinion shaft through the small bearing and the worm gear At this point the small bearing worm gear and large bearing are loose and can be lifted out of the housing Figure 5 15 45 027 REV 8 15 Allied 21 COMPANY NOTICE Equipment damage hazard A chipped pinion shaft will affect machine performance Do not drop the pinion shaft onto a hard surface or it may chip NOTICE 10 22 The small bearing cup in the housing and the large bearing cup in the housing cover will need to be removed with a bearing puller Wipe as much grease out of the housing as possible with a rag and inspect for any foreign particles The oil seals m
17. seals when reassembling motor Refer to parts coverage Do not stretch seals before installing them NOTICE Fully cured Loctite resists most solvents oils gasoline and kerosene and is not affected by cleaning operations It is not necessary to remove cured Loctite that is securely bonded in tapped holes however any loose particles of cured Loctite should be removed 3 Wash the housing with solvent to remove oil grease 26 and debris Pay particular attention to four tapped holes on the flange end Allied COMPANY Blow dry with compressed air Clean and dry tapped holes Wire brush screw threads to remove cured Loctite and other debris Discard any capscrews that have damaged threads or rounded heads Wash capscrews with non petroleum base solvent Blow dry with compressed air If you remove a plug or seal lubricate new seal and install on plug Some plugs have two O ring grooves but require only one O ring Install O ring in the groove closest to the end of the plug Push the plug into the housing so the plug and housing are flush Be careful not to damage the seal Lubricate the output shaft with hydraulic oil then install the output shaft into the housing Figure 5 28 Lubricate these areas Needle thrust bearing Figure 5 28 Output Shaft NOTICE Do not permit oil to get into the four tapped holes Install the needle thrust bearing then the bearing race onto the output shaft Pull the out
18. truck s carriage Inspect any wear strips if applicable to insure they are properly aligned in the top hooks Weld on the supplemental locking lug that is sup plied with the attachment two pieces of 1 2 x 1 2 x 2 00 steel included with the attachment with either E 6011 or E 6013 welding rod or equivalent on each side of the truck carriage Figure 4 4 Allied COMPANY 9 YXE4C 307 1 2 x 1 2 x 2 00 steel supplemental locking lug O 1 16 clearance Locking lug in notch Figure 4 4 Locking Lug 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 5 Tighten the bolts to the torque specifications on page 38 Figure 6 3 Maximum clearance 3 32 j TT Shim s as required Figure 4 5 Lower Hook Clearance 10 If quick hooks are installed simply raise the slide plate until the button clicks into place Equipment failure hazard The attachment could fall off the truck if the quick hook is not properly installed Slide plate must click into place If the slide plate does not click into place because the truck carriage prevents the slide plate from being raised up high enough install shims between the attachment and the body of the quick hooks 45 027 REV 8 15 onc REACH A Division of Allied Systems Company 11 To ensure proper locking of the slide plate
19. usea 4 4 Arm Movement screwdriver to try to pry down the slide plate If the slide plate is not locked in place inspect andcorrect 1 Arm movement is controlled by the position and any cause that might restrict the slide plate from sequence function of the swivel valve Figure 4 6 going up enough to allow the button to become fully ici NOTICE 12 Check all fittings connections and bolts for any interference Boundaries are not as exact as shown Arms will move more slowly the closer they 4 3 Hydraulic Connections aie tothe doat bant 1 Install the lines from the truck s hydraulics to the at tachment s hydraulics See Figure 5 48 for a general Dead Band schematic Refer to your parts manual for model 6 i specific hydraulic schematics and hose routing 2 Inspect installation to ensure hoses are not kinked or i pinched between the truck carriage and attachment 3 After completing the installation operate all functions of the attachment without a load for several cycles to remove any air in the hydraulic system Test the attachment with a load to make sure the attachment operates correctly 4 With the mast in the vertical position rotate the attachment fully 360 After this procedure check that the truck s hydraulic reservoir oil level is at the recommended level Figure 4 6 Arm Movement 5 Before placing the attachment in operation re inspect 2 Positioning of the long arm is allowed in all positions al
20. 0 Figure 5 20 Pinion Shaft Assembly 17 Remove grease plugs and completely fill with grease See Section 5 5 5 6 Motor Disassembly If you are experiencing motor problems start with replac ing the shaft seal If the motor needs further repairs we recommend replacing it 1 Remove the motor from gearbox Clean the outside of the motor Service the motor in a clean dust free work area When clamping use a protective device on the vise such as special soft jaws pieces of hard rubber or board Figure 5 21 2 Place the motor in a vice and clamp across the edge of the flange with output shaft up Figure 5 21 Do not clamp on the side of the housing Alied COMPANY 1 2 in 13mm 1 2 in 13mm Figure 5 21 Motor Port Clamping NOTICE w Equipment damage hazard Excessive clamping pressure on the side of the housing causes distortion Use caution when clamping the motor housing Remove capscrews from the mounting flange These capscrews are installed with Loctite and will require 300 400 Ib in of torque to break loose and 100 Ib in of torque to remove Do not use an impact wrench NOTICE If more torque than given above is required to break capscrews loose apply heat according to the following instructions Loctite partially melts when heated reducing the torque required to remove the capscrew Use a small flame propane torch to heat a small area of the housing where the capscrew enters
21. 0 Ib 70 7 000 Ib G 4 MIN ROLL OPTIONS soo om e i ARM MOVEMENT 10 10 C Consult factory 0 0 RN Rotating non 12 kel H Consult factory 2 920 side shifting 16 16 HP Consult factory 4 4 NN Non rotating 20 cael M01 4 Mounting non side shifting 23 23 STD Standard 24 24 S11 Rubber bonded pads SERIES 25 25 13 Polyurethane bonded CPE Coated paper roll clamp 26 26 pads w equal arm lengths 30 30 S29 Bolt on rubber pads CPR Coated paper roll clamp 32 32 w pad protectors CPS Coated paper roll clamp S36 14 X 48 polyurethane w split long arm bonded pads KPE Kraft paper roll clamp w equal arm lengths HOOK TYPE KPR Kraft paper roll clamp N Bolt On KPS Kraft paper roll clamp split long arm KTR Kraft tissue paper roll clamp NPR Roll clamp Q Quick Change 4 H 45 027 REV 8 15 Allied COMPANY fone REACH A Division of Allied Systems Company SECTION 3 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 warnin
22. 3 12 Load Handling e Treat an unloaded forklift with an attachment as par tially loaded Equipment overload hazard Injury or equipment damage may result if the capacity of the truck and attachment combined are less than the attachment capacity Consult truck nameplate for truck capacity with an attachment installed e 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 e Always check loads to be handled Correct loads that are broken unbalanced loose or too heavy e 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 e 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 e Donotcarry 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
23. Figure 5 33 45 027 REV 8 15 fone REACH A Division of Allied Systems Company 27 Rotate the gerotor to line up the bolt holes Be careful Gerotor 42 DS D not to disengage the star from the drive or disturb S the gerotor seal Point 28 Install the drive spacer if applicable Gerotor Seal lt 29 Install 73 mm 2 875 in seal into the end cap Care fully place the end cap on gerotor Spacer Plate 4 30 Install the capscrews and seal washers if applicable into the end cap Pretighten the capscrews to 40 Ib in Make sure the seal washers are properly seated Then torque the capscrews to 235 250 Ib in Housing Forward Valving Slot 5 8 Cylinder Removal 1 Fully extend the cylinder rod 2 Turn off truck and disconnect the hydraulic connections 3 Remove the pivot pin retainers and cylinder Figure 5 35 Figure 5 33 Standard Rotation 26 For reverse rotation align any star valley with the marked tooth on the drive Figure 5 34 Gerotor _ l Star Valle Gerotor Seal y Timing Dot Spacer Plate Housing Forward Valving Slot Figure 5 35 Pivot Pin Retainers 5 9 Cylinder Disassembly 1 Remove the cylinder from the attachment See re moval instructions Section 5 8 Figure 5 34 Reverse Rotation 45 027 REV 8 15 Allied 29 COMPANY 2 Cylinder Tube Check Valve Fitting Bushing gt yor Figure 5 36 Cylinder Assembly Clamp the cylinde
24. ase to lubricate this gearbox Do NOT use oil 20 H Allied COMPANY The grease in the gearbox will not need to be filled or changed unless the gearbox itself has been serviced If the gearbox has been serviced remove the top and bottom plugs from the gearbox Completely fill the gearbox with Mobilux EP1 or equivalent grease Figure 5 12 m Top Plug Figure 5 12 Gearbox Grease Plugs YGC 49 shown Lay the gearbox with the pinion gear down and fill the gearbox from the top plug hole allowing trapped air to escape through the bottom plug hole and until grease shows in the bottom plug hole To fill a gearbox mounted to a back plate follow the same procedure as above Reinstall the plugs 45 027 REV 8 15 fone REACH A Division of Allied Systems Company 5 5 2 Disassembly for Part Numbers YGC 48 YGC 49 YGC 49 LH YGC 50 And YGC 50 LH 1 Remove the attachment from truck 2 Before removing the gearbox from the back plate place a support overhead or under the gearbox Remove the mounting capscrews from the gearbox Figure 5 13 Motor Figure 5 13 Gearbox Removal 3 Place the gearbox on a flat surface and remove the motor mounting capscrews Figure 5 14 F Capscrew N Housing Cover Figure 5 14 Motor Housing cover Removal 4 Remove the capscrews from the housing cover The housing cover capscrews are installed with Loctite so use a long handle wrench to break them loose Using a large
25. ations Pinion Ring Gear Grease Ring Gear Bearing Grease Fitting Figure 5 1 Grease Fitting Locations 5 3 Bearing Seal Replacement NOTICE Equipment damage hazard Foreign matter in the bearing could cause bearing failure Prevent any foreign matter from falling into the bearing during the seal replacement procedure Remove all traces of glue and the old seal from the seal groove by mechanically scraping the groove Clean the groove with a no residue commercial sol vent trichloroethylene to remove any trace of oil or grease Wipe the seal with the same solvent to insure cleanli ness Apply a bead of adhesive to the back of the seal groove Use enough adhesive to coat the seal on all three sur faces contacting the groove 16 H 45 027 REV 8 15 Allied COMPANY fone REACH A Division of Allied Systems Company NOTICE Oo p Equipment damage hazard Foreign matter in the bearing could cause bearing failure Keep adhesive from being extruded into the bearing SEPARATION LINE as the seal is installed Separation Seal Lin Separation Seal Line Figure 5 2 Bearing Seal Insert the seal into the groove with firm steady pres sure but avoid stretching the seal The length of the seal provided is longer than re quired Before gluing the last six inches insert the seal into the groove to determine the exact length required Trim the excess with a sharp knife so it smoothly meets the
26. ay now be serviced Note the orienta tion of the seals Figure 5 16 Housing Cover Figure 5 16 Pinion Shaft Seals Remove the housing cover and motor adapter Make note of any installed shims Capscrews are installed with Loctite so use a long handled wrench to break them loose Use a large screwdriver and hammer to separate the worm cap from the housing Note any installed shims Figure 5 17 Allied COMPANY Motor Adapter O Ring a O Ring Capscrew af Figure 5 17 Worm Cap Motor Adapter NOTICE Equipment damage hazard Damage to the housing cover or housing could reduce machine performance or void the warranty Do not damage the machined surfaces of the housing cover and housing 11 The seal in the motor adapter can now be replaced Figure 5 19 Motor Adapter Figure 5 19 Motor Adapter Seal 12 Using a rubber mallet lightly tap on the extended end of the worm gear shaft and remove it through the housing 45 027 REV 8 15 onc REACH A Division of Allied Systems Company NOTICE The bearing cup on the motor adapter side of the housing will need to be removed with a bearing puller 13 Wipe as much grease out of the housing as possible with a rag and inspect for any foreign particles 5 5 3 Assembly for Part Numbers YGC 48 YGC 49 YGC 49 LH YGC 50 And YGC 50 LH 1 Install all seals When replacing seals use the fol lowing suggestions to ensure leak free opera
27. cles broken cartons or damaged products in the stack e 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 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 Fork position Push pull Rotate Sideshift 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 45 027 REV 8 15 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
28. g a spanner wrench Allied COMPANY 5 12 Cylinder Installation i 2 Install the pivot pin retainer to the cylinder base end Attach the hydraulic connections to the cylinder Line up the cylinder rod end to the body by extending the cylinder rod Install the pivot pin retainer Figure 5 39 Turn on the truck s power and activate the cylinders several times to bleed out trapped air NOTICE Equipment damage hazard Equipment damage and loss of performance could result if air is trapped in the hydraulic system Activate the hydraulic functions several times after hydraulic service has been performed to bleed trapped air out of the system before returning attachment to service 45 027 REV 8 15 fone REACH A Division of Allied Systems Company 5 13 Swivel Assembly Removal 1 Turn off the truck s power and activate the hydraulic functions in both directions several times to relieve the built up hydraulic pressure 45 027 REV 8 15 Crush Hazard Serious injury could result if residual hydraulic pressure causes components to drift Cycle all hydraulic circuits as described above to relieve all system pressure Disconnect hydraulic hoses from the truck at the attachment s swivel assembly ports 1 2 3 and 4 Figure 5 43 Cap hose ends with metal plugs and caps Tag hoses for reassembly Disconnect the cylinder hydraulic hoses at the swivel assembly ports P1 P2
29. gs 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 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 45 027 REV 8 15 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 dea
30. 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 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 e 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 e Do not wear electrically conductive jewelry clothing or other items while working on the electrical system 45 027 REV 8 15 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 e Do not attempt to make adjustments or perform maintenance or service unless you are authorized and qualified to do so e Include attachments in 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 chi
31. l hoses and fittings for leaks and routing clearance Be sure to include clearance of jumper hoses to the 3 Positioning of the short arm will be allowed as shown mast in Fig 4 6 Equipment damage hazard Equipment damage performance reduction personal injury and or loss of warranty could result if any alterations are made to the original attachment Consult with factory before altering original equipment 45 027 REV 8 15 Allied 15 COMPANY SECTION 5 SERVICE PROCEDURES 5 1 General Not all procedures require that the attachment be re moved from the truck Review each procedure before beginning Make sure lifting equipment is rated for the load being lifted 5 2 Pinion Ring Gear and Bearing 1 Grease the pinion ring gear every 40 hours Grease the ring gear bearings every 100 hours See Section 6 Equipment damage hazard Gears may wear out prematurely if not properly greased Worn gears may affect performance or safety and result in loss of warranty Grease gears with recommended lubricant as described 2 Grease the pinion ring gear with Mobil lubricating grease NLGI grade EP2 ISO 220 or equivalent 3 Grease the ring gear bearings with Aeroshell 22 grease or equivalent 4 To ensure proper greasing of gears and bearings slowly rotate the ring gear 360 while greasing This will allow grease to completely coat the gear Gears must be fully greased Figure 5 1 Also see Figure 6 1 for grease zerk loc
32. lide plate latch for engagement Weekly 40 Hour Maintenance 1 Complete the above daily checks 2 Inspect all hoses and fittings for wear or damage Inspect for hydraulic leaks 3 Check for loose or missing bolts 100 Hour Maintenance 1 Grease the ring gear bearing assembly See Section 5 2 2 Grease the pinion ring gear See Section 5 2 3 Grease all pivot pins See Figure 6 1 36 H Allied COMPANY 500 Hour Maintenance 1 Remove attachment from lift truck for this inspection and maintenance cycle Inspect mounting hooks for cracks wear and deflection Remove attachment from service if any defect is found NOTICE If welding is required to make a structural repair consult Long Reach factory before proceeding 2 Re torque the ring gear bearing capscrews See Figure 6 3 for torque values 1 000 Hour or 6 Month Maintenance 1 Remove attachment from lift truck for this inspection and maintenance cycle Inspect mounting hooks for cracks wear and deflection If any defect is found remove attachment from service 2 000 Hour or 12 Month Maintenance 1 Replace oil in the gearbox oil filled gearboxes only part numbers YGC 29 YGC 32 YGC 43 YGC 43 LH YGC 50 and YGC 50 LH 45 027 REV 8 15 ONG REACH A Division of Allied Systems Company TEE a a
33. ne 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 measures 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 e Use caution when working around hot fluids Always allow lubricating and hydraulic oils to cool before draining Burns can be severe e 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 Allied COMPANY 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
34. nisacactesaveieetesnccasnen 7 5 11 Cylinder Assembly ccceeceeeees 31 3 10 Electrical Hazards 0eeeeeeeeeee 7 5 12 Cylinder Installation ccccceeee 32 3 11 Maintenance Warnings 8 5 13 Swivel Assembly Removal 06 33 3 12 Load Handling icccst cceincai cites 8 5 14 Swivel Assembly Installation 34 3 13 Load PoSitioning sseeeeeeeeeeees 9 5 15 Stop Link Adjustment cceeeee 34 3 14 Operators Controls ccccceceeeeeee 10 5 16 Attachment Removal c ceeeee 35 3 15 Industry Stan ards ccsiiccincscisireedsenecsnnes 10 SECTION 6 MAINTENANCE cccsssseeeeeees 36 3 16 Clamp Open Control eeeeeeees 10 6 1 Schedule cisse 36 SECTION 4 INSTALLATION PROCEDURE 12 6 2 Torque Specifications c0 e 38 45 027 REV 8 15 fone REACH A Division of Allied Systems Company 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 with the date received at the bottom of this page If the nameplate is missing look for the serial number stamped directly into the metal at the nameplate location and consult the factory for details Date received O Cc O OME REACT rir Company MODEL NO APACITY
35. ntrol 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 45 027 REV 8 15 Allied 11 COMPANY SECTION 4 INSTALLATION PROCEDURE 4 1 Truck Requirements Long Reach attachments have been designed to oper ate within specific limits Operating pressures above the recommended maximum may cause damage to the at tachment and may void the warranty Operating pressure specifications for your attachment can be found on the attachment nameplate Section 1 Hydraulic flow less than the recommended rates or the use of small ID hoses may reduce operating speed Higher flow can result in excessive heat buildup erratic operation and damage to the truck attachment hydraulic system Hydraulic flow specifications for your attachment can be found on the attachment nameplate Section 1 NOTICE The dealer and or the user must provide and install the valving required to meet the recommended hydraulic pressures and flow or must arrange installation of the required valving at the truck factory The attachment model description found on your shipped invoice will state the following truck requirements flow gpm psi and minimum truck carriage width 1 The truck carriage must conform to the American National Standard ANSI dimensions shown in
36. oating on plated fasten ers No special steps are taken to add further lubrication prior to assembly GRADE 8 COARSE THREAD K Grade 5 7 SEn GRADE 5 COARSE THREAD Grade 8 Socket Head Capscrew Figure 6 2 Bolt Identification SOCKET HEAD COARSE THREAD Bolt Size Lubricated Torque Bolt Size Lubricated Torque Capscrew Size Lubricated Torque 129 in Ibs 1 4 1 4 1 4 150 in Ibs 5 16 23 ft lbs 5 16 5 16 26 ft lbs 3 8 40 3 8 3 8 46 7 16 63 7 16 7 16 74 1 2 96 1 2 1 2 9 16 9 16 9 16 5 8 5 8 5 8 3 4 3 4 3 4 7 8 7 8 7 8 1 4 1 1 1 8 1 1 8 1 1 8 1 1 4 1 1 4 1 1 4 1 3 8 1 3 8 1 3 8 1 1 2 38 1 1 2 Figure 6 3 Torque Values Allied COMPANY 1 1 2 45 027 REV 8 15
37. put Shaft 8 The output shaft fits tightly so you may need to re move the cap on the back of the gearbox and lightly tap the end of the output shaft with a rubber mallet to remove it Figure 5 9 45 027 REV 8 15 Figure 5 9 Output Shaft Cap Remove the end cap and motor adapter Make note of any installed shims Capscrews are installed with Loctite so use a long handle wrench to break them loose Figure 5 10 Motor Adapter Capscrew Figure 5 10 End Cap Motor Adapter Remove the input shaft assembly The assembly fits tightly so use a rubber mallet or press on the extended shaft to remove it Remove the exposed key with a screwdriver allowing the bearing and worm to slide off of the shaft Figure 5 11 Alied 19 COMPANY Screwdriver Figure 5 11 Input Shaft 5 4 3 Assembly for Part Numbers YGC 29 YGC 32 YGC 43 and YGC 43 LH 1 Reassemble in reverse order Use Loctite Blue on all capscrews See Section 6 for Torque Specifica tions NOTICE It is important to get oil to the worm and worm bearings Before reinstalling dip the worm and worm bearings in oil for proper lubrication See Section 5 3 5 5 Grease Filled Gearboxes 5 5 1 Lubrication for Part Numbers YGC 48 YGC 49 YGC 49 LH YGC 50 and YGC 50 LH Load loss hazard Putting oil in this gearbox may result in loss of control leading to equipment damage damaged load or personal injury Use ONLY Mobilux EP1 gre
38. put shaft partially out of the housing Push all three parts into the housing together Figure 5 29 The bearing race must rotate freely when in position 45 027 REV 8 15 onc REACH A Division of Allied Systems Company NOTICE After installing the seal in the mounting flange examine the seal condition If damaged or improperly installed you must replace it before continuing with reassembly 13 Install the 49mm 1 937 in ID seal in the flange 14 A light coat of Loctite Primer NF in tapped holes of housing is recommended Allow primer to air dry for at least 1 minute Do not force dry with air jet the primer will blow away Figure 5 29 Output Shaft In Position 10 Install the exclusion seal into the mounting flange Carefully press the exclusion seal into place Figure 5 30 NOTICE Primer is optional With primer Loctite curing time is approximately 15 minutes Without primer curing time is approximately Shaft Pressure Seal y 6 hours 15 Apply 3 or 4 drops of Loctite sealant at the top of the seal Tube threads for each of the four holes in the housing Do not allow parts with Loctite applied to come in contact Exclusion with any metal parts other than those for assembly Wipe off excess Loctite from the housing face using a non petroleum base solvent y NOTICE Moan Do not apply Loctite to threads more than 15 minutes before installing capscrews Figure
39. r lightly at the base end in a soft jawed vise Use a block or other support under the rod end of the cylinder Figure 5 37 30 Figure 5 37 Cylinder Vise Allied COMPANY Cylinder Tube Rod Assembly Gland Cap Figure 5 38 Rod Assembly Remove the rod assembly from the cylinder tube 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 5 39 Figure 5 39 Piston Rod Remove the piston retaining nut and remove the piston Figure 5 36 Carefully pry up on the piston seals using a blunt tip screwdriver being careful not to scratch the seal grooves Cut the seals to remove them from the piston Figure 5 40 45 027 REV 8 15 fone REACH A Division of Allied Systems Company Figure 5 40 Seal Removal 8 Use the same procedure as above to remove the seals from the gland cap 5 10 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 the seal grooves 2 Wear on the OD 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 the seal grooves 2 Damaged threads or spanner wrench holes
40. shaft cannot fall out Install dry capscrews and alternately torque them immediately to 250 Ib in If you use a primer allow to cure for 10 to 15 minutes Without primer allow 6 hours for curing time before subjecting the motor to high torque reversals Oth erwise you can run the motor immediately Figure 5 32 Figure 5 32 Motor Clamping Allied COMPANY NOTICE 19 Make sure any new capscrews used are the correct length 22 mm 875 in under head length See parts coverage for correct part number Reposition the motor with the geroter end up then clamp the motor across the ports NOTICE To aid the installation of seals apply a light coat of clean petroleum jelly to seals Do not stretch the seals before installing them in groove Pour approximately 1 2 ounces 35 cc of clean hydraulic oil into the output shaft cavity Install 73 mm 2 875 in ID seal into the housing seal groove Avoid twisting the seal Install the drive Use a felt tip marker to mark one drive tooth Align this tooth with the timing dot on the shaft NOTICE If the drive is not symmetrical install the larger splined end into the shaft Install the spacer plate Install 73 mm 2 875 in ID seal into the gerotor seal groove Carefully place the gerotor onto the spacer plate seal side toward the spacer plate For standard rotation align any star point with the marked tooth on the drive
41. 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 on 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 45 027 REV 8 15 fone REACH A Division of Allied Systems Company e Always lower the attachment if you need to leave the lift truck A lift truck supporting a load requires your full attention 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 e Wear personal protective equipment such as gloves and safety glasses whenever servicing or checking a hydraulic system e Assume that all hydraulic
42. th 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 e Change capacity operation and maintenance 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 e 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 ol 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 When removing or installing dismountable at tachments always keep hands and feet free from dangerous positions or pinch points Never lea
43. 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 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 8 H 45 027 REV 8 15 Allied COMPANY fone REACH A Division of Allied Systems Company e 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 e Limit lift truck movement to a minimum when high stacking Limit sideshift movement to a minimum when high stacking e Always be observant when high stacking Look for poorly stacked loads overhead obsta
44. tion and long seal life 2 Cover the keyway and any other surface breaks with smooth tape to protect the seal lip from being dam aged 3 Useasealant between the OD of the seal and the ID of the bore into which the seal is installed Make sure the seal bore is free of any burrs nicks or scratches 4 Be sure that the seal is not cocked in the seal bore The outer face of the seal should be flush with the surface into which it is mounted 5 Press on the bearing cup for the worm gear shaft into the housing on the worm cap side 6 Install the worm cap and shims if applicable NOTICE Use Loctite Blue on all capscrews See Section 7 for Torque Specifications 7 Place the bearing cones on both ends of the worm gear shaft and install into the housing 8 Press on the bearing cup for the worm gear shaft into the housing on the motor adapter side 9 Install the motor adapter and shims if applicable 10 Press on the small bearing cup for the pinion shaft into the housing 11 Press on the large bearing cup for the pinion shaft into the housing cover 12 Slide the housing cover onto the pinion shaft 13 Slide on the large bearing cone onto the pinion shaft 45 027 REV 8 15 14 Press the gear onto the pinion shaft to the large bearing 15 Slide on the small bearing cone onto the pinion shaft and secure with the snap ring 16 Install the pinion shaft assembly and shims if ap plicable Figure 5 2
45. ve 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 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 Allied COMPANY 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 drivers 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
46. ystems Company Bolt Spacer Hydraulic Swivel Assembly Body Assembly aed Pivot Pin Retainer Group f 7 Short Arm Cylinder Y Not Shown Short Arm Stop Link Assembly Long Arm Cylinder Body w Seal Ring Back Plate Contact Pad Short Arm and Cylinder Figure 4 2 Major Assemblies 45 027 REV 8 15 Allied 13 COMPANY 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 carriage If the attachment is equipped with quick hooks simply depress the button on the back of the hooks allowing the slide plate to drop Removing the quick hooks from the attachment is NOT recommended Figure 4 3 Raise slide to secure attachment to truck Push button to lower slide Figure 4 3 Quick hook Center the truck behind the attachment and drive toward the attachment with the mast tilted forward approximately 4 degrees Line up the locking lug under the hanger plate if applicable with the appropriate notch on the truck s carriage Check that the bronze sideshifting wear strips are in the proper place if applicable 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 Inspect for proper engagement of the locking lug in the corresponding notch of the
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