User Manual & Parts Book - MSE
Contents
1. us xen setis G mm D kg G Capecilsit Capacity Capaciteit ci ULLUS 1750 xg 655 kg Tragfahigk e Losicentr Loadcenve Lastcentr Loadcentre Lestient C D G charge 600 mmn 1600 mm Lastzent C D G charge H E Wax Wertdruk Mex Operating pres MPa E o 034 295 Max Werkdruk Max Operating pres J Max Arbetsdruck Max ression a nv 31 63 519 Max Arbeitsdruck Max Pression 4108 The combneton d attachment ples hod may rot acord the capacty o the lfttuci 4 493 837 Dee Kominaton ces iobasgeratm mit Las dri die Tragfatigker des Gibeluper The combination of attachment phus load may not exceed the capacity of the litttrack Die Kombination des Ambaugerates mit Last dari die Tragfahigket des Gabelstapiers i B combinan ver vosrcetapperbt pka lest mag di capaci sr yan de wiruh net cvenchriden 1 IPIE De combinstie van voorretapparzat pas ast mag de capote ven de heftruck met overschrijden a LET nicht uberichreten Li cixnibirasten d atiaherweno pha charge ne peu pan parser a capecre d chariot elevareu Ht00270230 La combinaison d attachements plus charge ne peut pes passer la capacte du chariot devateur RE0022000 i Cudebildtdijk 894 Oudebildtdijk 894 Meijer Special Equipment BV v Meijer Special Equipment BV E 99079 NG St Jacobiparochie NL E EJ 9079 NG St Jacobiparochie NL Tel 3 0 518 497979 Fax 3110 5 8 499915 Fig 4 2 Triple Fork type plate Description 4 s Belo S2. valve pump worn out Insufficient oil flow Check with your forklift truck supplier Check with your forklift truck supplier One outer fork remains stationary when retracting and then retracts suddenly Spiral clamping bush broken Replace spiral clamping bush One of the outer forks cannot be retracted Spiral clamping bush broken Replace spiral clamping bush One fork point hangs lower than the other One of the forks has been deformed by overloading Wear strip on one fork is more worn than the other Check with your forklift truck supplier Replace wear strips Excessive play between inner and outer forks Table 8 2 Triple Fork fault table Wear strips worn out Sleeve worn out Replace wear strips Replace sleeve 8 3 Instructions for Replacing Hydraulic Components 38 Position Triple Forks at hip height tip the mast forwards and remove the key from the ignition 39 Remove the outer fork by removing the Allen bolts from the side of the outer sleeve and the spiral clamping bushes from the tip 40 Insert an M5 x 0 8 bolt into the opening on the underside of the inner sleeve and pull the lip outward and remove the bolt Remove the inner sleeve 41 Loosen the hose on the top side of the Triple Fork slightly so that the piston rod does not create a vacuum when dismantling 42 Place a drip tray below the Triple Fork Loosen the cylinder head using a cylinder head wrench 43 Carefully ex
3. 835 2 6 a 9 Cylinder head incl sealsD30__ RE2009031_ Other products wtf Compact Double Height Shift System www telescopicforks com otf Single Height Shift System optional with Reachforks www telesco s RollerForks www rollerforks com Meijer Special Equipment of Reachforks with Camera System www telescop
4. Reachforks A Trademark of Meijer Special Equipment User Manual amp Parts Book Order Code RE6006 EN 3 Edition 14 03 2012 English TRIPLE FORK TRG2 30 www telescopicforks com Table of Contents LE eun T 4 2 FOLIGWOEFO RTA E A cvi Donde Da EDI Dui dI LUI T 5 S ritui p 6 Ay dMdentulicallok era A te ix uev Fais coti pbi Redi uie tb iw ib dr Res 7 4 1 Type Information ee kc a cer cae eere ceo icai rc vid dee 7 4 2 Type Plate Explanation 2 acne eleva dedere eec ere dev ede eoe ted eee ec 8 4 3 Type Indication Explanation seio aiei EE AE E AAE R 9 4 4 Load Bearing Capacity ssri eia e a eaaa aa aa a a Ee a pa a Ra aa ae ESEE Daar anias 9 e aa 11 6 Usage Instructions cuna oce aod rec pd an n edo od n bL b d a 12 7 Assembly Instructions 2 2 2 orc eecisesio aine anita a canda daa nano ada do cR adn an Ra aoo andae 13 7 1 Precautlors 2 d f iere tvatetu iet d Re iiu te e des iuttbre pe aee SS 13 7 2 Triple Fork Assembly Instructions sseeeeenene enn enn eene 13 7 2 1 Recommended Oil Flow and Hose Diameter sisse 14 7 2 2 Triple Fork Commissioning essi reai eea daaa einen either hians snnt sitet enini annt 14 7 3 Triple Fork Protection 2 ien ice cresceret ro npo nace Ro Ee duis 14 7 4 Triple Fork Usage E 15 8 Inspect
5. d of replacement then this work should be performed by a qualified person Alternatively contact an official importer listed on the website www telescopicforks com 8 1 Maintenance Schedule Table 8 1 lists which components require inspection what actions should be taken and how frequently these should be performed Description Daily Weekly Half Yearly Annually or every or every 2 000 1 000 hours hours Grease the underside and topside of the inner fork Check inner fork for leaks Check wear strips for any sign of wear Check for any signs of wear underneath the outer forks especially at rear Check for and remove any dirt accumulated in the outer sleeve Check for any cylinder head leaks Check inner fork in accordance with ISO 5057 standards Table 8 1 Maintenance schedule Below is a more detailed explanation of the maintenance schedule given in Table 8 1 31 32 33 34 35 36 37 We recommend Novatex EP 2 lubricating grease as this is a special purpose calcium based grease designed to protect sliding parts from wear and corrosion when subjected to heavy loads In the event of leakage disconnect the Triple Forks from the forklift truck immediately and contact your supplier In the event of connector leaks either tighten and or replace attachments Wear strips should be replaced or filled with packing if they wear down to less than 1 5 mm Outer forks should be replaced when
6. e 8 3 Tightening moments For more information about various Loctite products please visit the www loctite com website For more information about Copaslip please visit the www kroon oil com website 8 4 Ordering Components Any discrepancies in the Triple Forks bore diameter have been engraved on their side It is recommended that you order complete assemblies whenever individual pistons cylinder heads or even certain seals wiper rings or guide rings need to be ordered to avoid any assembly problems Please provide the Triple Fork s serial number when ordering piston rods inner and or outer sleeves top block stop rings stop pins pawls spiral clamping bushes for pawl and ratchets or hydraulic screw in connectors Appendices Appendix 1 Appendix 2 Spare parts drawing Article numbers Appendix 1 Spare parts drawing Left fork Right fork Left fork Right fork Appendix 2 Article numbers 1200 1150 1275 1225 Pos number Article descri Article number 1 1 1 2 2 1 Piston guide ring D35 2 2 1 Cylinder head without seals D30 REO009031 1 Piston rod seal D3O RE0013016_ 1 Cylinder head O ring D30 REOOT2001 1 Cylinder head Wiper ring D30 REOO14011 1 Cylinder head incl seals D35 RE2009032 1 1 1 1 1 1 TN i d 19 nnerslevei200 Bik00041837 amp 2 jmerseevei27 5 0 Cd 20 jOuterslevei200 BuK00041
7. e normal operations Both forks will now be at the same length After each extension it is advisable to return the Triple Forks to the rearmost position for a few seconds using the handle Note If forks are not reset using this procedure then they will gradually start to operate out of unison over the course of time To resolve this problem follow the instructions in 7 4 8 Inspection and Maintenance Triple Forks operate on a closed self lubricating hydraulic system Triple Forks are supplied with Rando HD 32 hydraulic oil Very little work is required to keep Triple Forks in good condition However it is important that maintenance be performed in a timely and correct fashion Check the Triple Forks every day for signs of damage or oil leaks Any damage or leaks found should be reported to the person in charge When carrying out work on Triple Forks the forklift truck must be switched off with the key removed from the ignition and the system depressurized Consult the maintenance schedule for additional inspection work Under some circumstances e g in exceptionally dirty environments it may be necessary to amend the maintenance schedule In such cases seals should be replaced more often in particular the wiper ring Triple Forks should be tested by a specialist at least once a year in accordance with ISO 5057 standards The results of the test should be recorded in a logbook If piston or cylinder head components are in nee
8. erial No L Left R Right Dead Mass Centre of Gravity Capacity retracted Capacity extended Load Centre retracted Load Centre extended Maximum Operating Pressure E pemsee Table 4 1 Description of details provided on a Triple Fork type plate Tel 31 0 518 492929 Fax 31 0 518 492915 MPa 1 MPa 10 bar 4 3 Type Indication Explanation Section A in Fig 4 1 contains the Triple Fork type Various details can also be derived from the type code Table 4 2 explains the various parts of the type code Here is an example TRG2 30 1200 1150 Type Indication Description Section Fork Type in this case a Triple Fork with separate flow divider 2 30 B No of Cylinders per Triple Fork Set B0 oui Triple Fork Capacity Load Centre 600 mm 1200 Retracted Fork Length 1150 Stroke distance between fully retracted and fully extended forks x 2 mm Table 4 2 Various parts of the type code and their associated meanings 4 4 Load Bearing Capacity Type plates mounted on the top side of Triple Forks include information about the Triple Forks load bearing capacity This is also engraved on the side of the Triple Forks It possible to determine the load bearing capacity at each loading point for each Triple Fork using the loading diagram shown below Correction factors are shown vertically and load centre distances are shown horizontally measured in millimetres from the fork back An example of how t
9. follows 28 Incline the forklift truck mast forwards and backwards several times 29 Tilt the mast forwards and retract the Triple Forks using the handle Keep the handle pulled back for 30 seconds so that the Triple Forks stay retracted and oil continues to circulate 30 Extend and retract the Triple Forks several times Next check whether the hoses are unobstructed and that there are no oil leakages 7 3 X Triple Fork Protection In order to prevent Triple Forks coming into contact with the ground we recommend that you place a plastic bush on the lift cylinder in such a way that Triple Forks cannot touch the ground Forklift truck lifting chains may also be shortened slightly which has the same effect Always consult your dealer or manufacturer before carrying out such modifications 7 4 Triple Fork Usage Triple Forks are equipped with an integrated system that enables both forklift truck tines to operate in unison If both Triple Fork shafts are not at the same length retract both forks entirely rearmost position and keep them in this position for approximately 3 seconds while running so that the hydraulic system has the opportunity to flush out and to bring both shafts to an equal height In the event of a large difference between the two forks it is advisable to keep the forks in the rearmost position for slightly longer while running until both forks are again at the same length The forks are now reset You can now continu
10. he forks This can lead to serious injury and or damage to goods 6 Usage Instructions Triple Forks allow trucks to be loaded from one side goods to be stacked double deep in warehouses two pallets to be lifted simultaneously and pallets of varying dimensions to be lifted when using Triple Forks as extendable forks Triple Forks are easy to assemble and dismantle Triple Forks mounted on forklift trucks should be properly adjusted for the purpose intended The combined load bearing capacity should be calculated by an accredited forklift truck dealer The load bearing capacity shown on the forklift truck s type plate should be amended accordingly for the new forklift truck Triple Fork combination It is strongly recommended that forklift truck drivers be properly trained in the use of these Triple Forks Warning Contact between the Triple Forks and the ground should be avoided as much as possible while manoeuvring to reduce wear This prevents wear and tear to the underside of outer forks Wear resistant strips can also be welded to the underside of these outer forks to help prevent wear Warning Make sure that the Triple Forks do not drag on the floor when moving in reverse This can cause damage to the outer forks and their piston rods 7 Assembly Instructions This section primarily deals with a number of precautions to be heeded when working with Triple Forks regardless of their type Section 7 2 deals with the flow divide
11. ion and Maintenance eeeeeeeeeeeeeeeeeenenee nennen nennt 16 8 1 Maintenance Schedule ssssssssssssssseese enne nnne en nennen inen nennen nes 16 8 2 Fault Table for Triple Forks with Flow Divider seeeenn mmm 18 8 3 Instructions for Replacing Hydraulic Components sssssseeeeeeenneene 19 8 4 Ordering Comiponherits etico hen teta eb ete ei e eh ees 19 ADPONGICES Mus 20 1 Comments Copyright 2012 Meijer Special Equipment VOF All rights reserved Unless otherwise indicated information provided in this manual including but not limited to the illustrations and textual content is not to be reproduced or distributed without the prior written permission of Meijer Special Equipment The information in this manual is provided without any form of guarantee Under no circumstances shall Meijer Special Equipment be held liable for accidents or damage arising from the use of this manual Please note that information in this manual may be changed at any time without prior notice Please note that this manual may also contain technical inaccuracies and typing errors Meijer Special Equipment makes every effort to avoid errors in this manual but cannot guarantee this Please inform us if you find any typing errors or technical inaccuracies or if you have any suggestions KOOI REACHFORKS is a registered trademark of Meijer Special Equip
12. irective ISO 3834 2 Quality Requirements for Fusion Welding of Metallic Materials Part 2 Comprehensive Quality Requirements LOY ON Triple Forks are randomly subjected to dynamic testing in accordance with ISO 2330 standards 3 Introduction Triple Forks are hydraulically retractable and extendible forklift truck tines They are designed for a maximum service life and a minimum of maintenance To achieve this however it is important that maintenance be carried out in accordance with the manufacturer s instructions This user manual is intended to familiarize you with these Triple Forks Please study it carefully before assembling and using the Triple Forks The manufacturer reserves the right to change specifications without prior notice Because we constantly strive to improve the product it is possible that the images in this manual do not correspond to the Triple Forks that you have purchased It is therefore important to state their type and serial number when ordering parts or requesting information Drawings and specification sheets for all types of Triple Fork are included in the appendices so that you can state the relevant product number when ordering 4 Identification This section explains the information shown on the type plate This information contains technical specifications for the Triple Forks that are required when ordering components It is therefore important to know what information is shown on the plate and ho
13. lowing safety instructions 14 15 16 Do not load the Triple Forks beyond the limits stipulated by the manufacturer concerning lifting capacities and load centres Retract the load whenever possible Retract the Triple Forks fully when moving and not carrying a load Always drive with Triple Forks in their lowest possible position Never drag the Triple Forks over the ground while driving Never let anyone hitch a ride on Triple Forks or the load Defective Triple Forks must be taken out of service until they have been repaired or replaced by a qualified technician Before working on Triple Forks make sure that the forklift truck is turned off and that the hydraulic System is depressurized take key out of ignition Distribute the load as evenly as possible between the two Triple Forks Keep Triple Fork surfaces clean and free of grease and oil All the above points should be read and understood by the forklift truck driver Warning Never exceed the forklift truck s maximum load bearing capacity regardless of that stated for the Triple Forks Warning Never walk under Triple Forks Warning This only applies to Triple Forks with a high pallet stop position Type Y2 and Y3 less than 50mm from the fork back when retracted measured from the front of the pallet stop to the front of the fork back Avoid getting body parts or goods trapped or jammed between the fork back and the pallet stop when retracting t
14. ment Other trade or product names used in this manual but not mentioned here are the trademarks of their respective holders 2 Foreword Meijer Special Equipment is the world s largest manufacturer of hydraulic extendable and retractable forklift truck tines produced under the trade name KOOI REACHFORKS Triple Forks were introduced in 1980 by KOOI BV the manufacturer of the KOOI AAP portable lift truck However the forks were always manufactured by Meijer BV Since November 2000 Meijer Special Equipment subsidiary of Meijer Holding has been responsible for not only the production but also for Triple Fork sales and marketing Congratulations on the purchase of your new Triple Forks a reliable product that meets the highest standards of quality and user friendliness You should familiarize yourself with these operating instructions before using these Triple Forks This manual contains everything you will need to know about these Triple Forks and their optimal use Our After Sales department is also at your disposal if you should require any technical assistance KOOI REACHFORKS comply with the following quality standards ISO 9001 2008 Quality Management System ISO 13284 Fork Arm Extensions and Telescopic Fork Arms ISO 4406 Hydraulics Fluids Method for Coding Levels of Solid Particle Contamination ISO 2328 Fork Lift Trucks Hook On Type Fork Arms and Fork Arm Carriages CE 2006 42 EC Machinery D
15. ne of the recesses in the fork attachment plate 25 Attach the hydraulic hoses supplied with the Triple Forks and those on the forklift truck as shown in Fig 7 1 Pay particular attention to the letters engraved on the top side of each fork 26 Make sure that hydraulic connections have been well tightened 27 The Triple Forks maximum permitted operating pressure is 250 bar Fig 7 1 illustrates how the hydraulic hoses should be attached for Triple Forks with an integrated equalizer system The figure shows the letters used on the Triple Forks 7 2 1 Recommended Oil Flow and Hose Diameter Table 7 1 lists the recommended hose diameters for a given oil flow for Triple Forks with a separate flow divider The recommended flow divider type is also indicated Triple Fork Type Recommended Oil Flow Recommended Hose Diameter L min TRa230 30 T 7520 n Table 7 1 Recommended hose oil flow combinations If the oil flow rate is greater than 20 L min then this will have little influence on the speed It is also recommended that oil flows be kept under this level so that the pump is not required to provide maximum pressure on a constant basis thus preventing oil being pumped back to the tank via the safety release valve This also requires less power 7 2 2 Triple Fork Commissioning Before starting it is essential to make sure that there is no air in the system This can be done as
16. o apply this information is given on the following page correctie factor 0 800 1000 1200 1400 1600 1800 2000 2200 last centrum mm Fig 4 3 Correction factors for the maximum load bearing capacity for a given load centre In this example we will be using the information as engraved on the type plate shown in Fig 4 2 TRG2 30 1200 1150 The Triple Forks maximum load bearing capacity is 30 x 100 3000 kg with a load centre positioned at 600 mm It may therefore be deduced that the maximum load bearing capacity of a single Triple Fork is 3000 2 1500 kg with a load centre at 600 mm If the Triple Forks have been extended then use should be made of Fig 4 3 to calculate the corrected maximum load bearing capacity for the load centre in question If the load centre is at 1200 mm then Figure 4 3 shows that a correction factor of 0 5 should be applied The Triple Forks maximum capacity with a load centre at 1200 mm is thus 1500 x 0 5 750 kg Warning Fig 4 3 is only applicable to the Triple Forks themselves The forklift truck s residual load bearing capacity in combination with the Triple Forks should be provided by an official forklift truck dealer 5 Safety The forklift truck driver is primarily responsible for safety We strongly advise that your forklift truck drivers receive proper training and gain recognized certification It is also important to observe the fol
17. r Section 7 3 explains how to limit wear and tear to the underside of the Triple Forks 7 1 Precautions There are a number of precautions to be taken when assembling inspecting and maintaining Triple Forks 17 The forklift truck should be turned off and the key removed from the ignition whenever work is being performed on Triple Forks 18 The forklift truck s hydraulic system should be fully depressurized whenever maintenance is being performed on the Triple Forks 19 Position the Triple Forks at the most ergonomic height to prevent any back problems 20 Wear proper work clothing shoes and safety glasses 21 Triple Fork connectors should always be plugged when disconnecting the Triple Forks from the fork carriage to prevent contamination of the hydraulic system 22 Triple Forks may never be welded without written permission from the manufacturer Any Triple Fork warranties shall be voided in the event that welding work is performed on Triple Forks without this written permission 7 2 Triple Fork Assembly Instructions In order to get the best results from your Triple Forks after assembly you should follow the assembly instructions as given below 23 An L and an R can be found on the Triple Forks type plates Mount the Triple Forks accordingly left and right as viewed from the driver s seat in the forklift truck 24 Slide the Triple Forks onto the fork attachment plate making sure that the locking pin drops into o
18. the hardened wear plates on the outer fork have been worn down to such an extent that they are flush with the underside of the outer fork or more seriously if the outer fork itself has been worn down Any dirt at the front of the sleeve can adversely affect the Triple Forks stroke Depending on usage inspection may be required more or even less frequently The wiper ring can be inspected more easily by removing the outer sleeve see Section 8 3 for instructions on removing the outer fork International ISO 5057 standards apply to telescopic forklift tine inspection except for Section 5 6 1 as the inner fork may not be subjected to any wear For more information about Novatex EP 2 and Rando HD 32 please visit www texaco com 8 2 Forks not moving in unison Fault Table for Triple Forks with Flow Divider Possible Cause Possible Solution Hydraulic hoses incorrectly attached Dirt between inner and outer forks Piston leak Hose lengths unequal Attach hoses as per diagram Fig 7 2 Clear out outer fork Replace piston seal Attach hoses of equal length Forks move on their own Operating valve leak Check with your forklift truck supplier Forks leaking oil Connections leaking Cylinder head seal damaged Fork is cracked Retighten or replace Replace cylinder head seal Immediately disconnect the forks from the fork carriage and contact your forklift truck supplier Forks move unevenly Operating
19. tract the piston rod 44 Unscrew the piston Piston rods should be held in a fixing clamp to prevent them from being damaged Slide the cylinder head off the piston rod 45 Replace components 46 Remove any Loctite from the piston rod screw thread 47 Clean the piston rod and screw thread using Loctite 7063 48 Slide the cylinder head back onto the piston rod 49 When reassembling the piston on the piston rod use Loctite 270 to prevent the piston from working loose 50 Hold the piston rod together with the piston and cylinder head directly in line with the cylinder and carefully tap it in in a straight line 51 Lubricate the cylinder head screw thread with Copaslip 52 Carefully tighten the cylinder head using a cylinder head wrench 53 Slide the inner sleeves back onto the fork and make sure that the lip passes the stop Push the lip in the direction of the fork making sure that it does not hit the cylinder 54 Reassemble the outer fork Make sure that the piston rod clamps are positioned exactly beneath the outer fork holes Insert a screwdriver or a bolt into one hole and hammer the new spiral clamping bush into the other hole Remove the screwdriver or bolt from the other hole and then hammer in another spiral clamping bush Insert the Allen bolts back into the side of the outer fork 55 Reconnect and tighten the hose attachments 56 Start the forklift truck up and extend and retract the Triple Forks several times Tabl
20. w it should be used 4 1 Type Information The following information should be specified when ordering components or requesting information The serial number and type are shown on each Triple Fork s type plate see Fig 4 1 This information is also engraved on the inner side of each fork Type Serial Number Build Year 4 Type Plate m Engraved Data Fig 4 1 Type plate positioning and engraved details Manufacturer 3 Meijer Special Equipment Manufacturer s Address Oudebildtdijk 894 9079 NG Sint Jacobiparochie The Netherlands Tel 31 0 518 492929 Fax 31 0 518 492915 Websites s www telescopicforks com www rollerforks com E mail forks meijerbv nl 4 2 Type Plate Explanation The type plate can be found on the top side of each Triple Fork Type plates are mounted on left and right hand forks The type plate contains important information about the Triple Forks technical specifications Fig 4 2 shows an example of a type plate The letters on the left hand plate can be found in Table 4 1 which also provides a description and units of measurement The right hand plate gives an example of the details a type plate might provide kooi IOE RE4 35 1350 1000 A Sesial no B Serie n IS WWE 2001 M000299 L P BO C Eig mas sad mass Eig mas Zw pnt Dead mass Centre of grav Eigenmas 1 hlass vide Foint C D G 1 si ko 640 mm disset di
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