INSTALLATION, MAINTENANCE AND SERVICE MANUAL QCZB
Contents
1. Reach INSTALLATION MAINTENANCE AND SERVICE MANUAL QCZB 45 060 REV 3 08 Allied 1 of 10 COMPANY TABLE CONTENTS PAGE SECTION PAGE SECTION 1 NAME PLATE LOCATION 3 4 2 SAFETY SUMMARY 4 2 1 GENERAL 4 4 3 2 2 LOAD 5 2 3 LOAD 5 5 2 4 OPERATION 5 2 2 6 5 1 3 INSTALLATION PROCEDURE 3 1 TRUCK 7 3 2 2 7 3 3 4 7 3 4 ATTACHMENT 7 3 5 HYDRAULIC 8 2 10 SERVICE PROCEDURE ATTACHMENT 9 CYLINDER 9 CYLINDER 9 MAINTENANCE SCHEDULE 10 TORQUE 10 Allied 45 060 REV 3 08 COMPANY SECTION 1 NOTE When you receive your attachment locate the Long Reach nameplate upper left corner on the body and record the information to the blank nameplate tag with the date received in the space provided on the bottom of this page If the name plate is2. attachment that is being operated Figure 2 3 16 Do not allow riders on the truck at any time Figure 2 3 17 Always use reverse when carrying a load that impedes full vision 18 Watch for pedestrians when transporting Sudden stops can dislodge all or part of a load 2 2 Load Handling 1 All operators must be trained and qualified 2 Never overload the attachment Refer to the attachment nameplate for the rated capacity of the attachment Refer to the nameplate of the truck for the net working capacity of the truck and attachment Observe the lower of the two capacities The attachment capacity is the structural rating of the attachment and should not be exceeded Net working capacity is the truck manufacturer s rating of the truck at tachment combination 3 Never use a load to support or move another object Do ing so can easily exceed the holding capacity of the attach ment causing loss of the load 4 Never lift lower side shift pivot rotate or tilt loads while traveling Repositioning loads while traveling affects the stability of the truck and may impede vision or clearances 5 Never speed or race a lift truck High speed adversely af 45 060 REV 3 08 Allied COMPANY fects the stability and steering of the lift truck 6 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 result in product
3. b Check the valve and cylinder for leaks and spread on entire slide area of mid plate c Check cotter pins at each end of the cylinder for security 10 Check all fittings connections and bolts for any interference 6 After completing the installation operate the attach ment without a load for several cycles to remove any air the hydraulic system Test the attachment with a load 3 5 Hydraulic Connections to make sure the attachment operates correctly 1 Install the lines from the truck s hydraulics to the hydraulics of the attachment ANY ALTERATIONS TO THE ORIGINAL AT TACHMENT MAY AFFECT PERFORMANCE OR SAFETY AND RESULT IN LOSS OF WAR RANTY 8 of 10 stems 45 060 REV 3 08 Reach SECTION 4 SERVICE PROCEDURE 4 1 Attachment Removal 1 Position the attachment arms to the width of the unit s body BEFORE DISCONNECTING ANY HYDRAU LIC CONNECTIONS BE SURE TO TURN OFF THE TRUCKS POWER AND ACTIVATE THE TRUCKS HYDRAULIC FUNCTIONS IN BOTH DIRECTIONS TO BLEED OFF THE HYDRAULIC PRESSURE 2 Disconnect the hydraulic connection for the attach ment positioning at the cylinders 3 Disconnect the side shift connections 4 Slightly raise the truck carriage to allow the removal of the bottom mounting hooks 5 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 dis
4. damage 7 Do not carry loose items or unsupported loads on top of a clamped load 8 Never allow anyone under a load or under the carriage 9 Never use chains cables or other devices in conjunction with an attachment for load handling 10 Never clamp loads other than what the attach ment was designed to handle 11 Travel slowly around corners Sound horn on blind corners Be careful of tail swing and over head clearances Watch in all directions Avoid sudden stops 12 Do not exceed the specified maximum operat ing pressure or flow for the attachment To do so can severely damage the attachment and cause loss of warranty 2 3 Load Positioning 1 Always operate an attachment from the drivers seat 2 Always lower the attachment if you need to leave the lift truck Remember a lift truck support ing a load requires your full attention 3 Never use the attachment or its load to support or move other loads or equipment 4 Always carry loads as close to the floor as pos sible consistent with the surface being traversed Scraping or bumping the floor surface with the load or the attachment can severely damage the attachment and cause product damage The mast should be tilted back 5 of 10 5 Always keep the load positioned as close as possible to the horizontal center of the lift truck 6 Always back down ramps or inclines Driving forward down a ramp or incline with a clamped load will lessen the stabi
5. allation of backrests We suggest that you check your application against those re quirements 6 of 10 stems 45 060 REV 3 08 SECTION 3 INSTALLATION PROCEDURE 3 1 Truck Requirements Long Reach attachments have been designed to operate within specific limits Operating pressures above the stipulated maximum may cause structural damage to the attachment and may result in loss of warranty Hydraulic flow less than the recommended rates or the use of small 1 0 hoses may reduce oper ating speed Higher flow can result in excessive heat buildup erratic operation and damage to the truck attachment hydraulic system NOTE it is the responsibility of the dealer and or the user either to furnish and install the required valving to meet the recommended hydraulic pressures and flow or to arrange installation of the required valving at the truck factory or at Long Reach 3 2 Carriage 1 The truck carriage must conform to the American National Standard ASME dimensions shown in ASME B56 11 4 1992 reaffirmed 2000 2 Make sure the truck carriage is clean conforms to ASME recommendations and the notches are not damaged NOTE the model description found on your shipped invoice will state the following truck requirements flow gpm psi and min truck carriage width 3 3 Hydraulics 1 The truck hydraulic system must supply to the at tachment hydraulic oil that meets the specifications re
6. e shifting wear strips in the proper place if applicable 4 6 Make sure roller assembly is in place making con t tact with lower carriage bar 3 32 L MAXIMUM CLEARANCE 3 32 _ N 7 Slowly raise the truck carriage completely to engage the bolt on top hooks See Figure 3 2 with the truck cae carriage Tilt carriage back until the unit is against the as Required carriage bottom fork bar 0 degrees Figure 3 3 Lower Hook Clearance Grease Fitting 2 Inspect installation to ensure hoses are not kinked or pinched between the truck carriage and attachment 3 Operate the attachment continuously for several minutes to determine that all hydraulic connections are secure with no leaks 4 With the mast in the vertical position open the at tachment arms fully After this procedure check that the truck s hydraulic reservoir oil level is at the recom mended level Figure 3 2 Mounting 5 Before placing the attachment in operation check the 8 Install the bolt on lower hooks Inspect clearance to following the carriage on lower hooks Adjust the lower hooks for a maximum clearance of 3 32 see Figure 3 3 a Inspect all hoses and fittings for leaks and routing Tighten the bolts to 40 50 ft lbs clearance Be sure to include clearance of jumper hoses to the mast 9 Apply grease to bronze top hooks through fittings
7. eaks and cracked hoses or fittings 4 Check the hydraulic oil level in the lift truck hydrau lic reservoir 5 Check for physical damage to the attachment If anything looks wrong unusual or different report it before using the attachment 6 When removing installing dismountable attach ments always keep hands and feet free from danger ous positions or pinch points Never leave a dismount ed attachment in a dangerous position 7 Check to make sure that the dismountable attach ment is properly secured to the truck carriage before using the lift truck and attachment 8 Never stand on top of material being raised low ered or transported Figure 2 1 4 of 10 Allied COMPANY 9 Never use the attachment or its load to support man carrying device Figure 2 1 10 Never position an attachment or load over people Figure 2 2 Figure 2 2 11 Never leave an attachment or load in an elevated position 12 Never reach through the mast of the truck Keep all parts of the body within the driver s compartment 13 Never leave a lift truck unattended without lowering the load to the floor setting the brake and turning the truck off 45 060 REV 3 08 Reach 14 Always operate an attachment from the operator s seat never while standing next to the lift truck 15 Never stand in front of or beside an attachment that is being operated Never allow another person to approach an
8. engage from the upper mounting hooks and back away If lowering onto a floor blocks of wood can be place under the body of the attachment to raise the rear 6 To reinstall follow the installation procedure in this manual WHEN HYDRAULIC SERVICING HAS BEEN PERFORMED BEFORE RETURNING AT TACHMENT TO SERVICE BE SURE TO ACTIVATE THE HYDRAULIC FUNCTIONS SEVERAL TIMES TO BLEED OUT TRAPPED AIR IN THE SYSTEM 45 060 REV 3 08 Allied COMPANY 4 2 Cylinder Removal 1 Disconnect the hydraulic connections 2 Remove the cylinder rod end cotter pin and clevis pin BEFORE DISCONNECTING ANY HYDRAU LIC CONNECTIONS BE SURE TO TURN OFF THE TRUCKS POWER AND ACTIVATE THE TRUCKS HYDRAULIC FUNCTIONS IN BOTH DIRECTION TO BLEED OFF THE HYDRAULIC PRESSURE 3 Remove cotter pin and clevis pin at the base end of the cylinder 4 3 Cylinder Installation 1 Install the clevis pin and cotter pin into the base end of the cylinder 2 Attach the hydraulic connections to the cylinder 3 Extend the cylinder until the rod end hole lines up with the mounting hole Install the clevis pin and cotter pin into the rod end of the cylinder 4 Turn on the trucks power and activate the positioning cylinders several times to bleed out trapped air 9 of 10 SECTION 5 MAINTENANCE 5 2 Torque Specifications 5 1 Schedule Daily Nominal 1 Visually inspect all hoses fittings cylinders and valves for signs of hydraulic leaks 2 Vi
9. lity of the truck Figure 2 4 Figure 2 4 7 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 8 Always check loads to be handled If they are bro ken unbalanced loose or too heavy advise a supervi sor or properly correct the situation prior to handling 9 Limit lift truck movement to a minimum when high stacking Limit sideshift movement to a minimum when high stacking 10 Always be observant when high stacking Look for poorly stacked loads overhead obstacles broken cartons or damaged products in the stack 11 Always carry cylindrically shaped loads in the verti cal position not the horizontal 12 Always clamp loads with the contact pads if ap plicable not the arm or arm base 13 Never rotate a load that is off center to the center line of rotation Severe damage to the rotator could result 14 Always check the attachment for proper fit and engagement of the truck carriage 2 4 Operator s Controls 1 For clarity the direction of arm movement is shown on the control handle To move the arms in the direc tion shown pull the handle towards the operator To move the arms in the opposite direction the push the handle away from the operator Clamp Fork Positioner Push Pull Rotate Side Shift Figure 2 5 Note OSHA or state regulations may require the inst
10. missing look for the serial number stamped directly into the metal at the original location and consult factory APPROX S N PLATE LOCATION Date Received 7 ONE 5 ot Systems Company 77 MODEL SERIAL MAXIMUM HYD PRESS PSI WEIGHT LBS CAPACITY LBS inch LG SEE TRUCK NAMEPLATE FOR COMBINED TRUCK amp ATTACHMENT NET CAPACITY LOST 42 inches inches LOAL inches Ro CG AND SPECIFICATIONS ARE APPROXIMATE ET Manufactured By Allied Systems Company 21 4 Oregon Street Sherwood OR 97140 USA www alliedsystems com 2500005 RC 45 060 REV 3 08 Allied 3 of 10 COMPANY SECTION 2 SAFETY SUMMARY 2 1 General 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 1 Check your equipment before you operate it 2 Check to make sure the attachment on your truck is the same as on the truck capacity plate 3 Check for hydraulic l
11. quired to operate the attachment properly 2 When the truck hydraulic system pressures exceed this maximum a relief valve is recommended in the attachment auxiliary system of the truck or on the at tachment 3 Consult the truck factory and or Long Reach for guidance 45 060 REV 3 08 Allied COMPANY 3 4 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 THE CAPACITY OF THE TRUCK AND AT TACHMENT COMBINATION MAY BE LESS THAN THE CAPACITY SHOWN ON THE ATTACHMENT ALONE CONSULT TRUCK NAMEPLATE 2 Purging can be accomplished by installing a jumper line and operating each hydraulic function clamp rotate and side shift if equipped in each direction for a minimum of 30 seconds Figure 3 1 5 Figure 3 1 Jumper Line 3 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 4 Center the truck behind the attachment and drive toward the attachment with the mast tilted forward ap proximately 4 degrees 7 of 10 5 Line up the locking lug under the mid plate if ap plicable with the appropriate notch on the truck s car riage Check that the bronze sid
12. sually inspect for external damage or cracks 3 Check lower hooks for proper clearance Maximum clearance is 3 32 of an inch 4 If the attachment is equipped with Quick Change Hooks check the slide plate latch for engagement 100 Hour Maintenance 1 Complete the above daily checks 2 Check all hoses and fittings for wear or damage Inspect for hydraulic leaks 3 Check for loose or missing bolts 4 Check grease fittings to ensure that they are clean and working properly 200 Hour Maintenance er 1 Re torque Bronze hook bolts per chart Size 250 Hour Maintenance 1 Apply grease to bronze top hooks through fittings Use EP 2 Chassis Lube See Section 3 4 Notes i Allied COMPANY SAE Grade 5 Capscrews Dry Lubed 8 6 10 7 Thread Series SAE Grade 8 Capscrews Thread Series Torque Ft Lbs Inches Dy Lubed K 0 20 0 15 45 060 REV 3 08
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