Service Manual - Hans H. Meyer GmbH
Contents
1. 625 02 07 Ver GB01 GB5 Hans H Meyer GmbH List of Contents SCOPE OL delivery PTT ea TT 7 Standard ACCESS ONES nn da aide einen nds 7 Opt ONAlLACCESSOLIES sie 7 INGLICE TOP TNE Teader unsre 7 bled B rM 8 THOU ATOMS as tases 8 Acconmae oq tongues E E 8 ProducbdescripBOB 5 222555 ut 122b ee armani 9 PFroductmdent ftcatlOncse seq tentatio au ted ERE ERU de tease diet 9 Intended application uinci teri an I 10 PROGUCEGESCEIDUON us dob nia oa endroit 10 FUNCHONALGESCH POON a aus en ae a u 10 Possible applications aoo oot NO Huet em aO a2 11 Operator classification Qualification c cc ceeescscccececeeseeseeeeceeceeeesaeenseeeeeess 11 Period OF operation Les ne nono 11 Forklifttr ck requiremen sa ua 11 Si pM 12 Qualitication Of personnel una a a a aa a 12 Copal sale y ouseentttant ae ee 12 Personalsale y side an P 13 Progiet sale EP ET 14 Transport andmountine nu a ua 16 Delivery and transport au ae Eee 16 PACKAGING euere een senden 16 UNPACKING PA ae 16 Mounting Install anon au ua 16 Notice to ecological Operation essen ana Ea 16 Mounting and connections to the forklift truck sss 16 Initialoperation 1509 9 Bc ee TR LE 20 Initial peration a 20 Pressure SETHI OS a nn ee 20 Settings The pressure sus ne cran sania ral nan 21 Trail operaton eek ae EEE 23 Conductine a TEatl san 23 Preparation for continuous operation s ries 23 COMMISSION S ee ehe 23 Han2. procedure by using compressed air 3 Inspect the attachment for leaks in hydraulic cylinders valves and the various other hydraulic connections 4 Inspect the load arms forks and the main frame for deformation and cracks 5 Inspect all fastening bolts if necessary by using a torque wrench to check tightness a torque table can be found in the addendum 6 Apply fresh lubricant to the guide profiles Be sure to use grease that will not thicken or harden when exposed to very low temperatures Grease recommendations GENERAL PURPOSE Class 2 7 Take all relevant moving parts through their movements to disperse the lubricants evenly 8 Spray all blank metallic parts with a commercial preservative intended for this purpose o Always give the type and serial number see product identification label when technical assistance or spare parts are required GB27 Hans H Meyer GmbH Addendum Torque table for bolted fastenings When tightening cylinder and hexagon type bolts the correct torque must be obtained by using a torque wrench The necessary torque requirements are classified by their sizes and strengths in the table below Old and used bolts must always be replaced by new ones Anzieh Drehmomente torque table couples de serrage Fiir for avec Schrauben bolts vis Verbus Ripp Festigkeitsklasse class of strength Force de r sistance GB28 625 02 07 Ver GB01 GB28 625 0
3. Operating personnel Must have adequate instruction in the functional and operational sequences Knowledge of operational sequences while executing the required work operations Service personnel Established knowledge of mechanical engineering electrotechnology and hydraulics Authorisation to comission the attachment according to the relevant standards of technical safety Established knowledge of the composition and functioning of the attachment As an operator of attachments it must be ensured that all persons involved in the mounting operating servicing or repairing of attachments have thoroughly read and understood the relevant parts of the Operating and Service Instructions This attachment complies to the current state of science and technology It is dependable and safe to operate Even so it could still harbour possible dangers to persons or faults may occur Attention to the Operating and Service Instructions is therefore mandatory The manufacturer s Operating and Service Instruction manual is a conduct of behavior for the operators of attachments and for all persons involved in the mounting operating servicing or repairing of attachments Risk of injury through improper application Be aware that persons may be at risk through improper use Furthermore damage to the cargo or the attachment may also result from incorrect handling GB12 625 02 07 Ver GB01 GB12 625 02 07 Ver GB01 GB13 Hans H Meyer Gmb
4. Preparation for continuous operation Commissioning Regular checks before starting work Inspect the complete hydraulic system for leaks Inspect for damage to hydraulic cylinders and fittings such as hoses pipes valves and connectors Inspect for wear and cracks in the load arms Inspect for deformation of any parts indication of a possible accident That the attachment is well seated on the forklift truck and that the retaining bolts for the upper and lower hooks are screwed in tightly see addendum Torque Table If damage is detected By no means is the attachment to be used Inform the appropiate supervisor responsible immediately GB23 Hans H Meyer GmbH Handling continuous operation Caution Operational pauses Short pause Warning The attachment on its own not attached to a forklift truck cannot be activated and can therefore not be operated Because of the wide variety of forklift trucks and the differing operating functions levers pedals and switches etc it is necessary that the operating instructions for these functions be taken from the forklift truck instruction manual Danger to life Adhere to all safety regulations Pay attention to this instruction manual The attachment may only carry loads in relation to its load centre that do not exceed the maximum load stated on the attachment identification label If reduced load capacities are stated on the rating plate for forkl
5. 2 07 Ver GB01 GB29 Hans H Meyer GmbH Hydraulic circuits The reference markings on the hydraulic valve are interpretated as follows Al A2 open load arms B1 B2 close load arms S1 S2 side shifting to the left and right ZAl ZA2 cylinder connections to the piston head side ZB cylinder connections to the piston rod side NNNM RENE Be e o e B f IL T D UT 2 tun da LH o gt S1 mE ZB ZA3 ZA GB29 Hans H Meyer GmbH For your notes GB30 625 02 07 Ver GB01 GB30
6. 625 02 07 Ver GB01 GB1 stapleranbauger te forklift truck attachments quipements hydrauliques seit 1953 Made in QUALITY heftruck voorzetapparatuur Fork Positioner Type 6 25 Operating and Service Instructions GB Hans H Meyer GmbH cd9 1089 J9 20 c0 829 GB2 625 02 07 Ver GB01 GB3 Hans H Meyer GmbH Titel Product Product type Issued by Contact Suggestions and tips Further information Operating and Service Instructions Fork Positioner 6 25 Hans H Meyer GmbH Gittertor 14 D 38259 Salzgitter Tel 49 0 5341 803 0 Fax 49 0 5341 803 196 Mail info meyer sz de Web www meyer world com Hans H Meyer Ltd Unit 15 Haigh Park Whitehill Ind Est Reddich UK Stockport SK4 1QR Tel 44 0 161 4806464 Fax 44 0 161 4804082 Mail sales meyer uk com This document is copyrighted All rights reserved This document may not be copied duplicated translated or transformed into an electronic medium or other machine readable form either as a complete document or as segments of it without the permission of Hans H Meyer GmbH Subject to change without notice about this Documentation or to the Product may be sent to the above address covering other products from Hans H Meyer can be found on our Internet page www meyer world com or by phoning us on 49 0 5341 803 0 or 44 0 161 4806464 GBS Hans H Meyer GmbH vaS 1085 19 70 20 8c9 GB4
7. H Personal safety Caution Caution Caution Danger to life through crushing and shearing The life of persons may be endangered through the crushing and shearing actions that occur during the movements of the load arms The attachment may only be activated when the danger zone is free of all persons 0 5m lt lt Danger zone Dangers through crushing You may be in danger of being crushed by the attachments own net weight Always safeguard the attachment against the possibility of it falling over or falling off The attachment has a substantial net weight This may cause dangerous crushing actions during mounting or storage proceedures Taking this into consideration initiate the appropriate safety precautions Dangers through poisoning Skin contact with lubricants is health threatening Avoid all skin contact with lubricants and hydraulic oils The technical features of all modern lubricants and hydraulic oils can cause serious illness if swallowed or come into contact with the skin GB13 Hans H Meyer GmbH Product safety Warning Damages caused to products and the attachment Incorrect handling of the attachment is likely to cause damage to the product Always apply the attachment correctly to the product Always use the attachment and its functions in the correct form and manner Note the following instructions Ensure that the attachment is mounted securel
8. dling continuous operation ss 24 Operational PISE aussehen run 24 SNO PAUSE au ee een 24 Restart operatios neue 24 IB eee 9110 ass 25 Decommissioning the attachments 25 Removing the attachment from the forklift truck sssssee 25 DISPOSAL an ea en u u lu 26 Disposal Of the attachment a 26 Maintenance and serviche una einen 26 Preventive measte o 030 quii a nn eu 26 Regular inspections before starting work ccccseseessseceeeceeeeeeeseseeeeeeeeeaas 27 Resular MAIMENANES Sn E T E 27 GB5 Hans H Meyer GmbH Addendum Torque table for bolted fastenings a an Rt e Poe dun Im y CALI eine US gop pce ee erteilen TODS OUI MONG a A nd De emailen GB6 625 02 07 Ver GB01 GB6 625 02 07 Ver GB01 GB7 Hans H Meyer GmbH Scope of delivery The Fork Positioner in future known as the attachment s delivered completely assembled and ready for use Standard accessories The attachment is delivered without accessories Optional accessories Optional accessories and spare parts obtainable on request Further information covering optional delivered accessories may be found in the documentation delivered herewith GB7 Hans H Meyer GmbH Notice for the reader Validity Illustrations This document contains information and the code of conduct required for safely operating this attachment We advise reading this document completely before operating the attachment Keep t
9. following information Manufacturer and address Warning notice to load capacity Year of manufacture Type Serial number Load capacity Loadcentre Mass Centre of gravity Hydraulic operating pressure CE Symbol Works number if applicable GB9 Hans H Meyer GmbH Intended application The Fork Positioner is an attachment for forklift trucks which replaces the trucks own forks and is used to transport loads A different application or an application far in excess of the intended rating is not in compliance Misappropriate use in particular Any kind of transportation of persons Carrying loads in excess of the maximum stated on the identification label Displacing loads sideways that are not free of the ground Operating an attachment that is not correctly mounted on the forklift truck Operating a defective attachment Operating an attachment on a defective forklift truck Handling by unqualified persons Product description The attachment has a very sturdy and torsion resistant basic chassis Incorporated in this basic clamp body are two horizontal chromed guide bars Mounted on the guide bars are two ajustable fork carriers which are conform with ISO 2328 and enables standard forks to be used Optionally the forks can also be bolted on The attachment also has an upper mounting hook which extends across the whole width of the back structure which provides more ridgidi
10. his document ready for reference at all times In order to operate this attachment effectively the following aspects are covered in this document Transportation of the attachment mounting and trail operation Working with the attachment Maintainance and servicing the attachment This document is valid for the operating company all persons working on or operating this attachment Some of the illustrations in this document show the attachment in a simplified or diagrammatic manner Accentuated text Caution Warning Varying circumstances have been accentuated Symbols mark important information The following examples show the principal accents and symbols used 1 Step an operational sequence 2 Step the next operational sequence etc These are health and safety notices Warning notices point out dangers to life and limb or damage that may occur to the attachment through improper use This is an indication of further available information Such references are intended to help simplify working with the attachment GB8 625 02 07 Ver GB01 GB8 625 02 07 Ver GB01 GB9 Hans H Meyer GmbH Product description Product identification All attachments are clearly marked with a identification label The identification label is attached to the front righthand side of the backplate as seen from the operators driving position Identification label The identification label bears the
11. hocks or n shelves such as bar sections or where the load itself can be entered e g large pipes It is not allowed to clamp loads of any kind using only the tips of the load arms Operator classification Qualification As an operating company you must have adequate qualified personnel to operate forklift truck attachments Further details to this subject may be found in the following chapters of this instruction manual In the case of not having qualified personnel or furthermore having doubts to this subject you may ask Hans H Meyer GmbH or Hans H Meyer Ltd for assistance Period of operation The attachment is designed for uninterupted operation on forklift trucks Forklift truck requirements The forklift truck carriage dimensions must comply to the ISO Standard 2328 The following values may help for the orientation Reference dimension h3 Hydraulic delivery volumes aw Po n Mounting classes Truck Carriage ISO 2328 The hydraulic delivery volume should be approx 30 l min Lower hydraulic delivery volumes will result in slower and irregular load arm travel speeds Higher hydraulic delivery volumes result in excessive oil temperatures which will cause greater wear and less efficiency in the Hydraulic system GB11 Hans H Meyer GmbH Safety Qualification of personnel Global safety Caution All persons either working on or with the attachment must be qualified to do so
12. ift trucks with attachments then these specify the maxmimum loads to be carried Suitable load types and their handling can be found in chapter Product description In order to avoid further damage occuring after an accident a trained person must thoroughly inspect all parts of the basic unit for distortion and fractures A short pause can be defined as switching off the forklift truck to end a working day or before the start of a work break In these or similar cases follow the instructions in the forklift truck instruction manual Dangers caused by falling or slipping loads No loads may be resting on the load arms while the attachment is standing idle Observe the instructions in the forklift truck instruction manual Relieve the attachments hydraulic system of pressure see forklift truck instruction manual Restarting operations See chapter Preparation for continuous operation GB24 625 02 07 Ver GB01 GB24 625 02 07 Ver GB01 GB25 Hans H Meyer GmbH Decommissioning To decommission an attachment means that the attachment is removed from the forklift truck for either being refitted at a later date being fitted to a different forklift truck Decommissioning the attachment Requirements a suitable vessel to be at hand to catch escaping hydraulic oil either sawdust or a similar binding agent is at hand to absorb leaked hydraulic oil asuitable transport pallet is at ha
13. k away from under the upper mounting hooks 7 Lower the attachment onto the transport pallet and safeguard it against falling over e g by tying it down 8 Tosafeguard against loss refit the lower bolts and mounting hooks 9 Store the attachment in a dry place and cover it using a suitable covering A GB25 Hans H Meyer GmbH Disposal After the expiration of the assigned working period or working life has been reached the attachment may be decommissioned and scrapped Disposal of the attachment Follow the next steps 1 Decommission the attachment see the last chapter 2 Take appropriate measures to ensure that the attachment is kept from being used again Dismantle the attachment professionally 4 Seperate all individual parts and scrap them according to the materials used 5 Dispose of all surplus fluids according to regulations 9 Maintenance and servicing Warning Caution Service and repairs at regular intervals are the vital key to prolonging the attachments working life Breakdown Repairs to major functional elements such as hydraulic cylinders and valves must only be carried out by persons trained to do so Danger to life Work on the hydraulic system must only be carried out after first depressurising the hydraulic circuits Escaping jets of high pressure hydraulic oil can cause bad injuries if the hydraulic circuit 1s not first depressurised before working on it Preven
14. lic pressure constant for 10 seconds Inspect all hydraulic couplings for leakages When neccesary retighten any leaking hydraulic couplings The preliminary working pressure neccesary to operate the side shifting function of the load arms is preset in the factory The diversity of hydraulic systems and forklift trucks and the different perfomance rates of these systems requires indiviual pressure settings Ideally amaximum pressure of 120 bar should not be overstepped for any of the functions This maximum pressure is to set on the forklift truck It is not always neccesary to use the maximum hydraulic working pressure The pressure settings should in fact be adjusted to suit the load type this will guard against damage and prolong the working life of the attachment Valve with cap nut GB20 625 02 07 Ver GB01 GB20 625 02 07 Ver GB01 GB21 Hans H Meyer GmbH Setting the pressure Requirements Prepare a load with the maximum permitted load capacity Follow the next steps 1 Remove the existing cap nuts Valve with cap nut removed 2 Slacken off the locknut Slackening off the locknut 3 Completely unscrew the adjusting screw anti clockwise Unscrew the adjusting screw GB21 Hans H Meyer GmbH gt Now lift the maximum load in preparation for setting the side shifting function 5 Operate the sideshift lever 6 Slowly turn the adjustment screw for the side shift function clock
15. nd Follow the next steps 1 With the help of a high pressure cleaner remove all dirt and the remains of lubrication from the guide profiles 2 Leave the attachment to dry in the open air or speed up the procedure by using compressed air 3 Apply fresh lubricant to the guide profiles for suitable lubricants see the chapter on Maintenance and Servicing 4 Takeallrelevant moving parts through their movements to disperse the lubricants evenly 5 Spray all blank metallic parts with a commercial preservative intended for this purpose 6 Switch off the forklift truck 7 Relieve the hydraulic system of pressure see the instructions in the forklift truck manual Removing the attachment from the forklift truck Caution Risk of injury through hydraulic oil spillage Hydraulic oil may be spilled onto the floor when disconnecting the hoses thereby increasing the danger of slipping Skin contact may cause chemical burns Follow the next steps 1 Wear your personal protective gear 2 Disconnect the hydraulic jumper hoses from the forklift truck 3 Catchany leaking hydraulic oil with an appropriate vessel 4 Any spilled hydraulic oil must be bound using the appropriate binding agent and disposed of in accordance to regulations Remove the bolts from the lower mounting hooks 6 Secure the attachment with suitable lifting tackle and by tilting the mast forwards and lowering the fork carriage reverse the forklift truc
16. the attachment must be either onthe original pallet securely mounted on the forklift truck hung inappropriate lifting gear 1 e with ropes or slings Generally the attachment 1s delivered on a suitable transport pallet and secured with security bands but without any further packaging In some cases foil packaging may be used to avoid corrosion Remove all existing packaging Dangers through overturning After the removal of all security bands the attachment is in a free standing state and could possibly tip over Be sure the pallet with the attachment is on a level surface Support the attachment using lifting gear or similar before removing the security bands Remove the security bands Dispose of any packaging materials in the approved manner Further steps are to be taken from the following chapters Notice to ecological operation Warning Enviromental pollution through lubricants Great attention must be paid in stopping hydraulic oil and lubricants from polluting the environment Mounting and connections to the forklift truck Caution Personal injury Installation work Requirements Arrange the pallet with the attachment so that the forklift truck can drive behind the back Make sure that the attachment cannot fall over GB16 625 02 07 Ver GB01 GB16 625 02 07 Ver GB01 GB17 Hans H Meyer GmbH Follow the next steps 1 Apply a lifting rope or sling arround the
17. tive measures A higher rate of wear possibly causing corrosion to the guide profiles will result from attachments operating in extremely dirty environments this can also have negative effects on other blank metallic surfaces e g piston rods causing leaks around the packing seals Quite often dirt collecting on the attachment is caused by the front wheels of the forklift truck which throw up dirt and grit from the road surface Itis therefore advisable to fit the truck with suitable mudguards GB26 625 02 07 Ver GB01 GB26 625 02 07 Ver GB01 GB27 Hans H Meyer GmbH Regular inspections before starting work The following points must be accounted for before starting work Leakages in hydraulic cylinders valves and the various other hydraulic connections Deformation and cracks in the load arms The correct mounting of the attachment on the forklift truck and especially the fastening bolts for the mounting hooks If damage is detected inform the appropiate supervisor responsible immediately Regular maintenance Lubrication and maintenance intervals are dependant on the workload of the application and external influences e g the effects of dust and dirt fluctuations in temperature change and weather conditions Follow the next steps 1 With the help of a high pressure cleaner remove all dirt and the remains of lubrication from the guide profiles 2 Leave the attachment to dry in the open air or speed up the
18. ty and allows the attachment to be mounted on forklift trucks with narrower fork carriages The lower mounting hooks can also be of the quick release type Functional description The load arms are adjusted horizontally by hydraulic cylinders which are operated from the drivers position on the forklift truck To ensure safe transportation the load must be lifted with the forks adjusted to the widest possible setting The hydraulic load arms can also be adjusted horizontally as a pair lateral to the forklift trucks longditudinal axis this allows the operator to correct misalignment of the forklift truck during his approach This integrated side shifting only applies when the load arms are at an intermediate position between the opening range of the attachment The resulting reserve stroke of the adjusting cylinders is then available for side shifting The hydraulic circuit has an integral lockvalve which holds the load arms in the position to which they have been adjusted GB10 625 02 07 Ver GB01 GB10 625 02 07 Ver GB01 GB11 Hans H Meyer GmbH Possible applications This type of attachment may only be used for the transportation of loads that can to be carried on forks Suitable loads are loads to be carried on pallets in boxes or crates in tubs bins or in frames These loads must have suitable load holding facilities such as pockets or must be elevated to accept the forks Other suitable loads are those elevated by c
19. upper guide bars or screw ring bolts into the threaded holes in the top of the attachment frame to lift the attachment with hooks With ring bolts and hooks With lifting sling 2 Unbolt and remove the lower mounting hooks Fixing bolts for the lower mounting hooks GB17 Hans H Meyer GmbH 3 Drive the forklift truck centrally behind the hanging attachment 4 Lower the attachment onto the fork carriage of the truck until the upper mounting hooks have completely closed over the carriage profile Be sure that the centre locking pin of the attachment locates inthe central notch of the carriage Central slot of the fork carriage Refit the lower mounting hooks Now tighten up the bolts with a torque wrench Connect the hydraulic jumper hoses to the attachment and make the to the repective connections to the forklift truck GB18 625 02 07 Ver GB01 GB18 625 02 07 Ver GB01 GB19 Hans H Meyer GmbH Hydraulic jumper hose connections Connection 1 Load arm adjustment Connection 2 Side shifting GB19 Hans H Meyer GmbH Initial operation Initial operation Follow the next steps 1 Check the oil level in the forklift truck as the attachment withdraws Pressure settings Bauen a certain volume of hydraulic oil from the trucks tank When neccesary top up the hydraulic oil Take all functions that being all cylinders to the end of their travel Respectively keep the hydrau
20. wise until the load starts to move at an adaquate speed 7 Lock the adjustment screw with the locknut and refit the cap nut The cap nut has been refitted 8 All pressure settings have now been correctly adjusted GB22 625 02 07 Ver GB01 GB22 625 02 07 Ver GB01 GB23 Hans H Meyer GmbH Trail operation During the trail operation the verification of the load bearing capacity is to be carried out using the maximum load stated on the identification label of the attachment However if the forklift truck rating plate specifies a lower load carrying capacity only loads to or below this specification may be transported Conducting a trail Requirements Choose a suitable load for the trail opertation The load chosen must be of the same type as the load to be transported during normal daily operations Follow the next steps 1 Opened the load arms to an approriate width to safely lift the load 2 Lait the load to a height of approx 10 cm off the floor 3 Side shift the load to each side and hold the forklift truck lever in its fully deflected position for approx 10sec 4 Inspect all hydraulic elements and connctions for leaks 5 Ifall functions work correctly and no leaks are apparent the attachment may now be put into operation Should the trail be a failure check the pressure settings or reset them as required If no serviceable result can be obtained inform the appropriate supervisor responsible
21. y to the forklift truck When opening the attachment be sure not to shift other loads sideways Loads being forced sideways while opening the load arms The load arms and attachment are not designed to withstand this kind of overloading serios damage may be caused to both Loads on the ground must not be moved sideways with the sideshift function Loads being forced sideways while sideshifting GB14 625 02 07 Ver GB01 GB14 625 02 07 Ver GB01 GB15 Hans H Meyer GmbH No loads are to be clamped between the tips of the load arms 7 L 6222 277 ff 277 JL Loads being clamped between the tips of the load arms During transportation the load must rest against the backrest this applies especially to loads that reach the maximum load capacity of the attachment this may otherwise cause a change in load centre which in turn causes the attachment to be overloaded and the forklift truck may topple forwards CM The load against the fork backs GB15 Hans H Meyer GmbH Transport and mounting Delivery and transport Packaging Unpacking Caution Mounting Installation The Hans H Meyer GmbH delivers the attachment on a pallet During transportation
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