INSTALLATION, MAINTENANCE AND SERVICE MANUAL LP AND
Contents
1. AND FAV I THE TRUCK S HYDRAULIC FUNCTIONS IN BOTH DIRECTIONS TO BLEED OFF HY DRAULIC PRESSURE 5 1 Cylinder Installation 1 Install the clevis pin and cotter pin into the base end of the cylinder WARNING 3 Extend the cylinder until the rod end hole lines up with the mounting hole Install the clevis pin and cotter pin into the end of the cylinder 5 2 Cylinder Removal 1 Disconnect the hydraulic connections 2 Remove the cylinder rod end cotter pin and clevis 3 Remove cotter pin and clevis pin at the base of the cylinder Ah WARNING FAILURE TO CYCLE THE HYDRAULIC CIRCUIT AS DESCRIBED ABOVE COULD CAUSE SERIOUS INJURY 5 3 Cylinder Disassembly 1 Remove the cylinder from the attachment See removal instructions 2 Clamp the cylinder 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 3 45 042 REV 05 10 COMPANY ONG REACH Figure 5 3 Cylinder Vise 3 Use a spanner wrench or similar tool to unscrew the gland cap from the cylinder tube Figure 5 4 Figure 5 4 Cylinder Rebuild 4 Remove the rod assembly from the cylinder tube 5 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 scarring Figure 5 8 45 042 REV 05 10 Allied COMPA2. REACH INSTALLATION MAINTENANCE AND SERVICE MANUAL LP AND PLP 45 042 REV 05 10 Zillied 1 of 12 COMPANY TABLE OF CONTENTS SECTION PAGE SECTION PAGE 1 NAME PLATE LOCATION 3 5 MAINTENANCE SCHEDULE 4 1 SCHEDULE M ee ee 9 E SARETA SNA 4 2 TORQUE SPECIFICATIONS 9 2 1 GENERAL INFORMATION 4 2 2 LOAD HANDLING ne 5 5 SERVICE PROCEDURES 2 3 LOAD 5 2 4 rIYDRAULIC S u uuu 6 5 1 CYLINDER INSTALLATION 10 2 5 OPERATOR S CONTROLS 6 5 2 CYLINDER REMOVAL 10 5 5 CYLINDER DISASSEMBLY 11 5 6 CYLINDER INSPECTION 11 E iss Loan sis 5 7 CYLINDER ASSEMBLY 12 3 1 TRUCK REQUIREMENTS 7 3 2 ATTACHMENT INSTALLATION 7 3 3 HYDRAULIC S EN 7 3 4 ATTACHMENT REMOVAL 8 2 of 12 Allied stems 45 042 REV 05 10 ONG REACH SECTION 1 NAMEPLATE LOCATION 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 IS MISSING LOOK FOR THE SERIAL NUMBER STAMPED DIRECTLY INTO THE METAL AT THE ORIGINAL LOCATION AND CONSULT FACTORY D
3. LPM 3 2200 2300 PSI 150 160 Bar 4 At least one auxiliary function NOTE IT IS THE RESPONSIBILITY OF THE DEAL ER AND OR THE USER TO INSTALL THE RE QUIRED VALVING TO MEET THE RECOMMENDED HYDRAULIC PRESSURES AND FLOW THE RE QUIRED VALVING CAN BE FURNISHED BY THE DEALER THE TRUCK FACTORY OR LONG REACH Figure 3 1 Jumper Line 45 042 REV 05 10 Alllied COMPANY 3 2 Attachment Installation 1 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 2 Remove the lower bolt on hooks and if applicable make a note of any factory installed shims If Quick Change Hooks are equipped simply depress the but ton on the back of the hooks allowing the slide plate to drop Figure 3 2 3 Center the truck behind the attachment and drive toward the attachment with the mast tilted forward ap proximately 4 4 Line up the locking lug if applicable with the ap propriate notch on the truck s carriage Check that the bronze side shifting wear strips are in the proper place if applicable 5 Make sure the wear pad is in place and making contact with lower carriage bar FAILURE TO CYCLE THE HYDRAULIC CIRCUIT AS DESCRIBED ABOVE COULD CAUSE SERI OUS INJURY IF HYDRAULIC SUPPLY HOSES ARE DISCON NECTED HYDRAULIC FLUID WILL LEAK OUT AND PUSH PLATE MAY DRIFT OUTWARD 3 4 At
4. a doctor immediately to prevent loss of limb or death 2 5 Operator s Controls 1 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 push the handle away from the operator Clamp Fork Positioner N ND X x Yau con A Push Pull Rotate Side Shift Figure 2 5 NOTE OSHA OR STATE REGULATIONS MAY REQUIRE THE INSTALLATION OF BACKRESTS WE SUGGEST THAT YOU CHECK YOUR APPLI CATION AGAINST THOSE REQUIREMENTS 45 042 REV 05 10 ONG REACH SECTION 3 INSTALLATION AND REMOVAL 3 1 Hydraulics 1 Prior to connecting the truck hydraulic system to the attachment the system must be cleaned through the filtration system This will eliminate any contamination that may exist in the auxiliary hydraulic system of the truck 2 Filtering can be accomplished by installing a jumper line and operating each equipped hydraulic function in each direction for a minimum of 30 seconds Figure 3 1 THE CAPACITY OF THE TRUCK AND ATTACH MENT COMBINATION MAY BE LESS THAN THE CAPACITY SHOWN ON THE ATTACHMENT ALONE CONSULT TRUCK NAMEPLATE The lift truck hydraulic system must meet the following specifications 1 Supply petroleum based hydraulic oil 2 7 10 GPM 26 5 37 8
5. 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 affects the stability and steering of the lift truck 45 042 REV 05 10 Allied COMPANY 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 may result in product 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 l
6. NY A Figure 5 5 Cylinder Shaft 6 Remove the piston retaining nut and remove the piston Figure 5 4 7 Carefully pry up on the piston seals using a blunt tip screw driver being careful not to scratch the seal grooves Cut the seals to remove from the piston Figure 5 6 Figure 5 6 Piston Seal 8 Use the same procedure as above to remove the seals from the gland cap 5 4 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 seal grooves 2 Wear on Inspect the Cylinder Rod for 1 Scratches or nicks on the rod surface 2 Straightness of the rod 3 Damaged threads 11 of 12 Inspect the Gland Cap for 1 Scratches or nicks in seal grooves 2 Damaged threads or spanner wrench holes 3 Excessive wear in bore Replace any component found to be bad 5 5 Cylinder Assembly 1 Spray the Piston Gland Cap and Seals with WD40 or other similar product to ease slipping of the seals in place 2 Note the direction of the seal on the piston Im proper installation will result in poor performance The cupped side or O Ring side of the seal should be fac ing the gland cap Figure 5 10 Figure 5 10 Piston Seal 3 Install the seals and wipers in the gland cap Note the direction of the seals The cupped side or O Ring
7. ate Received A Division of ONE EAGT Allied Systems Company MODEL NO SERIAL NO MAXIMUM HYD PRESS PSI WEIGHT CAPACITY LBS inch LG SEE TRUCK NAMEPLATE FOR COMBINED TRUCK amp ATTACHMENT NET CAPACITY inches inches LOAD inches CG AND AET SPECIFICATIONS ARE APPROXIMATE Manufactured By Allied Systems Company Oregon Street Sherwood OR 97140 USA C wunwalliedsystems com 2500005 R C 45 042 REV 05 10 Allied 3 of 12 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 Checkto make sure the attachment on your truck is the same as on the truck capacity plate 3 Check for hydraulic leaks and cracked hoses or fittings 4 Checkthe 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 attachm
8. dled 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 2 4 Hydraulics 1 Be aware of the hazards of pressurized hydraulics 2 Wear personal protective equipment such as gloves and safety glasses whenever servicing or checking a hydraulic system 6 of 12 Allied COMPANY 3 Assume that all hydraulic hoses and components are pressurized Relieve all hydraulic pressure before disconnecting any hydraulic line 4 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 Small hydraulic hose leaks are extremely dangerous and can inject hydraulic oil un der the skin even through gloves Infection and gangrene are possible when hydraulic oil penetrates the skin See
9. ent 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 Checkto 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 12 Allied COMPANY Figure 2 1 9 Never use the attachment or its load to support a man carrying device 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 45 042 REV 05 10 ONG REACH 14 Always operate an attachment from the operators 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 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
10. ks 4 Activate cylinders fully and check that the truck s hy draulic reservoir oil level is at the recommended level 5 Before placing the attachment in operation check the following a Inspect all hoses and fittings for leaks and routing clearance Be sure to include clearance of jumper hoses to the mast b Check the valve and cylinder for leaks c Check cotter pins at each end of the cylinder for security 6 After completing the installation operate the attach ment 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 NOTE IT IS THE RESPONSIBILITY OF THE DEALER AND OR THE USER EAITHER TO FURNISH AND INSTALL THE REQUIRED VALVING TO MEET THE RECCOMENDED HYDRAULIC PRESSURES AND FLOW OR TO ARRANGE INSTALLATION OF THE REQUIRED VALVING AT THE TRUCK FAC TORY OR AT LONG REACH THE MODEL DESCRIPTION FOUND ON THE SHIPPING INVOICE WILL STATE THE FOLLOWING TRUCK REQUIREMENTS FLOW GPM PSA AND MIN TRUCK CARRIAGE WIDTH WARNING 45 042 REV 05 10 ONG REACH SECTION 4 MAINTENANCE 4 1 Schedule 4 2 Torque Specifications MekicCupscrews TomueNin FH bs Daily Tonu Mhn 1 Visually inspect all hoses fittings cylinders Che 3 8 Chess 10 0 valves for signs of hydraulic leaks 2 Inspect hoses for wear pinching and replace as required 3 Inspect forks for nicks dents rough sp
11. oads 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 driver s 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 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 stability of the truck Figure 2 4 5 of 12 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 Figure 2 4 8 Always check loads to be han
12. ots and repair as required 4 Visually inspect lower hook installation and check unit for external damage or cracks 40 Hour Maintenance 2 Inspect retaining pins and replace as required Notes 3 Tighten mechanism pivot retaining pin bolts 4 Lube bronze top hooks if needed 5 Lube mechanism if desired Use Light Oil 6 Check lower hook clearance 3 16 5mm maxi mum and adjust as required 1 Complete the above daily checks 500 Hour Maintenance 1 Perform 40 hour inspection 2 Inspect bushings for excessive clearance 1 32 1mm maximum at all pivots and replace as required 3 Tighten and torque all bolts a Top Hooks 225 N m b Lower Hooks 225 N m c Fork Hooks 225 N m Recommended Grease Mobile XHP222 Special or similar quality EP 2 with Lithium Complex Base 45 042 REV 05 10 Allied 9 of 12 COMPANY SECTION 5 SERVICE PROCEDURES 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 Raise Slide to secure attachment to truck Push button to lower Slide THIS SLIDE PLATE MUST CLICK INTO PLACE TO TO THE CARRIAGE IF THE SLIDE PLATE DOES NOT BECAUSE THE TRUCK TS THE SLIDE PLA ED UP HIGH ENOUGH ALLED BE 10 of 12 Allied WARNING VIT
13. side of the seal should be facing the piston Figure 5 11 12 of 12 Allied COMPANY Figure 5 11 Gland Cap Seal 4 Install the piston on the rod and tighten the locknut to 70 75 ft lbs 5 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 rub ber mallet if resistance is encountered 6 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 to cover the rod threads or plastic electrical tape 7 Tighten the gland cap using a spanner wrench 45 042 REV 05 10
14. tachment Removal 1 Disconnect hydraulic connection at the attachment from the truck 2 Disconnect the Quick Mounts to remove the attach ment Figure 3 2 3 Slightly raise the truck carriage to allow the removal of the bottom mounting hooks If the attachment is equipped with Quick Change Hooks Buiton Type press the slide plate release button and drop the slide plate down Figure 3 2 If the attachment is equipped with Quick Change Hooks Pin Type remove the Re 7 of 12 taining Pin and the Quick Change Hook THIS SLIDE PLATE MUST CLICK INTO PLACE TO ENSURE THE ATTACHMENT IS SECURED TO THE CARRIAGE IF THE SLIDE PLATE DOES NOT CLICK INTO PLACE BE CAUSE THE TRUCK CARRIAGE PREVENTS THE SLIDE PLATE FROM BEING RAISED UP HIGH ENOUGH SHIMS MUST BE INSTALLED BETWEEN THE ATTACHMENT AND THE BODY OF THE QUICK CHANGE HOOKS 3 5 Hydraulic Connections Raise Slide to secure attachment to truck Push button to lower Slide Figure 3 2 Quick Change Hook MAX CLEARANCE 2 mm SHIM S IF REQUIRED Figure 3 3 Lower Hook Clearance 8 of 12 Allied COMPANY ANY ALTERATIONS TO THE ORIGINAL AT TACHMENT MAY AFFECT PERFORMANCE OR SAFETY AND RESULT IN LOSS OF WAR RANTY 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 lea
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