Installation, Maintenance and Service Manual
Contents
1. 8 2 16 Industry Standards eros 8 2 17 Clamp Open 8 2 H 45 015 REV 2 12 Allied COMPANY 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 NM 2 2l 21433 SW Oregon Street 2500005 rF SN O ONG REACH A Division of Sherwood OR 97140 USA E Allied Systems Company www alliedsystems com MODEL SERIAL NO NO MM KG MM MASS AET IN LBS CAPACITY KG AT LOAD CENTER LBS MAXIMUM HYDRAULIC PRESSURE FLOW HCG L PSI GPM IN IN SEE TRUCK NAMEPLATE FOR COMBINED TRUCK amp ATTACHMENT CAPACITY C 45 015 REV 2 12 Allied 3 COMPANY UL NN DATE o SECTION 2 SAFETY SUMMARY 2 1 Safety Information Safety is Everyone s Responsibility Whether you are new on the job or a seasoned veteran these safety tips m2. Fork position Sideshift Push pull Figure 2 5 Operator controls Rotate Allied COMPANY 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 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 If the attachment does NOT operate smoothly do not take it on the job Check with your supervisor about needed repairs to avoid injury or equipment damage 2 16 Industry Standards ANSI ITSDF B56 1 2009 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 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
3. 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 All possible safety hazards cannot be foreseen so as to be included in this manual Therefore the operator must always be alert to possible hazards that could endanger personnel or damage to the equipment Obey the following warnings before using your machine to avoid equipment damage personal injury or death 2 4 Operation Warnings e You must be trained to operate this equipment prior to operation Be extremely careful if you do not nor mally operate this machine Reorient yourself to the machine before starting then proceed slowly Always operate an attachment from the driver s seat Always lower the attachment if you need to leave the lift truck A lift truck supporting a load requires your full attention 2 5 Hydraulic Hazards Danger Small hydraulic hose leaks are extremely dangerous and can inject hydraulic oil under the skin even through gloves Infection and gangrene are possible when hydraulic oil penetrates the skin See a doctor immediately to prevent loss of limb or death 45 015 REV 2 12 ONG REACH A Division of Allied Systems Company e Wear personal protective equipment such as gloves and safety glasses whenever servicing or checking a hydraulic
4. 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 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 2 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 2 4 Figure 2 4 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 Limit lift truck movement to a minimum when high stacking Limit sidesh
5. moving a control lever to the rear 2 17 Clamp Open Control Effective October 7 2010 a new safety standard ANSI ITSDF B56 1 Section 7 25 7 for all lift trucks with a load bearing clamp paper roll clamp carton clamp etc 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 45 015 REV 2 12 REACH A Division of Allied Systems Company Direction of motion Load Operator s hand on control handle facing the load Up Rearward or up Reach Retract Rearward or up Extend Forward or down Tilt Rearward Rearward or up Forward Forward or down Right Rearward or up NS TNNT Rearward Rearward or up P Forward Forward or down Rotate lateral Clockwise Rearward or up Counterclockwise Forward or down Rearward Rearward or up Load stabilizer Down Rearward or up Up Forward or down Right Rearward or up Slope Clockwise Rearward or up P Counterclockwise Forward or down Together Rearward or up Tri Engage Rearward or up P Release Forward or down Gri Engage Rearward or up P Release Forward or down Truck stabilizer Raise Rearward or up Lower Fo
6. parts of the body within the drivers compartment 45 015 REV 2 12 ONG REACH A Division of Allied Systems Company Always operate an attachment from the operator s 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 2 12 Load Handling 45 015 REV 2 12 Treat an unloaded forklift with an attachment as par tially loaded 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 Always check loads to be handled Correct loads that are broken unbalanced loose or too heavy 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 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 Do not carry loose items or unsupported loads on top of a clamped load Never use
7. sup 2 Inspect installation to ensure hoses are not kinked or plied with the attachment two pieces of 1 2 x 1 2 x pinched between the truck carriage and attachment B RU E ipie el ipd 3 Operate the attachment continuously for several ds fthet ing no E op enon minutes to determine that all hydraulic connections each side of the truck carriage Figure 3 2 are secure with no leaks YXE4C 307 4 With the mast in the vertical position open the at 1 2 x 1 2 x 2 00 tachment arms fully After this procedure check steel supplemental that the truck s hydraulic reservoir oil level is at the locking lug 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 Locking lug 1 16 clearance jumper hoses to the mast in notch b Checkthe valve and cylinder for leaks Figure 3 2 Locking Lug c Check cotter pins at each end of the cylinder for security 10 Install the bolt on lower hooks Inspect clearance 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 Any alterations to the original attachment may affect performance or safety and result in loss of warranty Allied B COMPANY SECTION 4 SERVICE PROCEDURE 4 1 Attachment Removal 1 Po
8. system Assume that all hydraulic hoses and components are pressurized Relieve all hydraulic pressure before disconnecting any hydraulic line 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 2 6 Electrical Hazards Remain at least 25 feet from high voltage electrical wires Failure to do so may result in injury or death and will damage equipment 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 Do not wear electrically conductive jewelry clothing or other items while working on the electrical system 2 7 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 Do not attempt to make adjustments or perform maintenance or service unless you are authorized and qualified to do so 45 015 REV 2 12 Include attachments in a scheduled maintenance and inspection program Tailor inspection steps to the attachment Unless specified in service procedures never attempt maintenance or lubrication procedures while the ma chine is moving or
9. the engine is running 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 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 Use caution when working around hot fluids Always allow lubricating and hydraulic oils to cool before draining Burns can be severe 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 Engine exhaust fumes can cause death If it is neces sary to run the engine in an enclosed space remove the exhaust fumes from the area with an exhaust pipe extension Use ventilation fans and open shop doors to provide adequate ventilation 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 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 Allied COM
10. ONG REACH A Division of Allied Systems Company Installation Maintenance and Service Manual SDN SLN SLJ AND SPN 45 015 REV 2 12 Allied COMPANY TABLE OF CONTENTS Section 1 Nameplate Location 3 Section Installation Procedure 10 Section 2 Safety Summary 4 3 1 Truck Requirements 10 2 1 Safety InfOFaltOli 4 3 2 Carriage D 10 2 2 Safety Regulations 4 3 3 Hydraul ese ns 10 2 3 Safety Symbol Seen 4 3 4 Attachment Installation 10 2 4 Operation Warnings 4 3 5 Hydraulic Connections 11 2 5 Hydraulic Hazards 4 Section 4 Service Procedure 12 2 6 Electrical Hazards 5 4 1 Attachment Remowval 12 2 7 Maintenance Warnings 5 4 2 Cylinder Remowval 12 PN SNC e P 6 4 3 Cylinder Installation 12 2 9 Labeling M T ian 6 Section 5 Maintenance 13 2 10 Pre Start Checks 6 5 1 Schedule citron pires 13 2 11 Personnel Safety 6 5 2 Torque Specifications 13 2 12 Load Handling ous 7 2 13 Load 7 2 14 Truck Requirements 7 2 15 Operators Controls
11. PANY 2 8 Training 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 operator s manual for instruc tions on how to use the new equipment Know the mechanical limitations of your forklift 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 2 9 Labeling 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 2 10 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 situations can cause or contribute to an accident or damage to the machine Stop the machine im
12. ay 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 warnings 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 2 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 2 3 Safety Symbols The following terms define the various precautions and notices Danger 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 A Allied COMPANY Indicates a hazardous situation which if not avoided
13. dd further lubrication prior to assembly Dry refers to parts that have been degreased both mating parts Grade 5 E Eum Grade 8 Socket Head Capscrew Figure 5 1 Fastener Identification GRADE 8 COURSE THREAD GRADE 5 COURSE THREAD SOCKET HEAD COURSE THREAD Bolt Size Lubricated Torque Bolt Size Lubricated Torque Capscrew Size Lubricated Torque 1 4 129 in Ibs 1 4 91 in Ibs 1 4 150 in Ibs 5 16 23 ft lbs 5 16 16 ft lbs 5 16 26 ft lbs 3 8 40 3 8 28 3 8 46 7 16 63 7 16 45 7 16 74 1 2 96 1 2 68 We 9 16 9 16 98 9 16 5 8 5 8 5 8 3 3 3 4 7 8 7 8 7 8 1 1 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 1 1 2 1 1 2 Figure 5 2 Torque Specification 45 015 REV 2 12 Allied 13 COMPANY
14. e truck behind the attachment and drive toward the attachment with the mast tilted forward approximately 4 degrees Line up the locking lug under the mid plate if ap plicable with the appropriate notch on the truck s carriage Check that the bronze side shifting wear strips are in the proper place if applicable Make sure roller assembly is in place making contact with lower carriage bar 45 015 REV 2 12 REACH A Division of Allied Systems Company 7 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 truck s carriage Inspect any wear strips if applicable to insure they are properly aligned in the top hooks the carriage on lower hooks Adjust the lower hooks for a maximum clearance of 3 32 see Figure 3 3 Tighten the bolts to 40 50 ft Ibs 3 32 clearance um Shim s if required Figure 3 3 Lower Hook Clearance 45 015 REV 2 12 11 Apply grease to bronze top hooks through fittings and spread on entire slide area of mid plate 12 Check all fittings connections and bolts for any interference 3 5 Hydraulic Connections 1 Install the lines from the truck s hydraulics to the hydraulics of the attachment Weld on the supplemental locking lug that is
15. he notches are not damaged Notice The model description found on your shipped invoice states the following truck requirements flow gpm psi and minimum truck carriage width 3 3 Hydraulics 1 10 The truck hydraulic system must supply to the at tachment hydraulic oil that meets the specifications required to operate the attachment properly 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 attachment Consult the truck factory and or Long Reach for guidance Allied COMPANY 3 4 Attachment Installation js 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 ofthe truck and attachment combination may be less than the capacity shown on the attachment alone Consult truck nameplate 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 C tr To truck ui ra J To attachment Figure 3 1 Jumper Line 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 Center th
16. ift movement to a minimum when high stacking Always be observant when high stacking Look for poorly stacked loads overhead obstacles broken cartons or damaged products in the stack 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 2 14 Truck Requirements Prior to connecting the truck hydraulic system to the at tachment the truck hydraulic system must be cleaned through the filtration system This will eliminate any contamination that may exist in the auxiliary hydraulic system of the truck Allied COMPANY The capacity of the truck and attachment combined may be less than the attachment capacity Consult truck nameplate Notice The dealer and or the user are responsible for installing any valving required to meet the recommended hydraulic pressures and flow The required valving can be furnished by the dealer the truck factory or Long Reach 2 15 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 2 5
17. l the clevis and cotter pin into the base end of the cylinder Attach the hydraulic connections to the cylinder Extend the cylinder until the rod end hole lines up with the mounting hole Install the clevis pin and cot ter pin into the rod end of the cylinder Turn on the truck s power and activate the positioning cylinders several times to bleed out trapped air 12 H 45 015 REV 2 12 Allied COMPANY REACH A Division of Allied Systems Company SECTION 5 MAINTENANCE 5 1 Schedule Daily 1 Visually inspect all hoses fittings cylinders and valves for signs of hydraulic leaks Visually inspect for external damage or cracks Check lower hooks for proper clearance Maximum clearance is 3 82 of an inch 4 f the attachment is equipped with quick change hooks check the slide plate latch for engagement 5 Apply grease to bronze top hooks 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 200 Hour Maintenance 1 Re torque bronze hook bolts per chart 5 2 Torque Specifications The following torque values are to be used on all fasten 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 coating on plated fasten ers No special steps are taken to a
18. medi 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 2 11 Personnel Safety When removing or installing dismountable at tachments always keep hands and feet free from dangerous positions or pinch points Never leave a dismounted attachment in a dangerous position Allied COMPANY 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 2 1 Figure 2 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 2 2 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 2 3 Never leave an attachment or load in an elevated position Never reach through the mast of the truck Keep all
19. rward or down Clamp Rearward or up Forhigh lift order picker trucks and center control 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 Figure 2 6 ANSI ITSDF Sequence of location and direction of motion for lever or hand type controls 45 015 REV 2 12 Allied 9 COMPANY SECTION 3 INSTALLATION PROCEDURE 3 1 Truck Requirements Long Reach attachments have been designed to oper ate 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 operating speed Higher flow can result in excessive heat buildup erratic operation and damage to the truck attachment hydraulic system Notice The dealer and or the user are responsible for installing any valving required to meet the recommended hydraulic pressures and flow The necessary valving can be furnished by the dealer the truck manufacturer or Long Reach 3 2 Carriage 1 The truck carriage must conform to the American National Standard ANSI dimensions shown in ANSI ITSDF B56 11 4 2005 reaffirmed 2000 Make sure the truck carriage is clean conforms to ANSI recommendations and t
20. sition the attachment arms to the width of the unit s body Turn off truck power and activate the truck hydraulic functions in both directions to bleed off the hydraulic pressure before disconnecting any hydraulic connections 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 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 6 To reinstall follow the installation procedure in this manual Activate the hydraulic functions several times to bleed out air trapped air in the system before returning attachment to service after hydraulic service has been performed 4 2 Cylinder Removal 1 Disconnect the hydraulic connections 2 Remove the cylinder rod end cotter pin and clevis pin Turn off truck power and activate the truck hydraulic functions in both directions to bleed off the hydraulic pressure before disconnecting any hydraulic connections 3 Remove cotter pin and clevis pin at the base end of the cylinder 4 3 Cylinder Installation Instal
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