Installation, Maintenance And Service Manual
Contents
1. EACH A Division of Allied Systems Company Installation Maintenance and Service Manual LCB LCC LCP LCS LCS Stationary LFP and LTF 45 006 REV 7 12 Allied 1 COMPANY TABLE OF CONTENTS Section 1 Nameplate Location 3 Section 4 Service Procedure 14 Section 2 Safety Summary 4 4 1 Attachment Removal 14 2 1 Safety InfOraliolisssseosut instet ions 4 2 2 es tete taceo hh aeter utei Sae 15 2 2 Safety Regulations eene 4 4 3 Arm Installation 15 2 3 Safety SyImDbOls ecu reb En dte engine 4 4 3a Arm Retention Pin 15 2 4 Operation Warnings 4 4 4 Cylinder Removal 16 2 5 Hydraulic Hazards 4 4 5 Cylinder Installation 17 2 6 Electrical 5 4 6 Cylinder Disassembly 17 2 7 Maintenance Warnings 5 4 7 Cylinder Inspection 18 Ne TR cS 6 4 8 Cylinder Assembly 18 2 9 Labeling rtc 6 4 9 Hydraulic Valve Removal 19 2 10 Pre start Chigoks acide di ntis 6 4 10 Hydraulic Valve Installation 20 2 11 Personnel Safety 6 4 11 Repair In Place Wear Strip 20 2 12 Load2. B Blow dry with compressed air Clean and dry tapped holes C Wire brush screw threads to remove cured Loc tite and other debris Discard any capscrews that have damaged threads or rounded heads D Wash capscrews with non petroleum base sol vent Blow dry with compressed air 3 If you remove a plug or seal lubricate new seal and install on plug Some plugs have two o ring grooves but require only one o ring Install o ring in groove closest to the end of the plug Push the plug into the housing so the plug and housing are flush Be careful not to damage the seal 4 Lubricate the output shaft with hydraulic oil then install the output shaft into the housing Figure 4 49 7 Lubricate these areas gt Needle thrust bearing Figure 4 49 Output Shaft Do not permit oil to get into the four tapped holes Allied 3 COMPANY 6 32 Install the needle thrust bearing then the bearing race onto the output shaft Pull the output shaft partially out of the housing Push all three parts into the housing together figure 4 50 The bearing race must rotate freely when in position Figure 4 50 Output Shaft In Position Install the exclusion seal into the mounting flange Carefully press the exclusion seal into place Figure 4 51 Shaft pressure seal Seal driver Seal tube Exclusion seal Backup ring Mounting flange Figure 4 51 Seal Installation Visually
3. Loctite use a long handle wrench to break loose 12 Reassemble in reverse order Use Loctite Blue Figure 4 29 all capscrews See Section 5 for Torque Specifica tions Notice It is important to get oil to the worm and worm bearings Before reinstalling dip the worm and worm bearings in oil for proper lubrication of these elements See Section 4 3 45 006 REV 7 12 Allied 25 COMPANY To install pinion gear heat gear to 250 F to expand I D for fit over shaft Hold 0 03 dimension Heat stick must be used for temp control or damage to gearbox will occur Part Number YGC 48 YGC 49 YGC 49 LH YGC 50 And YGC 50 LH 1 2 Remove the attachment from truck See Section 4 1 Before removing the gearbox from the back plate place a support overhead or under the gearbox Remove the mounting capscrews from the gearbox Figure 4 31 Motor Figure 4 31 Gearbox Removal 3 Place the gearbox on a flat surface and remove the motor mounting capscrews Figure 4 32 26 Figure 4 32 Motor Gear Cap Removal Allied COMPANY A Remove the capscrews from the gear cap The gear cap capscrews are installed with Loctite use a long handle wrench to break loose Using a large screw driver and hammer separate the gear cap from the housing Figure 4 32 Do not use a impact wrench on the screws that have been secured with Loctite This could result in rounded heads or broken sockets Do not damage m
4. 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 45 006 REV 7 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 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 t
5. 4 36 Motor Adapter Figure 4 36 Motor Adapter Seal 12 Using a rubber mallet lightly tap on the extended end of the worm gear shaft and remove through the housing Notice The bearing cup on the motor adapter side of the housing will need to be removed with a bearing puller 13 Wipe as much grease out of the housing as possible with a rag and inspect for any foreign particles 45 006 REV 7 12 Allied 27 COMPANY 4 18 Gearbox Assembly Part Number YGC 48 YGC 49 YGC 49 LH YGC 50 and YGC 50 LH 1 10 11 12 28 Install all seals When replacing seals use the fol lowing suggestions to insure leak free operation and long seal life Cover the keyway and any other surface discon tinuity with smooth tape to protect the seal lip from being damaged B A sealant should be used between the O D of the seal and the 1 0 of the bore into which the seal is installed The seal bore should also be free of any burrs nicks or scratches C Be sure that the seal is not cocked in the seal bore The outer face of the seal should be flush with the surface into which it is mounted Press on the bearing cup for the worm gear shaft into the housing on the worm cap side Install the worm cap and shims if applicable Notice Use Loctite blue onall capscrews See Section 5 for Torque Specifications Place the bearing cones on both ends of the worm gear shaft and install into the housing Press on
6. Allied Systems Company 2 Tie the cylinder up to support the weight when re moved from the arm lug Activate the hydraulics and retract the cylinder to the fully closed position Before disconnecting any hydraulic connections be sure to turn off the truck s power and activate the truck s hydraulic functions in both directions to bleed off the hydraulic pressure Turn off the truck s power and activate the hydraulic functions in both directions several times to relieve built up hydraulic pressure Disconnect the hydraulic connections Remove the cylinder base end flush nut and cotter pin The cylinder now can be removed through the front of the attachment 4 5 Cylinder Installation 1 Apply a thin coat of bearing grease to the spherical portion of the flush nut and concave section of the body lug Screw on the flush nuts until they stop Back the flush nut off lining up the cotter pin hole in the rod or base end stud with the slot in the flush nut Do not tighten the flush nut tight to eliminate all clearance between washer and body lug Adjust to allow 1 16 to 1 8 of an inch clearance between the base end of the cylinder and the body lug Figure 4 7 4 r 1 16 to 1 8 inch clearance Body lug M Cotter pin N Flush nut Cylinder base end Figure 4 7 Body Lug 2 Turn on the truck s power and activate th
7. any wear strips if applicable to insure they are properly aligned in the top hooks Weld on the supplemental locking lug that is sup plied with the attachment two pieces of 1 2 x 1 2 x 2 00 steel included with the attachment with either E 6011 or E 6013 welding rod or equivalent on each side of the truck carriage Figure 3 3 YXE4C 307 1 2 x 1 2 x 2 00 steel supplemental locking lug 1 16 clearance Locking lug in notch Figure 3 3 Locking Lug Allied COMPANY Install the bolt on lower hooks Inspect clearance to the carriage on lower hooks Adjust the lower hooks for a maximum clearance of 3 32 see Figure 3 4 Tighten the bolts to 40 50 ft lbs ot med 3 32 maximum clearance xs Shim s if required Figure 3 4 Lower Hook Clearance 10 If quick hooks are installed simply raise the slide plate until the button clicks into place If the slide plate does not click into place because the truck carriage prevents the slide plate from being raised up high enough install shims between the attachment and the body of the quick change hooks Slide plate must click into place To ensure proper locking of the slide plate use a screwdriver to try to pry down the slide plate If the slide plate is not locked in place inspect and correct any cause that might restrict the slide plate from going up enough to allow the button to become fully engaged 45 006 REV 7 12 ONG REACH A Div
8. 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 sideshift 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 Requirement
9. 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 parts of the body within the drivers compartment 45 006 REV 7 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
10. 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 To truck t 4 clamp 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 If the attachment is equipped with quick change hooks simply depress the button on the back of the hooks allowing the slide plate to drop Removal of the quick change hooks is NOT recom mended Figure 3 2 Allied B COMPANY r Raise slide to secure attachment to truck Push button y to lower slide Figure 3 2 Quick Change Hook Center the truck behind the attachment and drive toward the attachment with the mast tilted forward approximately 4 degrees Line up the locking lug under the hanger plate if applicable with the appropriate notch on the truck s carriage Check that the bronze side shifting wear strips are in the proper place if applicable 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
11. the hydraulic functions several times to bleed out trapped air in the system before returning attachment to service 45 006 REV 7 12 ONG REACH A Division of Allied Systems Company 4 2 Arm Removal 1 Extend the arms outside of the body Remove the cotter pin retaining the flush nut Remove the flush nut Figure 4 3 Body Flush nut Cotter pin L s weldment Figure 4 3 Arm Tie the cylinder up to support the weight when re moved from the arm lug Activate the hydraulics and retract the cylinder from the arm lug Attach a suitable overhead hoist to the arm weldment Pull the arm assembly out of the body Notice It is not necessary to remove the arm assembly to replace wear strips See the section on repair in place wear strip replacement 4 3 Arm Installation 1 45 006 REV 7 12 Attach a suitable overhead hoist to the arm weld ment Line up the slide bar with the proper channel and slide into body Activate the hydraulics and extend the cylinder rod out until itis at the arm lug Insert the spacer washer on the cylinder rod and extend the cylinder through the arm lug until the arm moves Apply a thin coat of bearing grease to the spherical portion of the nut and concave section of the arm lug Screw on the flush nut until it stops Back off the flush nut while lining up the cotter pin hole in the rod with the slot in the flush nut Clearance between the spacer
12. to tap into channel Tap the center wear strip in far enough to leave a lip on the channel to start the last end piece Insert the last wear strip end piece with the plug hole out and tap into place lining up the retainer plug hole Figure 4 17 i 6 y j hs AMARI Figure 4 17 Wear Strips 7 Prime the retaining plug hole threads with a good primer following the manufacture s instructions Apply blue grade Loctite to the plug threads and torque plugs to 45 50 ft lbs 8 Turn on the truck s power and raise the attachment off of the supports Close the arms 9 Turn off the truck s power Insert the last two plugs using blue grade Loctite and torque to 45 50 ft lbs 10 Follow the same procedure for the other arm Notice Do not lubricate the wear strips or slide assembly No lubrication is necessary 4 12 Camber Adjustment For Articulating Arm Carton Clamps 1 Theterm camber refers to the tilt of the contact pads as viewed directly from the front or rear of the attach ment 2 Positive camber the desired configuration means that the contact pads are closer together at the bot tom than the top 45 006 REV 7 12 3 Negative camber means that the contact pads are closer together at the top than at the bottom 4 To help prevent loss of cartons from the lower tier LongReach recommends a positive camber of 0 0 to 0 50 inch
13. Always use personal protective equipment PPE appropriate to the situation 2 12 Load Handling 45 006 REV 7 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 Figure 2 5 Never use 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
14. Handling 7 4 12 Camber Adjustment For Articulating Arm 2 13 Load Positioning seee 7 Carton pe 2 14 Truck Requirements 7 Arieulating 2 15 Operator s Controls 9 4 14 Rotating Contact Pads 22 2 16 Industry Standards uoi tenete 9 4 15 Pinion Ring Gear and Bearing 22 err CAMP 3 4 16 Gearbox Lubrication 23 Section 3 Installation Procedure 11 4 17 Gearbox 23 3 1 Truck Requirements 11 4 18 Gearbox Assembly 28 3 2 RE eM IDEE 11 4 19 Motor Disassembly e 28 3 3 Hydra liCS MN 11 4 20 Motor Assembly 31 3 4 Attachment Installation 11 Sections Malntenanes Schedules 35 SiS 13 BWC NG mec 35 5 2 Schedule Stationary Load Inverter 35 5 3 Torque Specifications 36 2 H 45 006 REV 7 12 Allied COMPANY ONG 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 l
15. achined surfaces of the gear cap and housing 5 Remove the pinion shaft assembly Figure 4 33 Figure 4 33 Pinion Shaft Remove the snap ring from the end of the pinion shaft Figure 4 33 Place the assembly in a press supporting the gear cap not the pinion shaft Press the pinion shaft through the small bearing and the worm gear At this point the small bearing worm gear and large bearing are loose and can be lifted out of the housing Figure 4 33 Do not drop the pinion shaft onto a hard surface or it may chip Notice The small bearing cup in the housing and the large bearing cup in the gear cap will need to be removed with a bearing puller 45 006 REV 7 12 REACH A Division of Allied Systems Company 8 Wipe as much grease out of the housing as possible with a rag and inspect for any foreign particles 9 Theoilseals may now be serviced Note the orienta tion of the seals Figure 4 34 Gear Cap Figure 4 34 Pinion Shaft Seals 10 Remove the worm cap and motor adapter Make note of any installed shims Capscrews are installed with Loctite use a long handle wrench to break loose Use a large screwdriver and hammer to separate the worm cap from the housing Note any installed shims Figure 4 35 IN Motor adapter Figure 4 35 Worm Cap Motor Adapter Do not damage the machined surfaces of the worm cap and housing 11 The seal in the motor adapter can now be replaced Figure
16. ance Refer to the maintenance schedule in the separate Instal lation and Maintenance Manual included with your power unit 5 3 Torque Specifications Allied m COMPANY 5 3 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 add further lubrication prior to assembly Dry refers to parts that have been degreased both mating parts GRADE 8 COURSE THREAD 1 4 129 in Ibs GRADE 5 COURSE THREAD 1 4 91 in Ibs SOCKET HEAD COURSE THREAD Bolt Size Lubricated Torque Bolt Size Lubricated Torque Capscrew Size Lubricated Torque 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 1 2 9 16 9 16 98 9 16 5 8 5 8 5 8 3 4 3 4 3 4 7 8 7 8 7 8 1 1 1 1 1 8 1 1 8 TEUER 1 1 4 1 1 4 1 1 4 1 3 8 1 3 8 1 3 8 1 1 2 36 1 1 2 Allied COMPANY 1 1 2 45 006 REV 7 12
17. anual 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 IN Allied COMPANY Indicates a hazardous situation which if not avoided 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 poss
18. as the capscrew breaks loose remove heat from X the housing Continue turning the capscrew until itis completely removed Pressure Seal Seal UN Back Up Ring Mounting Flange Exclusion Seal Heat with a Figure 4 45 Mounting Flange Seals propane torch to melt Loctit p ee Bend tip Radius Modify Modify Screwdriver screwdriver a 885Wn Reece Mounting Flange Figure 4 46 Seal Removal Tool Figure 4 44 Capscrew Loctite 11 Work from the outer side for both either seals 9 Carefully remove the mounting flange from the housing Notice Some motors may have a quad seal and back up ring in place of the pressure seal The quad seal and back up ring are no longer available and are replaced by the pressure seal They are interchangeable but some precautions must be taken to insure proper installation Follow the Exclusion reassembly instructions Section 4 7 Seal Tool Seal eal Removal Too Mounting Flange Pressure Seal Back up Ring 10 The exclusion seal back up ring pressure seal and seal will come off with the mounting flange Figure 4 45 Use a seal removal tool Figure 4 46 and 4 47 Figure 4 47 Seal Removal to remove the exclusion and pressure seals Notice Be careful not to scratch the seal cavity O D This could create a leak path 30 H 45 006 REV 7 12 Allied COMPANY REACH A Division of Allied Systems Company 12 A m
19. base solvent Notice Do not apply Loctite to threads more than 15 minutes before installing capscrews If the housing stands for more than 15 minutes repeat application No additional cleaning or removal of previously applied Loctite is necessary 45 006 REV 7 12 REACH A Division of Allied Systems Company 12 Before installing the mounting flange and seal as sembly over the shaft place a protective sleeve or bullet over the shaft Then lubricate the space be tween the exclusion seal and pressure seal as well as the lips of both seals Figure 4 52 Apply petroleum jelly across this area Output Shaft Dust Seal This lip to Ring face inward Pressure eal Seal Bearing Interior of Race motor Figure 4 52 Output Shaft Lubrication 13 Install the mounting flange Rotate the mounting flange slowly while pushing down over the shaft Be careful not to invert or damage the seals 14 After removing the bullet clamp the motor in a vise Make sure the shaft cannot fall out Install dry cap screws and alternately torque them immediately to 250 Ib in If you use a primer allow to cure for 10 to 15 minutes Without primer allow 6 hours for cur ing time before subjecting the Motor to high torque reversals On all other applications you can run the motor immediately Figure 4 53 2 222 Figure 4 53 Motor Clamping 45 006 REV 7 12 Notice If you use new capscrews
20. check the seal seat in the mounting flange for scratches or other marks that might damage the pressure seal Check for cracks in the mounting flange that could cause leakage Allied COMPANY 8 Lubricate the 1 0 Of the seal tube and O D Of the shaft pressure seal with a light film of clean petroleum jelly Align the small 1 0 end of the seal tube with the seal seat in the mounting flange Install the back up ring and pressure seal in the tube with lips of the seal face up figure 4 51 Insert the seal driver in the tube and firmly push seal seat with a rotating action 11 After installing the seal in the mounting flange examine the seals condition If damaged or improperly installed you must replace it before continuing with reassembly Install the 49mm 1 937 in 1 0 seal in the flange It is recommended to apply a light coat of Loctite Primer NF in tapped holes of housing Allow primer to air dry for at least 1 minute Do not force dry with air jet the primer will blow away Notice The use of primer is optional With primer Loctite curing time is approximately 15 minutes Without primer curing time is approximately 6 hours Apply 3 or 4 drops of Loctite sealant at the top of the threads for each of the four holes in the housing Do not allow parts with Loctite applied to come in contact with any metal parts other than those for assembly Wipe off excess Loctite from the housing face using a non petroleum
21. e positioning 45 006 REV 7 12 cylinders several times to bleed out trapped air When hydraulic service has been performed activate the hydraulic functions several times to bleed out trapped air in the system before returning attachment to service 4 6 Cylinder Disassembly Remove the cylinder from the attachment See re moval 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 4 8 Figure 4 8 Cylinder Vise 3 Use spanner wrench or similar tool to unscrew the gland cap from the cylinder tube Figure 5 9 Piston nut Figure 4 9 Cylinder Rebuild Allied i COMPANY Remove the rod assembly from the cylinder tube 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 4 10 Figure 4 10 Cylinder Shaft 6 Remove the piston retaining nut and remove the piston Figure 4 9 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 Y d RS Figure 4 11 Piston Seal 8 Use the same procedure as above to remove the seals from the gland cap 4 7 Cylinder Inspection Inspect the cylinder tube bore for 1 Deep scratches or nicks 2 Sign
22. e rear edge of the contact pads 2 Toe out the preferred configuration means that the front edges are farther apart than the rear edges Allied 2 COMPANY 3 4 Toe in means that the front edges are closer together than the rear edges To adjust the toe out first loosen the lock nuts and then screw the adjustment screws out counterclock wise for greater toe out in for less Be sure to adjust both the top and bottom adjustment screws found on each platen support Figure 5 18 4 14 Rotating Contact Pads 1 As the contact pads wear it may be necessary to rotate or replace them Pad surfaces may wear un even more or less depending on the distribution of weight in the loads Figure 4 19 Figure 4 19 Contact Pad Wear Before rotating check flatness and deflection of the pad The pads surface flatness should not vary more than 1 8 inch The horizontal and vertical deflection of the pad should not be more than 1 4 inch On articulating clamps the pads can be rotated left to right top to bottom On adjust a force clamps the pads can be rotated left to right top to bottom on standard lengths 42 48 54 and 60 inches On non standard lengths the pads can only be rotated left to right 4 15 Pinion Ring Gear and Bearing 1 22 Greasing of the pinion ring gear should be done every 40 hours Greasing of the ring gear bearings should be done every 100 hours See Section 6 If gears are not greased pr
23. es 8 Wear Strip Retainer Plugs Tools Required 1 Rubber mallet 2 3 8 inch ratchet wrench 3 3 8 inch extension 4 Blue grade Loctite 1 Position the arms to the closed position Turn off the truck s power Figure 4 15 Wear Strip Retainer Plugs Figure 4 15 Arms Closed 20 H Allied COMPANY Do one arm at a time Remove two wear strip retainer plugs using your ratchet wrench and extension The retainer plug is designed for a 3 8 inch ratchet The plug was installed using Loctite at the factory and may require significant force to break loose Turn on the truck s power and extend the arms out side the body The wear strips where the plugs were removed will then be able to slide out Figure 4 16 Wear Strip Retainer Plugs Figure 4 16 Arms Open Raise the attachment and set the arms down on a stack of pallets table or other suitable support and lower the attachment until the arms just make con tact This will relieve the pressure on the arms side Turn off the truck s power With the arms extended remove the two remaining retainer plugs now exposed for the opposite side of the arm You can now remove the last end section of the wear strip Only the center section remains 45 006 REV 7 12 REACH A Division of Allied Systems Company 6 Insert new wear strip end pieces with the plug hole first Insert the wear strip center section Use the rubber mallet
24. etal plug with seal plugs a machining hole in the housing It is not necessary to remove the plug and replace seal unless leakage occurs around the plug To remove the plug insert a 5 mm 187 in hex key through the port opening and push it out Figure 4 48 Figure 4 48 Housing Plug 4 20 Motor Assembly 1 Check all mating surfaces Replace any parts with scratches or burrs that could cause leakage or dam age Clean all metal parts in clean solvent Blow dry with air Do not wipe parts with a cloth or paper towel because lint or other matter could get into the hydraulic system and cause damage 2 Check around the key slot and chamfered area of the shaft for burrs nicks or sharp edges that could damage seals during reassembly Remove nicks or burrs with a hard smooth stone such as an Arkansas stone Do not file or grind motor parts Notice Lubricate all seals with petroleum jelly Use new seals when reassembling motor Refer to Parts Coverage Do not stretch seals before installing them 45 006 REV 7 12 Notice Fully cured Loctite resists most solvents oils gasoline and kerosene and is not affected by cleaning operations It is not necessary to remove cured Loctite that is securely bonded in tapped holes however any loose particles of cured Loctite should be removed A Wash the housing with solvent to remove oil grease and debris Pay particular attention to four tapped holes on the flange end
25. for pads up to 48 inches high and 0 0 to 0 75 inch for pads over 48 inches high 5 Camber is adjusted by using 1 8 inch spacers P N Y 156057 to increase or decrease camber approxi mately 1 4 inch on a 48 inch high pad 6 To increase camber positively add one or more spacer s between the pad and the lower platen support Figure 4 18 Upper platen Top support Net gi Ii s j dh dr 10 d et qh ale i 7 j m cp 8 10 010 i fo i m I I 3 H d 2 o H m Bottom Lower aa CTUM support screws Front View Side View Figure 4 18 Camber And Toe Adjustment 7 To decrease camber negatively add one or more spacer s between the pad and the upper platen support 8 Use existing capscrews only if one spacer is used If two or three spacers are used use P N Y96G 0820 capscrew 9 Asthe clamp arms and slides wear it may be neces sary to increase the positive camber 4 13 Toe Adjustment For Articulating Arm Carton Clamps 1 The term toe adjustment refers to adjusting the dif ference in the distances between the front edge and th
26. hat 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 COMPANY 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
27. ible 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 45 006 REV 7 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 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
28. ision of Allied Systems Company 3 5 Hydraulic Connections 1 Install the lines from the truck s hydraulics to the hydraulics of the attachment Figure 3 5 V4 To truck Bim lt supply V1 side shift close V To truck supply open V2 To cylinder base end To cylinder To cylinder base end rod end Figure 3 6 Cylinder Connection 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 45 006 REV 7 12 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 recommended level Before placing the attachment in operation check the following A Inspect all hoses and fittings for leaks and rout ing 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 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 Allied COMPANY SECTION 4 SERVICE PROCEDURE 4 1 Attachment Removal 1 Position the attachment arms to the width of the unit
29. k V4 secondary side shift J V3 4 To truck supply open V2 To cylinder base end To cylinder rod end Figure 4 13 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 rod end to ease inserting the rod and piston Insert the rod and piston into the cylinder tube Tap the rod in with a rubber mallet if resistance is encountered Figure 4 14 Hydraulic Valve 6 Install the gland cap on the cylinder rod being ex Disconnect the hydraulic hoses at the valve ports tremely careful not to cut the rod seal on the threads C1 C2 C3 and C4 of the rod or rod shoulder If available use a sleeve to cover the rod threads or plastic electrical tape 4 Remove the valve mounting bolts and remove valve Tighten the gland cap using a spanner wrench 4 9 Hydraulic Valve Removal 1 Turn off the truck s power and activate the hydraulic functions in both directions several times to relief the built up hydraulic pressure 45 006 REV 7 12 Allied 19 COMPANY 4 10 Hydraulic Valve Installation 1 Reassembly in the reverse order above 2 Turn on the truck s power and activate the hydraulic functions several times to bleed out trapped air 4 11 Repair In Place Wear Strip Notice It is not necessary to remove the arms to replace the body wear strips Required Parts 8 Wear Strip End Pieces 4 Wear Strip Center Piec
30. mage 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 required valving can be furnished by the dealer the truck factory 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 2013 Make sure the truck carriage is clean conforms to ANSI recommendations and the notches are not damaged Notice 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 45 006 REV 7 12 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 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 attachment combination may be less than the capacity shown on
31. make sure they are the correct length 22mm 875 in under head length See parts coverage for correct part number 15 Reposition the motor with the geroter end up then clamp the motor across the ports To aid the installation of seals apply a light coat of clean petroleum jelly to seals Do not stretch the seals before installing them in groove 16 Pour approximately 35 cc of clean hydraulic oil into the output shaft cavity 17 Install 73 mm 2 875 in 1 0 seal into the housing seal groove Avoid twisting the seal 18 Install the drive Use a felt tip marker to mark one drive tooth Align this tooth with the timing dot on the shaft Notice If the drive is not symmetrical install the larger splined end into the shaft 19 Install the spacer plate 20 Install 73 mm 2 875 in 1 0 seal into the gerotor seal groove Carefully place the gerotor onto the spacer plate seal side toward the spacer plate Allied COMPANY 21 For standard rotation align any star point with the marked tooth on the drive Figure 4 54 e Gerotor f Qe 7 Star Point Gerotor Seal lt nw Spacer Plate ot E Housing Forward Valving Slot 55 Figure 4 54 Standard Rotation 22 For reverse rotation align any star valley with the marked tooth on the drive Figure 4 55 Spacer plate Housing Figure 4 55 Reverse Rotation 23 24 25 26 Rotate the gerotor to line
32. mber YGC 48 YGC 49 YGC 49 LH YGC 50 and YGC 50 LH 1 The grease in the gearbox will not need to be filled or changed unless the gearbox itself has been serviced 2 Remove the top and back plugs from the gearbox and completely fill with Mobilux EPO or equivalent grease Figure 4 22 45 006 REV 7 12 Figure 4 22 Gearbox Grease Plugs 3 Laythe gearbox with the pinion gear down and fill the gearbox from the top plug hole allowing trapped air to escape through the back plug hole until grease is present in the back plug hole 4 Tofill gearbox mounted to back plate fill gearbox from the back plug hole allowing trapped air to escape through the top plug hole until grease is present in the top plug hole 5 Reinstall the plugs 4 17 Gearbox Disassembly Part Number YGC 29 YGC 32 YGC 43 And YGC 43 LH 1 Remove the attachment from truck See Section 4 1 2 Before removing the gearbox from the back plate place a support overhead or under the gearbox Remove the mounting capscrews from the gearbox Figure 4 23 Back Plate Gearbox Capscrew Figure 4 23 Gearbox Removal Allied COMPANY 3 Place the gearbox on a flat surface and remove the Motor mounting capscrews Notice Coupling fits loose and may slide out Figure 4 24 Figure 4 25 Adapter Plate Removal Waming 4 Remove the pinion gear and key from the output shaft Use a screwdriver to knock loose the key Po
33. n care when taking on adap ud plate The gearbox is filled with oil Do not use a impact wrench on the 7 The output shaft seals may now be serviced Figure screws that have been secured with 4 26 Loctite This could result in rounded heads or broken sockets Seal 5 Remove the capscrews from the adapter plate The Adapter plate adapter plate capscrews are installed with loctite use a long handle wrench to break loose Lightly tap the back of the adapter plate with a rubber mallet to remove Figure 4 25 Figure 4 26 Output Shaft Seals 24 H 45 006 REV 7 12 Allied COMPANY REACH A Division of Allied Systems Company 8 Remove the output shaft assembly Figure 4 27 Motor Adapter Bearing Output shaft Bearing Snap ring Capscrew fe Figure 4 27 Output Shaft Figure 4 29 End Cap Motor Adapter 9 The output shaft fits tight you may need to remove 11 Remove the input shaft assembly The assembly fits the cap on the back of the gearbox and lightly tap tight use a rubber mallet or press on the extended the end of the output shaft with a rubber mallet to shaft to remove Remove the exposed key with a remove Figure 4 28 screwdriver allowing the bearing and worm to slide off of the shaft Figure 4 30 Screwdriver Figure 4 28 Output Shaft Cap 10 Remove the end cap and motor adapter Make note Fiaur e 4 30 Input Shaft of any installed shims Capscrews are installed with pu
34. ocation and consult the factory for details Date received vL d Approx nameplate location O TTACHMENT CAPACITY 21433 SW Oregon Street i fF O OMG REACT A Division of Sherwood OR 97140 USA Allied Systems Company www alliedsystems com MODEL SERIAL NO NO AT LOAD MASS AET MAXIMUM BAR L min MM MM HYDRAULIC FLOW HCG VCG PRESSURE PSI GPM Ej IN IN SEE TRUCK NAMEPLATE DATE FOR COMBINED TRUCK amp A 2500005 rF LBS IN LCG O IN O 45 006 REV 7 12 Allied COMPANY 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 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 The safety instructions and warnings as documented in this m
35. operly premature wear on gears may occur Wear on gears may affect performance or safety and result in loss of warranty 2 Grease the pinion ring gear with Mobil lubricating grease NLGI grade 2 ISO 220 or equivalent 3 Grease the ring gear bearings with Aeroshell 22 grease or equivalent 4 To ensure proper greasing of gears and bearings slowly rotate the ring gear 360 while greasing this will allow grease to completely coat the gear Gears must be fully greased Figure 4 20 Pinion Ring Gear Grease Ring Gear Bearing Grease Fork arm shank Grease zerk Figure 4 20 Grease Fitting Locations Allied 45 006 REV 7 12 COMPANY REACH A Division of Allied Systems Company 4 16 Gearbox Lubrication Part Number YGC 29 YGC 32 YGC 43 and YGC 43 LH 1 Remove the top plug and the oil level plug from the gearbox Figure 4 21 Oil Level Plug Figure 4 21 Gearbox Oil Plugs 2 Use Mobil HD 85W140 or equivalent oil If tempera tures drop below 20 F then use a synthetic oil Mobil SHC 634 or equivalent Do not overfill gearbox with oil Doing so may cause damage to seals and create leakage 3 Fill the gearbox to the oil level plug location 4 The oil level should be checked occasionally at the oil level plug If the oil level has dropped a leak may have occurred The leak should be corrected and the oil should be leveled off to the oil level plug location 5 Reinstall plugs Part Nu
36. or down Down Rearward or up Load stabilizer Up Forward or down Right Rearward or up Swing Left Forward or down Clockwise Rearward or up Slope Counterclockwise Forward or down Together Rearward or up Fork position Apart Forward or down Engage Rearward or up Trip Release Forward or down Engage Rearward or up Grip Release Forward or down Raise Rearward or up Truck stabilizer Lower Forward or down Clamp Rearward or up Clamp Release Forward or down For high 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 7 ANSI ITSDF Sequence of location and direction of motion for lever or hand type controls 45 006 REV 7 12 COMPANY REACH A Division of Allied Systems 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 da
37. re 4 43 Do not clamp on the side of the housing 13mm 1 2 in 13mm 1 2 in Figure 4 40 End Cap 4 Remove the gerotor and the drive spacer if appli cable The seal on the gerotor can now be serviced Figure 4 41 p Figure 4 43 Motor Port Clamping Excessive clamping pressure on the side of the housing causes distortion Drive inc Gerotor Seal eo Remove capscrews from the mounting flange These capscrews are installed with Loctite and will require 300 400 Ib in of torque to break loose and 100 Ib in ft t Figure 4 41 Gerotor of torque to remove 5 Remove the drive and the spacer plate The seal in AWaming the housing can now be serviced Figure 4 42 Do not use a impact wrench on the Drive screws that have been secured with Loctite This could result in rounded heads or broken sockets Notice If higher torque than given above is required to break capscrews loose apply heat according to the following Seal Spacer plate instructions Figure 4 42 Drive 45 006 REV 7 12 Allied 29 COMPANY A When heated Loctite partially melts This re duces torque required to remove the capscrew Use a small flame propane torch to heat a small area of the housing where the capscrew enters Figure 4 44 Be careful not to overheat the housing and damage the motor Gradually apply torque to the capscrew with a socket wrench as heat is applied for 8 to 10 seconds As soon
38. s 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 width as the load the load Pallet is the same X Pallet is wider than EEA EL HH IL Load is not stacked Too much clamping neatly force on the load Figure 2 5 45 006 REV 7 12 COMPANY REACH A Division of Allied Systems 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 tr
39. s body Before disconnecting any hydraulic connections be sure to turn off the truck s power and activate the truck s hydraulic functions in both directions to bleed off the hydraulic pressure 2 Disconnect the hydraulic connection for the attach ment positioning at the hydraulic valve ports V1 and V2 Figure 4 1 3 Disconnect the side shift connections at ports V3 and V4 Figure 4 1 To truck supply close V1 To truck V4o gt secondary S 9 side shift 3 To truck supply open V2 To cylinder base end To cylinder To cylinder rod end Figure 4 1 Hydraulic Connection 14 Allied COMPANY Slightly raise the truck carriage to allow the removal of the bottom mounting hooks If the attachment is equipped with quick change hooks simply press the slide plate release button and drop the slide plate down Figure 4 2 Raise slide to secure attachment to truck Push button y to lower slide Figure 4 2 Quick Change Hook 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 placed under the body of the attachment to raise the rear To reinstall follow the installation procedure in this manual When hydraulic service has been performed activate
40. s of galling or excessive wear 3 Out of roundness or deformities of the barrel 18 H Allied COMPANY 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 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 defective 4 8 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 Improper installation will result in poor performance The cupped side or O ring side of the seal should be facing the gland cap Figure 4 12 Seal Pm N X Detail A ee M lL Z L 1 Piston SA oe me ring Figure 4 12 Piston Seal 45 006 REV 7 12 REACH A Division of Allied Systems Company 3 Install the seals and wipers in the gland cap Note 2 Disconnect the hydraulic hoses from the truck at the the direction of the seals The cupped side or O ring attachments valve ports V1 open and V2 close side of the seal should be facing the piston Figure Figure 4 14 4 13 To truck supply close V1 To truc
41. 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 immedi 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
42. the bearing cup for the worm gear shaft into the housing on the motor adapter side Install the motor adapter and shims if applicable Press on the small bearing cup for the pinion shaft into the housing Press on the large bearing cup for the pinion shaft into the gear cap Slide the gear cap onto the pinion shaft Slide on the large bearing cone onto the pinion shaft Press the gear onto the pinion shaft to the large bearing Slide on the small bearing cone onto the pinion shaft and secure with the snap ring Allied COMPANY 13 Install the pinion shaft assembly and shims if ap plicable Figure 4 38 Large Bearing Figure 4 38 Pinion Shaft Assembly 14 Remove grease plugs and completely fill with grease See Section 4 16 4 19 Motor Disassembly 1 2 Remove the motor from gearbox Place the motor in a vice and clamp across the edge of the flange with output shaft down When clamping use a protective device on the vise such as special soft jaws pieces of hard rubber or board Figure 4 39 Figure 4 39 Motor Clamping 45 006 REV 7 12 REACH A Division of Allied Systems Company 3 Remove the capscrews and seal washers if ap 6 Remove the output shaft and the needle thrust bear plicable from the end cap The seal on the end cap ing from the housing can now be serviced Figure 4 40 7 Reposition the motor in the vise Clamp the motor across the ports as shown in Figu
43. uck 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 6 Fork position Push pull Sideshift Rotate Figure 2 6 Operator Controls 45 006 REV 7 12 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 preferabl
44. unting nuts flush nuts Apply wheel bearing grease to spherical portion of the nut and the concave section of the arm and body lug on both ends of the cylinders 500 Hour Maintenance 1 Inspectbase and lower retainer for hairline cracks or signs of structural failure particularly at the welds If welding is required to make a structural repair consult LongReach before proceeding 2 Visually inspect ring gear bearing seals to ensure they are properly inserted into their grooves and that they are fully intact preventing contaminants from entering the bearing 3 Re torque the fork bars front plate and ring gear bearing capscrews 5 8 UNF capscrews to 185 ft lbs 1 2 UNC capscrews to 77 ft Ibs 45 006 REV 7 12 2 000 Hour or 12 Month Maintenance 1 Replace oil in the gearbox YGC 29 YGC 32 YGC 43 and YGC 43 LH 5 2 Schedule Stationary Load Inverter Follow Daily Maintenance steps in Schedule 5 1 and 5 2 Daily Maintenance 1 Visually inspect the hydraulic power unit rotation motor gearbox and cylinders for leaks 2 Checkthe filer gauge and replace if indicated 100 Hour Maintenance 1 Check all bolt torques and re torque if necessary 2 Inspect all fittings and hoses for wear and or damage 250 Hour Maintenance Inspect all welds and joints for damage or cracking 1000 to 1500 Hour Maintenance Replace all oil in reservoir after 1000 to 1500 hours depending on use Hydraulic Power Unit Mainten
45. up the bolt holes Be careful not to disengage the star from the drive or disturb the gerotor seal Install the drive spacer if applicable Install 73 mm 2 875 in seal into the end cap Care fully place the end cap on gerotor Install the capscrews and seal washers if applicable into the end cap Pre tighten the capscrews to 40 Ib in Make sure the seal washers are properly seated Then torque the capscrews to 235 250 Ib in 34 H 45 006 REV 7 12 Allied COMPANY REACH A Division of Allied Systems Company SECTION 5 MAINTENANCE SCHEDULE 5 1 Schedule Daily Maintenance 1 Checklevel of hydraulic oil in the truck reservoir and add oil if necessary 2 Visually inspect all hoses and fittings for wear or damage Inspect for signs of hydraulic leaks Visually inspect for external damage or cracks 4 Inspect lower hooks for proper clearance Maximum clearance is 3 82 of an inch 5 f the attachment is equipped with quick change hooks check the slide plate latch for engagement Weekly 40 Hour Maintenance 1 Check for loose or missing bolts 2 Grease the Pinion Ring gear See Section 4 15 100 Hour Maintenance 1 Greasethe ring gear bearing assembly and fork arm shank at zerks For extreme applications grease at 40 hour intervals See section 4 15 2 Inspect the body wear strip retainer plugs do not tighten but visually inspect to make sure they have not loosened 3 Inspectthe cylinder mo
46. washer and the arm lug should be 1 16 to 1 8 of an inch or less Do not tighten the flush nut tight to eliminate all clearance between spacer washer and arm lug Figure 4 4 1 16 to 1 8 inch clearance washer Cotter pin t Flush nut onder 1 rod end 9 Figure 4 4 Arm Lug 4 Insert the cotter pin and bend to lock into place 4 3a Arm Retention Pin Retention pins are used only on folding arm bale clamps When the arms are folded these can be installed to insure that the arms do not open Remove the retention pin from its storage position on top of the machine Figure 4 5 The pin is attached with a clevis pin and hair pin to the bracket Allied COMPANY 15 Retention pin in 2 storage position Storage bracket apu Bolt to bracket here Retention pin in 4 place with arms j folded locked position P lie Cotter pin holds arm hinge pin lt Figure 4 5 Follow the illustrated instruction on Figure 4 6 to remove the pin Installation is the reverse 3 Rotate and lift out retention pin 2 Lift out hinge pin 1 Pull cotter pin Figure 4 6 4 4 Cylinder Removal 1 Extend the arms outside of the body Remove the cylinder rod end cotter pin and flush nut 16 H 45 006 REV 7 12 Allied COMPANY REACH A Division of
47. y 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 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 Allied COMPANY i Direction of motion Load Operator s hand on control handle facing the load Up Rearward or up Hoist Down Forward or down Retract Rearward or up Reach Extend Forward or down Rearward Rearward or up Tilt Forward Forward or down Right Rearward or up Sideshift Left Forward or down Rearward Rearward or up Push pull Forward Forward or down Clockwise Rearward or up Rotate lateral Counterclockwise Forward or down Rearward Rearward or up Rotate longitude Forward Forward
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