Allied Systems Long Reach PTC Series Installation Maintenance And Service Manual
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Allied Systems Long Reach PTC Series Installation Maintenance And Service Manual

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Installation, Maintenance
and Service Manual
PTC
Pipe Clamp
45-074, REV. 5/18
1

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Summary of Contents for Allied Systems Long Reach PTC Series

  • Page 1 Installation, Maintenance and Service Manual Pipe Clamp 45-074, REV. 5/18...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS SECTION 1 NAMEPLATE LOCATION ....3 SECTION 5 SERVICE PROCEDURE ....14 SECTION 2 MODEL NUMBER DESCRIPTION 4 5.1 Attachment Removal ......14 SECTION 3 SAFETY SUMMARY ......5 5.2 Pinion/Ring Gear And Bearing ....14 3.1 Safety Information ........5 5.3 Bearing Seal Replacement ....15 3.2 Safety Regulations ........5 5.4 Gearbox Lubrication .......15 3.3 Safety Symbols ........5...

  • Page 3: Section 1 Nameplate Location

    SECTION 1 NAMEPLATE LOCATION When you receive your attachment, APPROX. S/N PLATE locate the Long Reach nameplate (upper LOCATION 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...

  • Page 4: Section 2 Model Number Description

    SECTION 2 MODEL NUMBER DESCRIPTION Each clamp is identified by a model number and a serial number located on the name plate attached to the unit prior to shipment. Long Reach’s model numbers are designed to describe how an attachment is equipped. The guide below illustrates the information that is represented in its model number.

  • Page 5: Section 3 Safety Summary

    SECTION 3 SAFETY SUMMARY 3.1 Safety Information WARNING Safety is Everyone’s Responsibility Whether you are new on the job or a seasoned veteran, Indicates a hazardous situation which, these safety tips may prevent injury to you, to others, or if not avoided, could result in death or to the materials you are handling.

  • Page 6: Labeling

    3.4 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 Figure 3-1 the truck and attachment combination at maximum...

  • Page 7: Pre-Start Checks

    3.7 Pre-start Checks • Wear personal protective equipment, such as gloves and safety glasses, whenever servicing or checking • Check your equipment before you operate it. If any- a hydraulic system. thing looks wrong, unusual or different, report it before •...

  • Page 8: Load Handling

    • Always perform all maintenance and lubrication pro- cedures with the machine on level ground, parked away from traffic lanes. Equipment overload hazard. NOTICE Injury or equipment damage may result if the capacity of the truck and attachment Local laws and regulations may require combined are less than the attachment that additional safety measures be taken.

  • Page 9: Load Positioning

    3.13 Load Positioning For clarity, the direction of arm movement is shown on the control handle. To move the arms in the direction shown, • Be accurate in load placement. It’s important to know pull the handle towards the operator. To move the arms what the load will do when it’s released.

  • Page 10: Industry Standards

    3.15 Industry Standards 3.16 Clamp Open Control ANSI/ITSDF B56.1-2016 is the published sequence and Effective October 7, 2010, safety standard ANSI/ITSDF direction standard for lever- and hand-type controls. B56.1, Section 7.25.7 covers all lift trucks with a load bearing clamp (paper roll clamp, carton clamp, etc.), and requires the driver to make two distinct motions before opening or releasing the clamp.
  • Page 11 Direction of motion Function Load Operator's hand on control handle, facing the load* 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...

  • Page 12: Section 4 Installation Procedure

    SECTION 4 INSTALLATION PROCEDURE 4.1 Truck Requirements 4.2 Attachment Installation Long Reach attachments have been designed to oper- 1. Prior to connecting the truck hydraulic system to the attachment, the system must be purged through the fil- ate within specific limits. Operating pressures above the recommended maximum may cause damage to the at- tration system.

  • Page 13: Hydraulic Connections

    3. Install the pin-mount attachment to truck carriage. 4.3 Hydraulic Connections Using the attachment as a template, weld on the bracket lugs, supplied with the attachment, to lower 1. Install the lines from the truck’s hydraulics to the bar on the truck carriage. (Figure 4-2) hydraulics of the attachment.

  • Page 14: Section 5 Service Procedure

    SECTION 5 SERVICE PROCEDURE 5.2 Pinion/Ring Gear And Bearing 5.1 Attachment Removal 1. Grease the pinion/ring gear every 40 hours. Grease the Not all procedures require that the attachment be re- ring gear bearings every 100 hours. (See Section 6) moved from the truck.

  • Page 15: Bearing Seal Replacement

    5.3 Bearing Seal Replacement 5. Insert the seal into the groove with firm steady pres- sure, but avoid stretching the seal. 6. The length of the seal provided is longer than required. Before gluing the last six inches, insert the seal into the groove to determine the exact length required.

  • Page 16: Gearbox Disassembly

    5.5 Gearbox Disassembly Part Number: YGC-29, YGC-32, YGC-43 And YGC- 43-LH Equipment damage hazard. 1. Remove the attachment from truck. (See Section 5.1) Overfilling the gearbox may damage the 2. Before removing the gearbox from the back plate, gearbox, causing a leak. place a support overhead or under the gearbox.
  • Page 17 Capscrew Housing Cover Pinion Gear Capscrew Screwdriver Capscrew Adapter Plate Gearbox Motor Figure 5-8, Motor Removal 4. Remove the pinion gear and key from the output shaft. Use a screwdriver to knock loose the key. Capscrew Figure 5-9, Adapter Plate Removal Equipment damage hazard.
  • Page 18 7. Remove the output shaft assembly. (Figure 5-11) Motor Adapter Bearing O-Ring Coupling Shim Spacer Capscrew Shim Worm Gear Shim End Cap Output Shaft Bearing Shim O-Ring Snap Ring Capscrew Figure 5-13, End Cap / Motor Adapter Figure 5-11, Output Shaft 10.
  • Page 19 Part Number: YGC-48, YGC-49, YGC-49-LH, YGC-50 And YGC-50-LH 1. Remove the attachment from truck. (See Section 5.1) Equipment damage hazard. 2. Before removing the gearbox from the back plate, Impact wrenches could damage screws place a support overhead or under the gearbox. or sockets if screws have been secured Remove the mounting capscrews from the gearbox.
  • Page 20 Motor Adapter O-Ring Coupling Equipment damage hazard. A chipped pinion shaft will affect machine Capscrew performance. Shim Shim End Cap Do not drop the pinion shaft onto a hard surface or it may chip. NOTICE Shim O-Ring Capscrew 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.

  • Page 21: Gearbox Assembly

    5. Press on the bearing cup for the worm gear shaft into NOTICE the housing on the motor adapter side. 6. Install the motor adapter and shims (if applicable). The bearing cup on the motor adapter side 7. Press on the small bearing cup for the pinion shaft of the housing will need to be removed with into the housing.
  • Page 22 2. Place the motor in a vice and clamp across the edge of Drive spacer 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 5-22) Seal Gerotor Figure 5-24, Gerotor...
  • Page 23 Apply heat for 8 to 10 seconds while gradually applying torque to the capscrew with a socket wrench. As soon as the capscrew breaks loose, remove heat from the hous- 1/2 in. (13mm) ing. Continue turning the capscrew until it is completely 1/2 in.

  • Page 24: Motor Assembly

    NOTICE Seal Pressure Seal Equipment damage hazard. Any scratch or foreign material on the surface of the seal cavity outer diameter Back-Up Ring could create a leak path. Mounting Flange Be careful not to scratch the seal cavity O.D. Use lint-free towels to wipe parts Exclusion Seal 11.
  • Page 25 5. Install the needle thrust bearing, then the bearing race NOTICE onto the output shaft. Pull the output shaft partially out of the housing. Push all three parts into the housing together (Figure 5-33). The bearing race must rotate Fully cured Loctite resists most solvents, freely when in position.
  • Page 26 8. Lubricate the I.D. of the seal tube and O.D. of the shaft 12. Before installing the mounting flange and seal assem- pressure seal with a light film of clean petroleum jelly. bly over the shaft, place a protective sleeve or bullet Align the small I.D.
  • Page 27 19. Install the spacer plate. NOTICE 20. Install 73 mm (2.875 in.) I.D. seal into the gerotor seal groove. Carefully place the gerotor onto the spacer Make sure any new capscrews used are plate, seal side toward the spacer plate. the correct length: 22mm (.875 in.) under 21.

  • Page 28: Cylinder Removal

    5.9 Cylinder Removal CAUTION 1. Fully extend the cylinder rod. 2. Turn off truck and disconnect the hydraulic connections. Equipment damage hazard. 3. Remove the pivot pin retainers and cylinder. (Figure Equipment damage and loss of performance 5-38) could result if air is trapped in the hydraulic system.

  • Page 29: Cylinder Inspection

    6. Remove the piston retaining nut and remove the pis- ton. (Figure 5-40) 7. Carefully pry up on the piston seals using a blunt tip screwdriver being careful not to scratch the seal grooves. Cut the seals to remove them from the pis- ton.

  • Page 30: Cylinder Assembly

    5.13 Cylinder Assembly Backup 1. Spray the piston, gland cap and seals with WD40 or O-Ring Ring other similar product to ease slipping of the seals in Seal Gland Cap place. (Figure 5-40) Locknu 2. Note the direction of the seal on the piston. Improper installation will result in poor performance.

  • Page 31: Swivel Assembly Installation

    5.16 Swivel Assembly Installation 2. Disconnect the hydraulic hoses from the truck at the attachments swivel assembly ports 1, 2, 3 and 4. (Fig- 1. Reassemble in the reverse order above. ure 5-48) 2. Turn on the truck’s power and activate the hydraulic 3.

  • Page 32: Section 6 Maintenance

    SECTION 6 MAINTENANCE 6.1 Schedule 500 Hour Maintenance: Daily Maintenance: 1. Inspect arms and mounting hooks for cracks, or wear. If any defect is found, remove from service for replace- 1. Check level of hydraulic oil in the truck reservoir and ment or repair.

  • Page 33: Torque Specifications

    6.2 Torque Specifications The following torque values are to be used on all fasten- ers unless otherwise specified. Grade 5 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.

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