Related Manuals for Allied Systems LONG REACH FLN Series
Summary of Contents for Allied Systems LONG REACH FLN Series
- Page 1 Installation, Maintenance and Service Manual FLN and FLS Heavy Duty Fork Positioners 45-009 REV. 8/20...
- Page 2 THIS PAGE WAS INTENTIONALLY LEFT BLANK 45-009 REV. 8/20...
-
Page 3: Table Of Contents
TABLE OF CONTENTS 4.2.2 Installations with Quick Hooks ...21 SECTION 1 NAMEPLATE LOCATION ....4 4.2.3 Installations with Sideshift ....21 SECTION 2 MODEL NUMBER DESCRIPTION . 5 4.2.4 Lower Roller Assemblies (Sideshift FLN Series Model Number: ......5 Units Only) ..........22 FLS Series Model Number: ......5 4.3 Fork Cylinder Anchor (Some FLS and... -
Page 4: Section 1 Nameplate Location
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. -
Page 5: Section 2 Model Number Description
SECTION 2 MODEL NUMBER DESCRIPTION Each attachment is identified by a model number and a serial number located on the nameplate 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 a multi-digit model number. -
Page 6: Section 3 Safety Summary
SECTION 3 SAFETY SUMMARY 3.1 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. -
Page 7: Labeling
CAUTION 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. WARNING Multiple hazards. -
Page 8: Personnel Safety
3.6 Personnel Safety • When removing or installing dismountable attachments always keep hands and feet free from dangerous positions or pinch points. Never leave a dismounted attachment in a dangerous position. • Keep hands, feet, long hair and clothing away from power-driven parts. Do not wear loose fitting clothing or jewelry while performing maintenance and lubrication in these areas. -
Page 9: Pre-Start Checks
• 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 pedes- trians when transporting. -
Page 10: Electrical Hazards
• 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. -
Page 11: Load Handling
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 main- tenance or lubrication. Never stand under a component that is supported only by the hydraulics. -
Page 12: Load Positioning
• Never overload the attachment. Refer to the attachment nameplate for the rated capacity of the attachment. Refer to the truck nameplate for the maximum net working capacity of the truck/attachment combination. Never use a load to support or move another object. -
Page 13: Operator's Controls
Figure 3-4 • 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. -
Page 14: Industry Standards
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. - Page 15 WARNING Load loss hazard. Injury or equipment/load damage may result if a fork positioner attachment is used to clamp a load. The fork positioner does not have enough clamping force to safely hold a load. Always support the load with the forks. Do not use fork positioning attachments as clamps.
- Page 16 Direction of motion Function Load Operator's hand on contro 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 17: Section 4 Installation Procedure
SECTION 4 INSTALLATION PROCEDURE 4.1 Truck Requirements Long Reach attachments have been designed to operate within specific limits. Operating pressures above the recommended maximum may cause damage to the attachment and may void the warranty. Operating pressure specifications for your attachment can be found on the attachment nameplate. -
Page 18: Attachment Installation
When the truck hydraulic system flow (gpm) exceeds specified maximum, a flow control valve is recommended to ensure optimal performance. Consult the truck factory and/or Long Reach for guidance. NOTICE Equipment damage hazard. Equipment damage, performance reduction, personal injury and/or loss of warranty could result if any alter- ations are made to the original attachment. -
Page 19: Installations With Bolt-On Hooks
Quick Hooks There are two kinds of quick hook, detent-pin style and push-button style. Raise slide Slide Plate to secure attachment to truck. Button Body Push button to lower slide. Figure 4-3, Push-button style quick hook For push button quick hooks, depress the button on the back of the hook and allow the slide plate to drop. - Page 20 YXE4C-307 1/2 x 1/2 x 2.00 steel supplemental locking lug (optional) 1/16" clearance Locking lug in notch Figure 4-5, Welding the optional locking lug Install the bolt-on lower hooks. Check the clearance between the carriage and the lower hooks. Loosen the bolts on the front of the hooks, and slide them up or down so the clearance is no more than 3/32”...
-
Page 21: Installations With Quick Hooks
4.2.2 Installations with Quick Hooks 1. Follow steps 1-5 under bolt-on hooks. Truck Maximum Attachment Mast Clearance Frame 3/32" Slide Button Quick Hook Figure 4-7 , Quick hook inspection Raise the slide plate until the button clicks into place. WARNING The attachment could fall off the truck if the quick hook is not properly installed. -
Page 22: Lower Roller Assemblies (Sideshift Units Only)
Lube Fitting Capscrew & Washer Fork Base Spacer Top Hook Midplate Figure 4-8, Sideshifting top hook Inspect for proper engagement of the locking lug in the notch closest to the center of the truck’s carriage Weld on the (optional) extra locking lug supplied with the attachment, (two pieces of 1/2”... -
Page 23: Fork Cylinder Anchor (Some Fls And Fln Models)
Gently move the bottom of the attachment out to remove the block. Lower the attachment down the face of the carriage. Ensure that the rollers remained in the pockets and are in contact with the carriage. Install the bolt-on lower hooks. Inspect clearance between the carriage and the lower hooks. -
Page 24: Narrow Fork
4.4.1 Narrow Fork Tighten the included long Allen set screws until they touch the forks. Without further tightening of the set screws, tighten the installation jam nut against the carrier to 41 ft-lbs. Check the set screws for interference. Apply grease to face of the upper and lower fork bars. 4.4.2 Wide Fork Tighten the included short Allen set screws until they touch the forks. - Page 25 Gauge Post Clamp Open Figure 4-12, Hose connections To truck To truck supply secondary (close) V1 (side shift) To truck supply (open) V2 To cylinder base end To cylinder To cylinder base end rod end To cylinder rod end Figure 4-13, Hose connections Open Forks Port V2 Close Forks Port V1 Figure 4-14, Hose connections...
- Page 26 Inspect installation to make sure hoses are not kinked or pinched between the truck carriage and attachment. Operate the attachment continuously for several minutes to determine that all hydraulic connections are secure with no leaks, and to remove any air in the hydraulic system.
-
Page 27: Section 5 Maintenance Schedule
SECTION 5 MAINTENANCE SCHEDULE 5.1 Schedule Daily: 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 3/16 of an inch. If the attachment is equipped with quick change hooks check the retaining pin for engagement. -
Page 28: Torque Specifications
5.2 Torque Specifications The following torque values are to be used on all fasteners unless otherwise specified. Lubricated refers to fasteners in the “As Received” condition, which is normally a light preservative oil coating on unplated fasteners and no oil coating on plated fasteners. No special steps are taken to add further lubrication prior to assembly. -
Page 29: Section 6 Service Procedure
SECTION 6 SERVICE PROCEDURE 6.1 Attachment Removal Position the attachment arms to the width of the unit’s body. WARNING Crush hazard. Serious injury could result if residual hydraulic pressure causes equipment to drift during service procedures. Turn off truck's power, and activate hydraulic functions in both directions to bleed off hydraulic pressure. -
Page 30: Cylinder Removal
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. - Page 31 Push gland inward 1 inch and pry out lock ring. 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.
-
Page 32: Cylinder Inspection
6.4 Cylinder Inspection Inspect the cylinder tube bore for: Deep scratches or nicks. Signs of galling or excessive wear. Out-of-roundness or deformities of the barrel. Inspect the piston for: Scratches or nicks on seal grooves. Wear on O.D. Inspect the cylinder rod for: Scratches or nicks on the rod surface. -
Page 33: Cylinder Assembly
6.5 Cylinder Assembly Spray the piston, gland cap, and seals with WD40 or other similar product to ease slipping the seals in place. 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. -
Page 34: Cylinder Installation
Sideshift cylinder (if Model Fork positioning cylinder applicable) FLS/FLN055 90 ft-lbs 90 ft-lbs FLS/FLN100 90 ft-lbs 90 ft-lbs FLS/FLN120/150 165 ft-lbs 165 ft-lbs Spray the inside of the cylinder tube with lubricant to ease inserting the rod and piston. Insert the rod and piston into the cylinder tube. Tap the rod in with a rubber mallet if resistance is encountered. -
Page 35: Hydraulic Valve Installation
Disconnect the hydraulic hoses from the truck at the attachments valve ports V1 (open) and V2 (close). (Figure 6-9). Cap hoses to prevent contamination, and tag for reassembly. Disconnect the hydraulic hoses at the valve ports C1 and C2. Cap hoses to prevent contamination, and tag for reassembly. -
Page 36: Reusable Hose Fittings
6.9 Reusable Hose Fittings Kit hoses equipped with reusable fittings allow hoses to be cut to the exact length required for installation. NOTICE Do not shorten hoses to the point where they will be stretched or kinked when installed. Make sure hoses are not pinched, rubbed, twisted, or otherwise damaged throughout their full range of movement. -
Page 37: Fitting Assembly
6.9.2 Fitting Assembly The hose inserts into the fitting socket to the depth shown below and as indicated by the marks on the fitting wrench flats. Make sure the hose is not cut too short for proper installation. Cut the hose to the desired length using a fine toothed hacksaw or hose cutoff machine. - Page 38 THIS PAGE WAS INTENTIONALLY LEFT BLANK 45-009 REV. 8/20...
- Page 39 THIS PAGE WAS INTENTIONALLY LEFT BLANK 45-009 REV. 8/20...
- Page 40 Find the latest version of your complete parts documentation in the Manuals and Publications tab at www.alliedsystems.com. www.alliedsystems.com 21433 Oregon Street, Sherwood, OR 97140, USA Phone: 800.285.7000 Fax: 800.231.3273 45-009 REV. 8/20...
Need help?
Do you have a question about the LONG REACH FLN Series and is the answer not in the manual?
Questions and answers