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Allied Systems LONG REACH CR Series Installation Maintenance And Service Manual

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Installation, Maintenance
and Service Manual
CR
Series Rotators
45-022
REV. 04/22

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  • Page 1 Installation, Maintenance and Service Manual Series Rotators 45-022 REV. 04/22...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS SECTION 1 NAMEPLATE LOCATION ..3 SECTION 5 OPERATION ......22 SECTION 2 MODEL IDENTIFICATION ..4 SECTION 6 SERVICE PROCEDURE ..23 SECTION 3 SAFETY SUMMARY ....5 6.1 General .......... 23 3.1 Safety Information ......5 6.2 Attachment Removal ......

  • Page 3: 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 4: Section 2 Model Identification

    SECTION 2 MODEL IDENTIFICATION 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 an multi-digit model number.

  • Page 5: 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 6: 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 7: 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 8: Pre-Start Checks

    3.7 Pre-start Checks • Check your equipment before you operate it. If anything looks wrong, unusual or different, report it before using the attachment. • Do not operate this machine if you know of malfunctions, missing parts, and/or mis-adjustments. These situations can cause or contribute to an accident or damage to the machine.

  • Page 9: Electrical Hazards

    3.10 Electrical Hazards WARNING Electrocution hazard. Contact with energized equipment may result in injury or death and will damage equipment. Remain at least 25 feet from high voltage electrical wires. • All electrical cables and connectors must be in good condition (free of corrosion, damage, etc).

  • Page 10: Load Handling

    WARNING Suffocation hazard. Engine exhaust fumes can cause death. Remove the exhaust fumes from the area with an exhaust pipe extension, or 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.

  • Page 11: Load Positioning

    • 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 applicable, not the arm or arm base. •...

  • Page 12: Operator's Controls

    3.14 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.

  • Page 13: Clamp Open Control

    3.15 Clamp Open Control Effective October 7, 2010, safety standard ANSI/ITSDF 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. For example, you must press a switch and then move a lever to unclamp the load.
  • Page 14 Direction of motion Function Operator's hand on control handle, Load 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 15: 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 16 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 hooks, simply depress the button on the back of the hooks, allowing the slide plate to drop.
  • Page 17 YXE4C-307 1/2 x 1/2 x 2.00 steel Supplemental locking lug (optional) 1/16" clearance Locking lug in notch Figure 4-2, Locking lug 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” (Figure 4-3). Tighten the bolts to torque values on Figure 6-36 on page 52.

  • Page 18: Hydraulic Connections

    WARNING Equipment failure hazard. The attachment could fall off the truck if the quick hook is not properly installed. Slide plate must click 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 hooks.

  • Page 19: Third Hook Welding Instructions

    Install the hoses from the tr uck to the attachment. For specific hyd r a u l i c s c h e m a t i c s , s e e yo u r s e r i a l n u m b e r s p e c i f i c p a r t s manual, available online in the Manuals and Publications tab at www.alliedsystems.com.

  • Page 20: Fork Installation

    Use a 600° F. tempil stick frequently on the heated surface until it melts. Item No. Part No. Description 2500029 Hook, Class II 2500117 Hook, Class III 2500065 Hook, Class IV Figure 4-5, Rotator fork welding specifications Weld per drawings using low hydrogen filler wire (7018 or equivalent). Post-heat weld area to 800°...
  • Page 21 WARNING Crush hazard. Rotating equipment without a third hook installed could fall off the lift truck and may result in injury or death and will damage equipment. Install the third hook on the fork as described in Section 4.4 Third Hook Welding Instructions. Third hook Figure 4-6, Third hook...

  • Page 22: Section 5 Operation

    SECTION 5 OPERATION Check A Make sure load overhead Position load parallel has captive fork clearance. to the ground before slots or pockets rotating. before rotating. B Position forks to outside edge of slots. Check Tilt back if 4˚ clamp ground mounting is used.

  • Page 23: Section 6 Service Procedure

    SECTION 6 SERVICE PROCEDURE 6.1 General Not all procedures require that the attachment be removed from the truck. Review each procedure before beginning. Make sure lifting equipment is rated for the load being lifted. 6.2 Attachment Removal Position the attachment arms to the width of the unit’s body. Turn off lift truck. Relieve pressure in the hydraulic circuit to the attachment by cycling the lever back and forth several times.

  • Page 24: Pinion/Ring Gear And Bearing

    NOTICE Equipment damage hazard. Equipment damage and loss of performance could result if air is trapped in the hydraulic system. Activate the hydraulic functions several times after hydraulic service has been performed, to bleed trapped air out of the system before returning attachment to service. 6.3 Pinion/Ring Gear and Bearing Grease the pinion/ring gear every 40 hours.

  • Page 25: Bearing Seal Replacement

    6.4 Bearing Seal Replacement NOTICE Equipment damage hazard. Foreign matter in the bearing could cause bearing failure. Prevent any foreign matter from falling into the bearing during the seal replacement procedure. Remove all traces of glue and the old seal from the seal groove by mechanically scraping the groove.

  • Page 26: Oil-Filled Gearboxes

    Allow ten minutes for the glue to cure. Re-grease the bearing until grease squeezes out from under the seal to remove any foreign matter that might have become lodged in the bearing separation line. 6.5 Oil-Filled Gearboxes 6.5.1 Lubrication for Part Numbers: YGC-29, YGC-32, YGC-43 and YGC-43-LH Remove the top plug and the oil level plug from the gearbox.
  • Page 27 6.5.2 Disassembly for Part Numbers: YGC-29, YGC-32, YGC-43 and YGC-43-LH Remove the attachment from truck. (See Section 6.1) Before removing the gearbox from the back plate, place a support overhead or under the gearbox. Remove the mounting capscrews from the gearbox. (Figure 6-5) Back Plate Gearbox Motor...
  • Page 28 NOTICE Equipment damage hazard. Impact wrenches could damage screws or sockets if screws have been secured with Loctite. Use care when working with the gear assembly. Do not use a impact wrench on the screws that have been secured with Loctite.
  • Page 29 Seal Adapter Plate O-Ring Figure 6-8, Output shaft seals Remove the output shaft assembly. (Figure 6-9) Bearing Shim Spacer Worm Gear Output Shaft Bearing Snap Ring Figure 6-9, Output shaft The output shaft fits tightly, so you may need to remove the cap on the back of the gearbox and lightly tap the end of the output shaft with a rubber mallet to remove it.
  • Page 30 Figure 6-10, Output shaft cap Remove the end cap and motor adapter. Make note of any installed shims. Capscrews are installed with Loctite, so use a long handle wrench to break them loose. (Figure 6-11) Motor Adapter O-Ring Coupling Capscrew Shim Shim End Cap...

  • Page 31: Grease-Filled Gearboxes

    Screwdriver Bearing Worm Bearing Snap Ring Figure 6-12, Input shaft 6.5.3 Assembly for Part Numbers: YGC-29, YGC-32, YGC-43 and YGC-43-LH Reassemble in reverse order. Use Loctite (Blue) on all capscrews. See Section 6.9 for Torque Specifications. 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.
  • Page 32 Top Plug Bottom Plug Figure 6-13, Gearbox grease plugs (YGC-49 shown) Lay the gearbox with the pinion gear down and fill the gearbox from the top plug hole, allowing trapped air to escape through the bottom plug hole, and until grease shows in the bottom plug hole.
  • Page 33 6.6.2 Disassembly for Part Numbers YGC-48, YGC-49, YGC-49-LH, YGC-50 and YGC-50-LH Remove the attachment from truck. (See Section 6.1) Before removing the gearbox from the back plate, place a support overhead or under the gearbox. Remove the mounting capscrews from the gearbox. (Figure 6-14) Motor Gearbox Capscrew...
  • Page 34 NOTICE Equipment damage hazard. Impact wrenches could damage screws or sockets if screws have been secured with Loctite. Use care when working with the gear assembly. Do not use an impact wrench on the screws that have been secured with Loctite. NOTICE Equipment damage hazard.
  • Page 35 NOTICE Equipment damage hazard. A chipped pinion shaft will affect machine performance. 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 housing cover will need to be removed with a bearing puller.
  • Page 36 Motor Adapter O-Ring Coupling Capscrew Shim Shim End Cap Shim O-Ring Capscrew Figure 6-18, Worm cap/motor adapter NOTICE Equipment damage hazard. Damage to the housing cover or housing could reduce machine performance or void the warranty. Do not damage the machined surfaces of the housing cover and housing.
  • Page 37 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 clean rag and inspect for any foreign particles. 6.6.3 Assembly for Part Numbers YGC-48, YGC-49, YGC-49-LH, YGC-50 and YGC-50-LH Install all seals.

  • Page 38: Motor Disassembly

    15. Slide on the small bearing cone onto the pinion shaft and secure with the snap ring. 16. Install the pinion shaft assembly and shims (if applicable). (Figure 6-20) Pinion Shaft Housing Cover Large Bearing Small Bearing Shims Worm Gear Snap Ring Figure 6-20, Pinion shaft assembly 17.
  • Page 39 1/2 in. (13mm) 1/2 in. (13mm) Figure 6-21, Motor port clamping NOTICE Equipment damage hazard. Excessive clamping pressure on the side of the housing causes distortion. Use caution when clamping the motor housing. Remove capscrews from the mounting flange. These capscrews are installed with Loctite and will require 300-400 lb-in of torque to break loose and 100 lb-in of torque to remove.
  • Page 40 Heat with a propane torch to melt Loctite Capscrew Seal Exclusion Seal Pressure Seal Back-up Ring Mounting Flange Figure 6-22, Capscrew Loctite Remove the shaft key. Mark the flange for proper orientation at reassembly. Press down on the end of the shaft while lifting the flange (Figure 6-23). Do not disturb the shaft.
  • Page 41 The exclusion seal, back-up ring, pressure seal and seal will come off with the mounting flange (Figure 6-24). Seal Pressure Seal Back-Up Ring Mounting Flange Exclusion Seal Figure 6-24, Mounting flange seals Use a seal removal tool (Figure 6-25 and Figure 6-26) to remove the exclusion and pressure seals.

  • Page 42: Motor Assembly

    NOTICE Equipment damage hazard. Any scratch on the surface of the seal cavity outer diameter could create a leak path. Be careful not to scratch the seal cavity OD . Work from the outer side for both (either) seals. 10. A metal 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.
  • Page 43 NOTICE Lubricate all seals with petroleum jelly. Use new seals when reassembling motor. Refer to parts coverage. Do not stretch seals before installing them. 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;...
  • Page 44 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 6-29). The bearing race must rotate freely when in position. Figure 6-29, Output shaft in position 10.
  • Page 45 12. Lubricate the ID of the seal tube and OD of the shaft pressure seal with a light film of clean petroleum jelly. Align the small ID 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 6-31).
  • Page 46 Figure 6-31, Output shaft lubrication 17. Install the mounting flange. Rotate the mounting flange slowly while pushing down over the shaft. Be careful not to invert or damage the seals. 18. After removing the protective sleeve, clamp the motor in a vise. Make sure the shaft cannot fall out.
  • Page 47 NOTICE Make sure any new capscrews used are the correct length: 22 mm (.875 in.) under head length. See parts coverage for correct part number. 19. Reposition the motor with the geroter end up, then clamp the motor across the ports. NOTICE To aid the installation of seals, apply a light coat of clean petroleum jelly to seals.
  • Page 48 Gerotor Star Point Gerotor Seal Timing Spacer Plate Housing Forward Valving Slot Figure 6-33, Standard rotation 26. For reverse rotation align any star valley with the marked tooth on the drive. (Figure 6-34) Gerotor Star Valley Gerotor Seal Timing Spacer Plate Housing Forward...

  • Page 49: Reusable Hose Fittings

    28. Install the drive spacer (if applicable). 29. Install 73 mm (2.875 in.) seal into the end cap. Carefully place the end cap on gerotor. 30. Install the capscrews and seal washers (if applicable) into the end cap. Pretighten the capscrews to 40 lb-in. Make sure the seal washers are properly seated. Then torque the capscrews to 236-250 lb-in.

  • Page 50: 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 51: Torque Specifications

    NOTICE Inspect the hose for proper assembly. Look inside the fitting for hose material that might prevent free flow. Use compressed air to clear the hose of debris. If the hose is damaged, remove the fitting and cut away the damaged hose. Reassemble the hose as in Fitting Assembly Steps 1 through 4.

  • Page 52: Section 7 Maintenance

    GRADE 8 COARSE GRADE 5 COARSE SOCKET HEAD THREAD THREAD COARSE THREAD Lubricated Lubricated Capscrew Lubricated Bolt Size Bolt Size Torque Torque Size Torque 1/4" 11 ft-lbs 1/4" 7.5 ft-lbs 1/4" 12.5 ft-lbs 5/16" 23 5/16" 16 5/16" 26 3/8" 40 3/8"...
  • Page 53 Weekly 40 Hour Maintenance: Complete the above daily checks. Inspect all hoses and fittings for wear or damage. Inspect for hydraulic leaks. Check for loose or missing bolts. Grease the pinion/ring gear. (See Section 6.3) If applicable, check the grease fittings on bronze top hooks, to ensure that they are clean and properly working.
  • Page 54 1,000 Hour or 6 Month Maintenance: Remove attachment from lift truck for this inspection and maintenance cycle. Inspect mounting hooks for cracks, wear and deflection. If any defect is found remove attach- ment from service. 2,000 Hour or 12 Month Maintenance: Replace oil in the gearbox, oil-filled gearboxes only (part numbers YGC-29, YGC-32, YGC-43, YGC-43-LH, YGC-50, and YGC-50-LH).
  • Page 55 Page intentionally left blank. 45-022 REV. 04/22...
  • Page 56 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 45-022 REV. 04/22...

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