1. Manuals
  2. Brands
  3. Allied Systems Manuals
  4. Industrial Equipment
  5. LONG REACH SQ Series
  6. Installation maintenance and service manual

Allied Systems LONG REACH SQ Series Installation Maintenance And Service Manual

Forging clamps, clamps
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Installation, Maintenance
and Service Manual
SQ Series Forging Clamps
and NSQ Series Clamps
45-025
REV. 05/23

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the LONG REACH SQ Series and is the answer not in the manual?

Questions and answers

Related Manuals for Allied Systems LONG REACH SQ Series

Summary of Contents for Allied Systems LONG REACH SQ Series

  • Page 1 Installation, Maintenance and Service Manual SQ Series Forging Clamps and NSQ Series Clamps 45-025 REV. 05/23...
  • Page 2 Page intentionally left blank. 45-025 REV. 05/23...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 NAMEPLATE LOCATION ..4 4.2 Arm Removal ....... 22 4.3 Arm Installation ......23 SECTION 2 SAFETY SUMMARY ..... 5 4.4 Cylinder Removal ......23 2.1 Safety Information ......5 4.5 Cylinder Installation ...... 24 2.2 Product Modifications ......

  • 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 Safety Summary

    Long Reach attachment. It’s your responsibility to see that they are carried out. 2.2 Product Modifications Any alterations to the product, that have not been approved by Allied Systems Company or use of any non-OEM replacement parts will void the warranty, and may introduce serious safety hazards.

  • 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

    2.7 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

    • 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 9: Hydraulic Hazards

    2.10 Hydraulic Hazards DANGER Injection hazard. Infection and gangrene will result when hydraulic oil penetrates the skin. See a doctor immediately to prevent loss of limb or death. Use a piece of cardboard to check for hydraulic leaks. • Wear personal protective equipment, such as gloves and safety glasses, whenever servicing or checking a hydraulic system.
  • Page 10 • 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 machine is moving or the engine is running. • Always perform all maintenance and lubrication procedures with the machine on level ground, parked away from traffic lanes.

  • Page 11: Load Handling

    2.13 Load Handling • Treat an unloaded forklift with an attachment as partially loaded. CAUTION Equipment overload hazard. Injury or equipment damage may result if the capacity of the truck and attachment combined are less than the attachment capacity. Consult truck nameplate for truck capacity with an attach- ment installed.

  • Page 12: Load Positioning

    2.14 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 attachment can severely damage the attachment and cause product damage.

  • Page 13: Clamp Open Control

    Clamp Fork position Push/pull Rotate Sideshift Figure 2-5, Operator controls 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 14: Industry Standards

    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 15 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 16: Section 3 Installation Procedure

    SECTION 3 INSTALLATION PROCEDURE 3.1 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 17: Ita/Hook-Type Mounting

    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) Hoses should meet or exceed SAE100 RI Type AT, with maximum working pres- sure of 3,000 psi for all attachment functions.
  • Page 18 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.

  • Page 19: Pin-Type Mounting

    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 20: Hydraulic Connections

    3.3 Hydraulic Connections Install the lines from the truck’s hydraulics to the hydraulics of the attachment. Inspect installation to ensure 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.

  • Page 21: Section 4 Service Procedures

    SECTION 4 SERVICE PROCEDURES 4.1 Attachment Removal Not all procedures require that the attachment be removed from the truck. Review each procedure before beginning. Make sure any lifting equipment used is rated for the load being lifted. 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 22: Pin-Type Mounting 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 23: Arm Installation

    Tie the cylinder up to support the weight when it is removed 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.

  • Page 24: Cylinder Installation

    4.5 Cylinder Installation Install the cylinder base end pin to the body and insert the cotter pin, if applicable. Bend out the cotter pin ends to lock. Apply a thin coat of bearing grease to the spherical and concaved portion of the flush nut, if applicable. Screw on the flush nuts or castle nuts until they stop.

  • Page 25: Cylinder Disassembly

    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. 4.6 Cylinder Disassembly Remove the cylinder from the attachment.

  • Page 26: Cylinder Inspection

    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 scaring.

  • Page 27: Cylinder Assembly

    Inspect the piston for: • Scratches or nicks on seal grooves. • Wear on outside diameter. Inspect the cylinder rod for: • Scratches or nicks on the rod surface. • Straightness of the rod. • Damaged threads. Inspect the gland cap for: •...

  • Page 28: Pinion/Ring Gear And Bearing

    Backup O-Ring Ring Seal Gland Cap Locknut Piston Cylinder Rod Wiper Ring Figure 4-10, Gland Cap Seal Install the piston on the rod and tighten the locknut to 70-75 ft-lbs. Spray the inside of the cylinder tube with lubricant to ease inserting the rod and piston.

  • Page 29: Oil-Filled Gearboxes

    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 4-11) Pinion/Ring Gear Grease Fitting Ring Gear Bearing Grease Fitting Figure 4-11, Grease Fitting Locations 4.10 Oil-Filled Gearboxes...

  • Page 30: Oil-Filled Gearbox Disassembly

    NOTICE Equipment damage hazard. Overfilling the gearbox may damage the gearbox, causing a leak. Do not overfill gearbox with oil. Fill the gearbox to the oil level plug location. The oil level should be checked occasionally at the oil level plug. If the oil level has dropped, a leak may have occurred.
  • Page 31 Capscrew Housing Cover Capscrew Gearbox Motor Figure 4-14, Motor Removal Remove the pinion gear and key from the output shaft. Use a screwdriver to knock the key loose. (Figure 4-15) NOTICE Equipment damage hazard. Impact wrenches could damage screws or sockets if screws have been secured with Loctite.
  • Page 32 Pinion Gear Screwdriver Capscrew Adapter Plate Capscrew Figure 4-15, Adapter Plate Removal The output shaft seals may now be serviced. (Figure 4-16) Seal Adapter Plate O-Ring Figure 4-16, Output Shaft Seals 45-025 REV. 05/23...
  • Page 33 Remove the output shaft assembly. (Figure 4-17) Bearing Shim Spacer Worm Gear Output Shaft Bearing Snap Ring Figure 4-17, 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 34: Oil-Filled Gearbox Assembly

    Motor Adapter O-Ring Coupling Capscrew Shim Shim End Cap Shim O-Ring Capscrew Figure 4-19, End Cap/Motor Adapter 10. Remove the input shaft assembly. The assembly fits tightly, so use a rubber mallet or press on the extended shaft to remove it. Remove the exposed key with a screw- driver, allowing the bearing and worm to slide off of the shaft.

  • Page 35: Grease-Filled Gearboxes

    4.11 Grease-Filled Gearboxes Part Numbers YGC-48, YGC-49, YGC-49-LH, YGC-50 and YGC-50-LH 4.11.1 Grease-Filled Gearbox Lubrication CAUTION Load loss hazard. Putting oil in this gearbox may result in loss of control, leading to equipment damage, damaged load or personal injury. Use ONLY Mobilux EP1 grease to lubricate this gearbox. Do NOT use oil.

  • Page 36: Grease-Filled Gearbox Disassembly

    4.11.2 Grease-Filled Gearbox Disassembly 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 4-22) Motor Gearbox Capscrew Backplate Figure 4-22, Gearbox Removal Place the gearbox on a flat surface and remove the motor mounting capscrews.
  • Page 37 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 38 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 39 Motor Adapter O-Ring Coupling Capscrew Shim Shim End Cap Shim O-Ring Capscrew Figure 4-26, 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 40: Grease-Filled Gearbox Assembly

    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. NOTICE The bearing cup on the motor adapter side of the housing will need to be removed with a bearing puller.

  • Page 41: Motor Disassembly

    11. Press on the large bearing cup for the pinion shaft into the housing cover. 12. Slide the housing cover onto the pinion shaft. 13. Slide on the large bearing cone onto the pinion shaft. 14. Press the gear onto the pinion shaft to the large bearing. 15.
  • Page 42 1/2 in. (13mm) 1/2 in. (13mm) Figure 4-29, 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 43 Heat with a propane torch to melt Loctite Capscrew Seal Exclusion Seal Pressure Seal Back-up Ring Mounting Flange Figure 4-30, 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 4-31). Do not disturb the shaft.
  • Page 44 Seal Pressure Seal Back-Up Ring Mounting Flange Exclusion Seal Figure 4-32, Mounting Flange Seals Use a seal removal tool (Figure 4-33) to remove the exclusion and pressure seals (Figure 4-34). Bend tip Radius Modify screwdriver Radius as shown. on end Remove all burrs.

  • Page 45: Motor Assembly

    11. Work from the outer side for both (either) seals. 12. 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. To remove the plug, insert a 5 mm (.187 in.) hex key through the port opening and push it out.
  • Page 46 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. Wash the housing with solvent to remove oil, grease and debris.
  • Page 47 Figure 4-37, Output Shaft In Position 10. Install the exclusion seal into the mounting flange. Carefully press the exclusion seal into place. (Figure 4-38) Shaft Pressure Seal Seal Driver Seal Tube Exclusion Seal Backup Ring Mounting Flange Figure 4-38, Seal Installation 11.
  • Page 48 NOTICE After installing the seal in the mounting flange, examine the seal condition. If damaged or improperly installed, you must replace it before continuing with reassembly. 13. Install the 49mm (1.937 in.) ID seal in the flange. 14. A light coat of Loctite Primer NF in tapped holes of housing is recommended. Allow primer to air dry for at least 1 minute.
  • Page 49 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 50 NOTICE If the drive is not symmetrical, install the larger splined end into the shaft. 24. Install the spacer plate. 25. Install 73 mm (2.875 in.) ID seal into the gerotor seal groove. Carefully place the gerotor onto the spacer plate, seal side toward the spacer plate. 26.

  • Page 51: Reusable Hose Fittings

    Gerotor Star Valley Gerotor Seal Timing Spacer Plate Housing Forward Valving Slot Figure 4-42, Reverse Rotation 28. Rotate the gerotor to line up the bolt holes. Be careful not to disengage the star from the drive or disturb the gerotor seal. 29.

  • Page 52: Remove Fitting

    4.14.1 Remove Fitting To shorten a hose, remove the reusable end-fitting using the following procedures: Clamp the fitting socket in a vise. Fitting Insert Fitting Socket Unscrew the fitting insert from the fitting socket. Unscrew the hose clockwise from the fitting socket. 4.14.2 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.
  • Page 53 Screw the hose into the fitting socket counterclockwise (CCW) to the hose insertion depth mark. Screw the fitting insert into the fitting socket until it touches the socket. NOTICE Inspect the hose for proper assembly. Look inside the fitting for hose material that might prevent free flow.

  • Page 54: Section 5 Maintenance Schedule

    SECTION 5 MAINTENANCE SCHEDULE 5.1 Maintenance Schedule Daily: Check level of hydraulic oil in the truck reservoir and add oil if necessary. Visually inspect all hoses and fittings for signs of hydraulic leaks. Visually inspect for external damage or cracks. Inspect lower hooks for proper clearance.

  • Page 55: Torque Specifications

    500 Hour: Inspect base and lower retainer for hairline cracks or signs of structural failure, particularly at the welds. CAUTION If welding is required to make a structural repair, consult Long Reach before proceeding. 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.
  • Page 56 Grade 5 Grade 8 Socket Head Capscrew Figure 5-1, Bolt Identification GRADE 8 COARSE GRADE 5 COARSE SOCKET HEAD COARSE THREAD THREAD THREAD Bolt Lubricated Bolt Lubricated Capscrew Lubricated Size Torque Size Torque Size Torque 1/4" 11 ft-lbs 1/4" 7.5 ft-lbs 1/4"...
  • Page 57 Page intentionally left blank. 45-025 REV. 05/23...
  • Page 58 Page intentionally left blank. 45-025 REV. 05/23...
  • Page 59 Page intentionally left blank. 45-025 REV. 05/23...
  • Page 60 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 45-025 REV. 05/23...

This manual is also suitable for:

Long reach nsq series

Table of Contents