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ATiB 598 Use And Maintenance Manual

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USE AND
MAINTENANCE
MANUAL
FORK POSITIONER
TYPE 598 | 599
I-D02-01-23 - Rev.2

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Summary of Contents for ATiB 598

  • Page 1 USE AND MAINTENANCE MANUAL FORK POSITIONER TYPE 598 | 599 I-D02-01-23 - Rev.2...

  • Page 2: Table Of Contents

    Use and Storage of the Manual ..................4 Equipment Description ....................... 5 3 INSTALLATION ..........................9 Installation Procedure ...................... 10 3.1.1 Equipment Installation - TYPE 598 ................10 3.1.2 Equipment Installation - TYPE 599 ................13 Fitting the Forks – With Pockets ..................16 Securing the Forks ......................17 3.3.1 Securing the Forks - “R”...
  • Page 3 Disassembling the forks ....................29 Disassembling the Pocket / Welded Forks ..............30 Removing the Sideshift Cylinder from the Equipment ..........31 7.4.1 Disassembling and Reassembling the Sideshift Cylinder ........32 Removing the Fork Cylinders from the Equipment ............33 7.5.1 Disassembling the Fork Cylinders ................34 8 TROUBLESHOOTING ........................

  • Page 4: Safety Regulations For The Operator

    1 SAFETY REGULATIONS FOR THE OPERATOR 1 SAFETY REGULATIONS FOR THE OPERATOR Do not cross the upright Do not transport passengers Tilting Lifting 75 mm Travel Do not stand under the load Page 3 of 37...

  • Page 5: Introduction

    2.1 Use and Storage of the Manual This "Use and Instruction Manual" (hereinafter referred to as the Manual) is issued together with the A.T.I.B. equipment. - FORK POSITIONER TYPE 598 | 599 in accordance with DIRECTIVE 2006/42/EC OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 17/05/2006 and subsequent additions.

  • Page 6: Equipment Description

    2 INTRODUCTION 2.2 Equipment Description TYPE 598 - POCKETS TYPE 599 - POCKETS Page 5 of 37...
  • Page 7 2 INTRODUCTION TYPE 598 - WELDED FORKS TYPE 599 - WELDED FORKS Page 6 of 37...
  • Page 8 2 INTRODUCTION All the A.T.I.B. equipment – FORK POSITIONER TYPE 598 | 599 are identified by means of an adhesive plate (see Table 1) located on the equipment (see Figure 1), always refer to the serial number. PLATE POSITION Figure 1 11.
  • Page 9 11. MAX. TORQUE Not applicable to this equipment. The A.T.I.B. equipment - FORK POSITIONER TYPE 598 | 599 has been conceived, designed and manufactured to allow continuous, synchronised motion of the forks. The equipment is able to perform the following functions: •...

  • Page 10: Installation

    FLOW RATE (l/min) Operating TYPE and ISO pressure minimum maximum recommended Maximum (Bar) 598 ISO II 598 ISO III 598 ISO IV 599 ISO II 599 ISO III 599 ISO IV Table 2 ATTENTION OBSERVE THE INDICATED MAXIMUM OPERATING PRESSURES...

  • Page 11: Installation Procedure

    3 INSTALLATION 3.1 Installation Procedure 3.1.1 Equipment Installation - TYPE 598 1. Prior to installation, check the condition of the fork carriage, TYPE 598 ensuring that the lower profile is smooth which may otherwise affect the sliding of the lower pads.
  • Page 12 3 INSTALLATION 5. Remove the lower couplings from the equipment and grease the gibs (see Figure 3). If quick-release couplings are fitted, simply remove the cotter pin and turn them downwards (a). If standard couplings are present, remove the bolts and their washers (b).
  • Page 13 3 INSTALLATION 8. Screw on the 2 lower couplings G in such a way that their bodies also remains coupled to the lower part of the fork carriage P (with max. clearance of 1.5 mm, see Figure 5), tightening with the torque indicated in Table 3. CLASS THREAD TIGHTENING TORQUE...

  • Page 14: Equipment Installation - Type 599

    3 INSTALLATION 3.1.2 Equipment Installation - TYPE 599 1. Prior to installation, check the condition of the fork carriage, TYPE 599 ensuring that the lower profile is smooth. 2. Also make sure that the profiles of the fork-holder plate are not deformed, in order to ensure good coupling with the equipment.
  • Page 15 3 INSTALLATION 5. Only swivel eyebolts can be used for handling, which must be screwed into the holes provided on the sides (see detail Figure 7). For this purpose, straps or chains must be used that are suitably sized for the weight of the equipment as indicated on the plate (see Figure 1 and Table 1 on page 7).
  • Page 16 3 INSTALLATION 7. Screw on the 2 lower couplings G in such a way that their bodies also remains coupled to the lower part of the fork carriage P (with max. clearance of 1.5 mm, see Figure 8), tightening with the torque indicated in Table 4. CLASS THREAD TIGHTENING TORQUE...

  • Page 17: Fitting The Forks - With Pockets

    3 INSTALLATION 3.2 Fitting the Forks – With Pockets 1. Attach the forks, after unscrewing the fork stops on the pockets and removing the lower pins (see Point Securing the Forks) that secure the forks (see Figure 9 Figure 9 2.

  • Page 18: Securing The Forks

    3 INSTALLATION 3.3 Securing the Forks 3.3.1 Securing the Forks - “R” Cotter Pin Version 1. Insert the fastening pins of the lower fork couplings and check that R COTTER PIN fork coupling is locked by the pin itself (see Figure 11, a). 2.

  • Page 19: Securing The Forks - Split Cotter Pin Version

    3 INSTALLATION 3.3.2 Securing the Forks - Split Cotter Pin Version 1. Insert the fastening pins of the lower fork couplings and check that SPLIT COTTER PIN fork coupling is locked by the pin itself (see Figure 12, a). 2. Insert the safety cotter pin into the holes on both sides of the pin (see Figure 12, b). 3.

  • Page 20: Securing The Forks - Lower Coupling Version

    3 INSTALLATION 3.3.3 Securing the Forks - Lower Coupling version 1. Loosen the side bolts of the lower fork coupling so that it can be moved to the upper extremity of the slot. Keep it in this position until LOWER COUPLING the fork is fitted (see Figure 13, a).

  • Page 21: Hydraulic System

    4 HYDRAULIC SYSTEM 4 HYDRAULIC SYSTEM 4.1 Hydraulic System - TYPE 598 TYPE 598 SUPPLY SIDESHIFT CYLINDER SUPPLY CHECK VALVE FORK CYLINDERS CHECK VALVE Figure 14 Page 20 of 37...

  • Page 22: Hydraulic System - Type 599

    4 HYDRAULIC SYSTEM 4.2 Hydraulic System - TYPE 599 TYPE 599 SUPPLY CHECK VALVE FORK CYLINDERS CHECK VALVE Figure 15 Page 21 of 37...

  • Page 23: Rules Governing Use

    5 RULES GOVERNING USE 5 RULES GOVERNING USE Before using the equipment, check the tightness of the piping and the correctness of assembly and also the connection by performing a dozen preliminary operations. The following instructions must be followed when using the equipment: 1.
  • Page 24 5 RULES GOVERNING USE If the distance of the centre of gravity from the vertical part of the fork needs to be increased, the weight of the load must be reduced. In this case, consult the chart shown in Figure 16 where, as the distance from the centre of gravity increases (x-axis line), a multiplicative factor is included for load reduction purposes (y-axis line).
  • Page 25 5 RULES GOVERNING USE It is advisable to consult the manufacturer of the forklift truck to check the residual capacity of the forklift truck-equipment assembly. The condition of the road surface, the speed at which the load is handled and the elevation may all affect the load’s grip, which must be taken into account on a case-by-case basis.

  • Page 26: Handling Loads

    5 RULES GOVERNING USE 5.1 Handling Loads The minimum transportable dimensions must be larger than the minimum opening. Depending on the load to be transported, this difference may vary and must be evaluated on a case by case basis by the operator. Avoid handling and/or sideshift of the forklift truck/equipment with a load that is excessively high off the ground, as this may affect its stability.

  • Page 27: Periodic Maintenance

    7 PERIODIC MAINTENANCE 6 PERIODIC MAINTENANCE Failure to comply with the rules and intervals established for maintenance will compromise the correct operation of the equipment and will void the conditions of the warranty. All maintenance operations must be carried out with the forklift truck stationary and the hydraulic circuit disconnected and depressurised.

  • Page 28: Maintenance Every 1000 Hours

    7 PERIODIC MAINTENANCE 6.3 Maintenance Every 1000 Hours 1. Check condition of bushes and sliding gibs. If excessively worn component are detected, A.T.I.B. recommends replacing the entire component assembly in question. 2. Check condition of sliding axis, ensuring that it is not scratched or deformed in any way. 3.

  • Page 29: Disassembly Procedure

    7 DISASSEMBLY PROCEDURE 7 DISASSEMBLY PROCEDURE All maintenance operations must be carried out with the forklift truck stationary and the hydraulic circuit disconnected and depressurised. The entire maintenance area must be barricaded using regulation protection devices and, if the cylinders require disassembly, a tray or container must be provided to catch the oil present in the cylinder.

  • Page 30: Disassembling The Forks

    7 DISASSEMBLY PROCEDURE 7.2 Disassembling the forks 1. Release the pressure from the hydraulic system and disconnect the lines. 2. Remove the forks after unscrewing the fork stops and removing the lower pins (see Figure 19). Figure 19 Page 29 of 37...

  • Page 31: Disassembling The Pocket / Welded Forks

    7 DISASSEMBLY PROCEDURE 7.3 Disassembling the Pocket / Welded Forks 1. Open the forks fully. 2. Release the pressure from the hydraulic system and disconnect the lines. 3. Remove bolts A and plate B. 4. Remove snap rings C that secure the cylinders. 5.

  • Page 32: Removing The Sideshift Cylinder From The Equipment

    7 DISASSEMBLY PROCEDURE 7.4 Removing the Sideshift Cylinder from the Equipment 1. Release the pressure from the hydraulic system and disconnect the lines. 2. Remove spring pins A and remove the cylinder from its housing (see Figure 21). N.B. Bolts or washers may be present to secure the cylinder. Figure 21 Page 31 of 37...

  • Page 33: Disassembling And Reassembling The Sideshift Cylinder

    7 DISASSEMBLY PROCEDURE 7.4.1 Disassembling and Reassembling the Sideshift Cylinder If the entire cylinder needs to be replaced, reassemble following the instructions listed in reverse order. If any cylinder components need to be replaced, proceed as indicated below: 1. Clamp the cylinder body in a vice using soft jaws (taking care not to deform the liner). 2.

  • Page 34: Removing The Fork Cylinders From The Equipment

    7 DISASSEMBLY PROCEDURE 7.5 Removing the Fork Cylinders from the Equipment 1. Release the pressure from the hydraulic system and disconnect the lines. 2. Remove bolts A and plate B. 3. Remove snap rings C that secure the cylinders. 4. Remove/extract the cylinders. 5.

  • Page 35: Disassembling The Fork Cylinders

    7 DISASSEMBLY PROCEDURE 7.5.1 Disassembling the Fork Cylinders If the entire cylinder needs to be replaced, reassemble following the instructions listed in the previous point. If any cylinder components need to be replaced, proceed as indicated below: 1. Clamp the cylinder body in a vice using soft jaws (taking care not to deform the liner). 2.

  • Page 36: Troubleshooting

    8 TROUBLESHOOTING 8 TROUBLESHOOTING 8.1 Probable Faults and Solutions FAULT CAUSE SOLUTION Calibration of the maximum pressure Increase the pressure without exceeding valve too low the maximum limit Insufficient pressure Contact the forklift truck manufacturer Insufficient force Worn pump Replace it Worn cylinder seals Replace them No oil in the tank...

  • Page 37: Lubrication

    8 TROUBLESHOOTING 8.2 Lubrication Clean and lubricate all sliding surfaces: Lubricate the fork sleeves using the grease nipples; Grease sliding gibs; Lubricate the dual coupling using the grease nipples. Figure 25 Page 36 of 37...
  • Page 38 I-D02-01-23 - Rev.2...

This manual is also suitable for:

599

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