Operating Manual. Sideshifter SF2-055 LTI # K Tel : (864) Fax : (864) Toll Free : (888) Website :

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1 Operating Manual Sideshifter SF2-055 LTI # Parts and Service Tel : (864) Fax : (864) Toll Free : (877) parts@lift-tek.com Lift Technologies, Inc South Highway 11 Westminster, SC USA Tel : (864) Fax : (864) Toll Free : (888) Website : Warranty Information Toll Free: (888) Fax: (864) warranty@lift-tek.com Lift Technologies, Inc.1

2 Contents Safety Information. 3 Safety Decals..3 Safety Operation..3 General Information..4 Intended Use..4 Proper Use...4 Limits of Intended Use.4 Improper Use.4 Transport Storage...4 Hydraulic System Terms of Delivery.4 Installation...5 Capacity and safety...5 Dimensions, weight and technical data...5 Parts Identification..6 Recommended Spare Parts..6-7 Routine Maintenance 8-9 Tightening Torque..8 Lubrications Approved / Recommended...8 Daily.8 After 50 hours / Every 500 hours thereafter.8 Weekly Grease..8 Every 200 hours Check Wear On..8 Every 500 hours...8 ITA Fork Carriage Notes Fork Notes As Necessary...9 Trouble Shooting.. 10 Decommissioning and Disposal.10 Bleeding the Hydraulic System Warranty Claims and Defects...10 Lift Technologies, Inc.2

3 Safety Information This manual applies to Lift Technologies, Inc. 2T151BP4N Sideshifter. The information contained in this manual will aide in operations, installation, preventative maintenance, and recommended spare parts. Revision 002 DATE 02/2018 ECN # Safety Decals 1. Identification plate. 2. Before putting into operation carefully read and take note of operating and safety instructions. 3. Never reach into moving unit. 4. Pinch point. 5. Lift at suspension point. 6. Test and operate the fork positioner with the fork arms attached only! WARNING: The capacity of the truck attachment combination may be less than the capacity shown on the attachment. Consult the truck nameplate. Safety Operation As the user, extend the safety instructions with generally applicable, legal and other measures that ensure a safe and environmentally friendly operation of the attachment. Pay close attention to all safety and danger related signs on the attachment and in this operating manual. Failure to observe these can result in severe injury or even death. Pay close attention to the operating manual provided by the manufacturer of the fork lift truck. Keep a safe distance from moving, reciprocating or rotating parts of the attachment to avoid danger of crushing, pinching or entanglement. Notify the responsible department/person immediately of changes and faults in operation of the attachment that affect safety. The attachment shall be shut down. Use aids to increase vision (e.g. mirrors, camera, etc.) where goods being transported obstruct vision. Only allow work on the attachment to be carried out by qualified and authorized persons. Adhere to the legal minimum age in the country of operation! The attachment should only be used for the purpose intended. Never work on or with attachments while under the influence of drugs, alcohol or medicines which affect reaction time. Be aware of persons present in the area where you are working or driving and ensure that they are not endangered. The nominal capacity of the forks must exceed the load Ensure that pallets, boxes, containers and packaging are in good condition. Do not drive with the mast tilted forward. Take care when driving that neither the attachment nor the load comes into contact with the ground. Ensure that multiple items stacked on top of one another are securely fastened. Lift Technologies, Inc.3

4 Intended use The sideshifter is intended for shifting raised loads 4.0 (100mm) sideways. This allows loads on the attached load forks to be positioned precisely in racks or on truck platforms without the need to maneuver the fork lift truck. Proper Use Observance of the operating manual at all times. Observance of the technical data on the identification plate on the attachment. Adherence to the specified inspection and maintenance instructions. Set the forks as wide apart as possible for the load to be carried Position the mast vertically and take up the load parallel to the floor. Always transport pallets, boxes and containers using both forks. Drive the attachment up to the load to maximum extent. Raise the load about 12 (300mm) and tilt the mast backwards. Center the load to the middle of the lift truck during take-up and transport. Limits of intended use Standard attachment models are not intended for continuous use (2 or more hours) in facilities with temperatures outside of the table provided. This attachment is not suitable for explosive environments, rough environmental conditions (e.g. seawater), the transportation of acidic liquids, or in conjunction with hydraulic systems involving biological oils. If attachments are needed for these special environments consult Lift Technologies, Inc. for a more suitable attachment. Improper Use Exceeding the allowable load capacity and load center Dragging or pushing loads with the attachment. Moving the load while it is resting on the floor or truck platform. Transporting people with the load or load handling devices. General Information Temperature Limits Max. (up to 1hr.) Average Min. (indoor) Min. (outdoor) 104 F (40 C) 77 F (25 C) 41 F (5 C) -4 F (-20 C) Mounting auxiliary equipment on the attachment such that the original mode of usage and/or HCG is changed, (e.g. fork extensions) must be authorized by the manufacturer. Transport During transport of the attachment, care should be given to using appropriate means of support (e.g. pallets). These must not be damaged. The attachment must be secured against slipping or tipping over on the support. Storage If the attachment is to be stored for an extended period, the hydraulic connections must be sealed to prevent against contamination damage. Store the attachment in clean, dry environment. Hydraulic System 1. This sideshifter is operated hydraulically with oil supplied from the forklift truck s hydraulic system. 2. The sideshifter requires a single hydraulic function operate. Terms of delivery If specified, this sideshifter is supplied with hoses and couplings necessary to connect to the truck hydraulic system. Please contact Lift Technologies Inc., inside sales for replacement hoses. Truck Hydraulic Requirements 2000 psi (140 bar) Recommended Relief Settings 2900 psi (200 bar) Maximum Min. 1GPM (4L/min.) Flow Volume Recommended 2.5 GPM (9.5 L/min.) Max. 4 GPM (15 L/min.) Cylinder Bursting Max. PSI 4950 (341 Bar) Pressure Lift Technologies, Inc.4

Installation Installation and commissioning should be performed by qualified and authorized personal only. Pay close attention to a sufficient load carrying capacity of the lifting means.

5 Installation Installation and commissioning should be performed by qualified and authorized personal only. Pay close attention to a sufficient load carrying capacity of the lifting means. Examples of preferred lifting means are shown below. Image for illustration only. Configuration may be different. Capacity Kg 250 kg/m kg/m kg/m16 (lb.). (550 lbs.) (2640 lbs.) (4400 lbs.) Part No NOTE: Attachments are delivered pre-lubricated. If the attachment has been in storage for a longer period, we recommend that it be lubricated again before being placed in service. Hoist the attachment at the position indicated (1). 4 Mount the attachment on the lift truck carriage (3) Check that the attachment is correctly seated in the center lock (4). Slide the lower hooks (5) into the fork carriage from the side. Screw in grease fitting. (11) Install screws (6) and tighten the locknuts (7). The hook (5) must remain free to move and must exhibit a clearance of (1-2 mm) from the lift truck carriage. (See detail A) Install hydraulic hoses (10) to proper locations (8). Make sure that all safety retaining stops (9) have been correctly reinstalled. Failure of the safety devices (e.g. the pressure relief valve and the non-return valve) and incorrect connection of the controls to the actuators can cause malfunctioning of the attachment and damage to it. 7 After mounting and before initial operation, check the functions and the identification of the attachment with the movement directions of the operating elements (operating lever, joystick, etc.). Mount the residual carrying capacity plate and identification of the operating elements (if not already present) of the combination of lift truck/attached equipment on the lift truck. DETAIL A Incorrect connection of the controls to the actuators can cause malfunctioning of the attachment and damage to it. After mounting and before initial operation, check the functions and the identification of the attached equipment with the movement directions of the operating elements (operating lever, joystick, etc.). Use only original spare parts from the manufacturer. Do not use third party spare parts. Through poor quality or incorrect matching they can result in a risk of accident. The warranty by the manufacturer becomes invalid and you assume full responsibility in the case of accident. The hydraulic system is under pressure. During work on hydraulic components oil spurting out can cause injuries. Unload the system in accordance with the operating instructions of the lift truck manufacturer. In the case of injuries caused by high pressure oil, inform the works physician and seek out a specialist immediately. Lift Technologies, Inc.5

6 Parts Identification A FORK POSITIONER K20252 PISTON BLOCK K30048 PART # DESCRIPTION QTY SOLD UPPER WEAR PAD 2 1 EA. FITTING, GREASE STR M8X1-A2E 4 IN KIT HEX SHCS M12x1.75x EA. K30048 WEAR PAD RETAINER 2 IN KIT PAD, LOWER WEAR 2 IN KIT K40002 M24 x1.5x40 DOG PT SET SCREW 2 1 EA. K40003 M24x1.5 - HEXAGON THIN NUT 2 1 EA. **K80011 INSTALLATION INSTRUCTIONS 1 1 EA. **K80031 OPERATING MANUAL 1 1 EA. **KS10003 DECALS 1 1 EA. *K20002 ROD,PISTON 2 1 EA. *K20003 PISTON BLOCK RETAINER 2 1 EA. * SEAL, STRIPPER 2 IN KIT * RING, GROOVE 2 IN KIT *K30004 BEARING, GUIDE 2 1 EA. K20252 #6 MORG/#6 MJIC W/ORIFICE 2 1 EA. *2645 NUT #6 CAP 2 1 EA. Part # Description # of Units Serviced K30026 Cylinder Seal Kit 1 per every 10 units K30027 Wear Pad Kit 1 per every 5 units * SEE CHART Recommended Spare Parts Complete Piston Block Assembly PISTON BLOCK ASSEMBLY (KS10118) WIDTH A K (25 ) K (31.5 ) NOTES: **ITEMS NOT SHOWN. INCLUDED IN WEAR PAD KIT # K30027 INCLUDED IN CYLINDER SEAL KIT K30026 *INCLUDED IN PISTON BLOCK ASSEMBLY 1 per every 25 units Lift Technologies, Inc.6

7 Parts Identification Fork Positioner PART NUMBER DESCRIPTION QTY CYLINDER, UPPER FP 1 CYLINDER, LOWER FP 1 GUIDE ROD SSFP 1 K20004 RH CYLINDER / ROD RETAINER 1 K20005 LH CYLINDER / ROD RETAINER 1 K40007 BOOT, FORK CARRIER RIGHT 1 K40008 BOOT, FORK CARRIER LEFT 1 K30010 SLEEVE BEARING 4 K40006 BRACKET HEX SHCS M12X K40017 HEX JAM NUT M16X1.5 2 K40016 HEX JAM NUT M20x1.5 2 K40019 HEX NYLOC M16x1.5 2 K40018 HEX NYLOC M20X1.5 2 Recommended Spare Parts Part # Description # of Units Serviced K30032 Upper FP Cylinder Seal kit 2 per every 20 units K30033 Lower FP Cylinder Seal Kit 2 per every 20 units Lift Technologies, Inc.7

8 Routine Maintenance Regular maintenance is essential to ensure reliable operation and long service life of the attachment. Ensure that maintenance and servicing are performed by qualified and authorized personnel only. Maintenance schedules may change as a result of extreme operating conductions, dust and/or poor ground conditions. Tightening Torques ISO 4762, ISO 4014, and ISO 4032 etc.: Screw / Bolt Rating Lubricants Approved / Recommended Daily M6 thread 6 ft.lb. 9 ft.lb. 10 ft.lb. M8 thread 15 ft.lb. 22 ft.lb. 28 ft.lb. M10 thread 30 ft.lb. 44 ft.lb. 55 ft.lb. Μ12 thread 52 ft.lb. 74 ft.lb. 95 ft.lb. Μ16 thread 125 ft.lb. 177 ft.lb. 240 ft.lb. Μ20 thread 244 ft.lb. 337 ft.lb. 394 ft.lb. Greases Lithium soap grease NLGI Class 2 Complex soap grease Every 200 hours Check wear on: Sliding pieces (3). Piston rod (9). NLGI Class 2 Teflon spray Check the clearance between the fork carriage on the lift truck (6) and the lower hooks (5). The clearance should be (1-2 mm). Correct the amount of clearance using the screw (7) and then tighten the lock nut (8). Every 500 hours Check wear on sliding pieces (4). Note Designation DIN51825: K 2 K-30 Foundry quality Only for plastic sections Check all lines, hoses and connections for leakage and damage. Ensure that all fork safety retaining stops (1) are present and undamaged. Inspected for visible damage and defects. Report faults to your supervisor have them rectified without delay After 50 hours / every 500 hours thereafter Check screws on the fork safety retaining stops (1). Replace loose or damaged screws. Torque the screws as specified in table. Weekly Grease: Sliding pieces (3) by way of the greasing nipples (2b). Sliding pieces (4) by way of the greasing nipples (2a). Check that screw connections are correctly torqued and replace screws which are visibly damaged. 6 7 WARNING: Relieve hydraulic pressure from cylinder hoses before disconnect. With truck turned off move control handle several times in both directions. WARNING: Always test sideshifter after reassembly without load, and with load to verify that all is working correctly. Lift Technologies, Inc.8

9 Lubrication and cleaning work on the attachment may also be performed by the lift truck operator. Perform maintenance and servicing work only when the attachment is parked securely on a stable, level foundation. For installing and removing, it is recommended to use a pallet to take the attachment. The attachment can thus be securely placed and transported. Pay attention to a sufficient load-carrying capacity of the lifting means. Replace missing or defective warning signs on the attachment. With other loads, such as fork arms with a length of over 94.5 (2,400 mm) or raised load centers, amended/shorter maintenance intervals should be agreed by the user with the manufacturer. ITA Fork Carriage Notes: Check the ISO strips at the fork carriage for wear. Routine Maintenance Render the fork positioner inoperative when at least one of the three wear limits c2, k2, or d2 is below safety specifications. k2 d2 Z A Min. Max Wear Limit (z) ISO Cl 2 c2 k2 d mm In. Fork Notes: Inspect per ANSI / ITSDF B Inspect the heel of the fork for wear and cracks annually. Remove forks from service when wear exceeds 10% of the original thickness of the fork. Bent Forks are not safe to operate and their continued use should be prevented. Straightening of forks may only be performed by the manufacturer of the fork or by one of their authorized workshops. You can increase the service life of forks by using forks especially protected against wear. A As necessary Replace worn wear pads (3) by removing nut (8) and screw (7). Activate sideshifter function with truck turned off and push sideshifter all the way to one side. Remove opposite side hook (5) and slider (4) sideways out of the sideshifter and carriage. Repeat for other side. With the truck turned off and the sideshift cylinder hoses drained and detached. Use appropriate lifting equipment to lift the sideshift frame from carriage base (6) of the lift truck. Leaving cylinder/bracket assembly resting on carriage. Replace the wear pads (3). During installation pay close attention that wear pads (3) are seated correctly. Use appropriate lifting equipment to lower sideshift frame onto carriage base (6) of the lift truck from above. Reassemble hook (5) and slider (4) back into sideshift and carriage. Secure with nut (8) and screw (7). Replace worn wear pads (4) by removing nut (8) and screw (7). Activate sideshifter function with truck turned off and push sideshifter all the way to one side. Remove opposite side hook (5) and slider (4) sideways out of the sideshifter and carriage. Repeat for other side. Replace worn slider (4). Reverse steps for reinstallation. Be sure to secure hook (5) and slider (4) with the nut (8) and screw (7). Replace worn Piston rod (9), guide bush (10), seal kit (11, 12) parts by removing nut (8) and screw (7). Slide hook (5) and slider (4) out of sideshift and carriage. With the hydraulic system depressurized. Use appropriate lifting equipment to lift the sideshift from carriage base (6) of the lift truck. Remove piston rod (9). Push the washer (13) out of the cylinder block. Replace faulty parts and reinstall the seal kit (11, 12), guide bushing (10), washer (13), and piston rod (9). Use appropriate lifting equipment to lower sideshift onto t h e carriage base (6) of lift truck from above and move the bracket (5) and slider (4) onto the sideshift and carriage from the side. Secure them using the bolt (7) and nut (8). Tighten to proper clearance of (1-2mm) between lower carriage bar and inside top of hook. Lift Technologies, Inc.9

10 Fault Possible cause Correction Sideshifter, When shifting Too slow Too fast Jerky shifting action Pressure supplied by the lift truck too low Bore of the throttle valve is too small Pressure supplied by the truck s hydraulics too high Defective supporting roller Wear pads not properly lubricated Increase pressure at the lift truck Rebore the throttle valve or replace it with a larger one Decrease pressure at the truck s hydraulics Purchase speed control kit from LTI (part# KS20048) Replace supporting roller Lubricate wear pads Supporting roller does not rotate Supporting roller is defective Replace supporting roller Housing scrapes on the conduit Slider is worn Replace slider No cushioning at end of travel Cushion defective Replace piston rod Oil leakage Is leaking Decommissioning and Disposal: Troubleshooting Troubleshooting should only be performed by qualified and authorized personnel. Screw fitting is leaking Sealing kit defective Piston rod scored Tighten / seal screw fitting Replace sealing kit Replace piston rod and sealing kit Prevent environmental damage by disposing of the following items properly in accordance with relevant national regulations Hydraulic fluids, greases, lubricants and soiled working materials (Cleaning rags, ect.) Packaging material (pallets, straps, cartons and plastic sheeting) After decommissioning, the attachment should be disposed of in accordance with local legislation and regulations. Bleeding the hydraulic system Start the lift truck. Move the sideshifter repeatedly in both directions to maximum extent. Inspect the hydraulic connections for leakage. Warranty Claims based on defects KAUP and/or Lift Technologies, Inc. shall not be liable for any damage to the equipment resulting from: Improper use / operation. Modifications to components. Inappropriate installation, maintenance, inspection and servicing. Assignment of unqualified or non-authorized personnel. Claims raised by third parties This documentation including all parts is copyrighted. Any use or change outside the narrow limits of copyright law without permission from KAUP GmbH & Co KG and Lift Technologies, Inc., is forbidden and liable to prosecution. This applies, in particular, to reproduction, translation, microfilming as well as storage and processing in electronic systems. Lift Technologies, Inc.10

Fork Positioner SF3-100

Fork Positioner SF3-100 LTI # K80036 Models Covered: LTI Model No. SF3-100-01xxx Inside Customer Service Parts Warranty Information & Support E-mail: E-mail: E-mail: parts@lift-tek.com warranty@lift-tek.com