Operating manual & book of parts

Operating manual & book of parts Ordering code: 08012014 Edition: 22-09-2014 (English) Mast Height Extension (MHE) www.telescopicforks.com

MEIJER HANDLING SOLUTIONS 2006 2

Table of contents 1 Remarks... 4 2 Preface... 5 3 Introduction... 6 4 Identification... 7 4.1 Type data... 7 4.2 Explanation of type shield... 8 5 Safety... 10 6 Instructions for use... 12 7 Fitting instructions; commissioning... 13 7.1 Fitting instructions and commissioning of a MHE... 13 7.2 Protecting the MHE... 13 8 Inspection and maintenance... 14 8.1 Maintenance schedule... 15 8.2 Faults table for MHE forks... 16 8.3 Ordering spare parts... 16 3 MEIJER HANDLING SOLUTIONS 2006

1 Remarks Copyright 2008, MEIJER HANDLING SOLUTIONS B.V. All rights reserved. Information which is supplied in this manual, including but not limited to the pictures and text, may not be reproduced or distributed without prior written approval of MEIJER HANDLING SOLUTIONS B.V., unless indicated otherwise. The information in this manual supplied without any type of guarantee. In no case shall MEIJER HANDLING SOLUTIONS B.V. be held liable for accidents and damage resulting from the use of this manual. Please pay attention to the fact that the information in this manual can be changed at any time without prior notice. Also pay attention to the fact that this manual may contain technical inaccuracies and typing errors. MEIJER HANDLING SOLUTIONS B.V. is doing its utmost to prevent errors in this manual, but cannot guarantee that. Should you find typing errors or technical inaccuracies, or in case you have any suggestions, please let us know. KOOI-REACHFORKS is a registered trademark of MEIJER HANDLING SOLUTIONS B.V. Other brand or product names which are used in this manual but which are not stated here are the trademarks of their respective holders. MEIJER HANDLING SOLUTIONS 2006 4

2 Preface MEIJER HANDLING SOLUTIONS B.V. is the world s largest producer of hydraulically collapsible and extending fork-lift trucks, which are manufactured under the trademark name KOOI-REACHFORKS. The telescopic forks were introduced in 1980 by KOOI BV, manufacturer of the pick-up fork-lift truck, the so-called KOOI-AAP, but were manufactured by Meijer BV. Since November 2000, MEIJER HANDLING SOLUTIONS B.V. (part of Meijer Holding) is, apart from the production, also responsible for the marketing and sales of the telescopic forks. With your new MHE you have obtained a reliable product which meets the highest quality and user requirements. Before you put the MHE into use, you should be aware of the correct operation of the system. This manual explains everything you should know about the MHE. It enables you to operate the MHE optimally. Apart from that, our After Sales Department is always there for you with regard to technical support. MHE complies with the following quality standards: 1. ISO 9001-2008 Quality Management System 2. ISO 4406 Hydraulics Fluids Method for coding the contamination level by solid particles 3. ISO 2328 Fork-lift trucks forks on type fork arms and fork arm carriages 4. CE (2006/42) E.E.C. Machine guideline 5. ISO 3834-2 Quality requirements for fusion welding of metallic materials- part 2: Comprehensive quality requirements 5 MEIJER HANDLING SOLUTIONS 2006

3 Introduction The MHE is a system for a fork-lift truck which is adjustable in height. It's designed in such a way that a minimum of maintenance is needed, by which a possible long life-span is attained. In order to achieve this, it is important though that the maintenance is carried out in the way the manufacturer prescribes. This instruction manual has the objective of familiarizing you with the MHE. We therefore advise you to study this instruction manual carefully before you start fitting the MHE, and subsequently begin to work with it. The MHE is a patented height-adjustable system with integrated fork-life forks. The MHE is available in capacities up to 2,000 kg. The manufacturer reserves the right to carry out changes to specifications without publishing them in advance. Because we constantly strive to improve the product, it may happen that the pictures in this manual do not correspond with the telescopic forks purchased by you. Therefore it is important to state the type and serial number when ordering spare parts or asking for information. For all types of telescopic forks there are drawings and specification sheets included in the Appendices, so that you can state the corresponding article number for your orders. MEIJER HANDLING SOLUTIONS 2006 6

4 Identification In this chapter the information which is listed on the type shield is explained. This information contains technical specifications on the MHE and is needed when ordering spare parts. It is therefore important to know which information is listed on the type shield and how this information should be used. 4.1 Type data For ordering spare parts or requesting information, the data below have to be specified. The serial number and the type are listed on the type shield of every MHE (see figure 4.1). These data are also engraved on the inner side of each fork. Type, serial number, year of manufacture: Figure 4.1 Position of type shield and engraved data Manufacturer s name : MEIJER HANDLING SOLUTIONS B.V. Manufacturer s address : Oudebildtdijk 894 NL-9079 NG Sint Jacobiparochie The Netherlands Phone : (+31) 518 492929 Fax : (+31) 518 492915 Website : www.meijer Handling Solutions.com Email : info@meijer Handling Solutions.com 7 MEIJER HANDLING SOLUTIONS 2006

4.2 Explanation of type shield For the MHE the type shield is located on the rear side of the system. The type shield contains important technical information on the MHE MEIJER HANDLING SOLUTIONS 2006 8

Explanation of type code From the type code various types of information can be deduced as well. Here is an example: Example : MHE20-0500 0820 2A Section of type Description Quantity code MHE Mast Height Extension 20 Total load-bearing capacity of the forks x 100 kg 0500 Play (height-difference between highest and lowest position) mm 0820 Width of carriage mm 2A Mounting class to lift truck Table 4.2 Various sections of the type code and their description! Warning: For a proper combination of a MHE with a fork-lift truck you must contact your fork-lift truck dealer. 9 MEIJER HANDLING SOLUTIONS 2006

5 Safety Safety depends completely on the discipline of the fork-lift truck driver. Therefore we recommend that the driver of the fork-lift truck holds a recognized diploma for fork-lift drivers. Apart from that it is important to take the following safety instructions into consideration: 1. Do not load the MHE above the loading values as indicated by the manufacturer, with regard to lifting capacity and load centre (see chapter 4). 2. Always drive with the forks in the lowest possible position, but do not drag them over the floor. 3. Never allow co-riding on the forks or load. 4. A MHE with defects may not be used until those defects have been repaired or replaced in a professional way. 5. Before you start to work with a MHE you should ensure that the fork-lift truck is switched off, and that there is no pressure on the hydraulic system (remove the key from the ignition). 6. The load should always be carried as evenly as possible by two forks. 7. Never use the MHE in rooms with temperatures lower than -30ºC, unless specifically stated by the manufacturer. 8. Pay attention, during the driving of a MHE, to the height of the construction (especially in the highest position) in order to prevent your colliding with something. 9. Depending on the type of MHE the forward view as seen from inside the truck can be hindered considerably. Pay attention to this when driving the truck. All abovementioned points must be read and understood by the fork-lift driver.! Warning: Never exceed the maximum load-bearing capacity of the fork-lift truck, regardless of the load-bearing capacity of the MHE.! Warning: Never walk under the MHE.! Warning: The combined downward speed of a MHE and the mast of the fork-lift truck should never be more than 0.6 m/sec.! Warning: The MHE should always we operated when the mast is in the lowest position. MEIJER HANDLING SOLUTIONS 2006 10

! Warning: Large volumes of hydraulic fluid are required to extend both the mast and the MHE. Make sure that the hydraulic fluid system is full enough to perform these operations. If hydraulic fluid levels are too low, then the MHE may skew out of alignment and cause the load to fall. 11 MEIJER HANDLING SOLUTIONS 2006

6 Instructions for use The MHE can easily be fitted and demounted, and can be adjusted transversely without demounting. With this it should be checked though whether the turn-off pin falls into the fork plate again, so that the forks are locked again. The MHE has to be adjusted to the fork-lift truck for the objective for which it is intended. The eventual load-bearing capacity should be determined by a registered fork-lift truck dealer. On the type shield of the fork-lift truck the load-bearing capacity has to be adjusted to the new combination of fork-lift truck and MHE. MEIJER HANDLING SOLUTIONS 2006 12

7 Fitting instructions; commissioning This chapter is divided into two parts. The first part describes the fitting instruction for MHE, and the second part describes how the MHE can be protected against touching the ground. 7.1 Fitting instructions and commissioning of a MHE In order to achieve the most optimal functioning of your MHE after fitting, the following fitting instructions should be observed: 1. Ensure that the fork-lift truck is switched off and that the key has been taken out of the ignition. Also, the hydraulic system should be pressure-free. 2. Slide the MHE onto the fork plate, and ensure that the lock pin falls into one of the notches of the fork plate. 3. Ensure that the hydraulic connections are tightened properly. 4. The maximum permitted operating pressure on the MHE is 200 bars. 5. Recommended flow 15ltr/min. 6. Slide the forks up and down a couple of times. 7. Check whether the hoses can rotate freely everywhere, and whether the system is properly sealed. 7.2 Protecting the MHE In order to prevent the MHE from touching the ground, we recommend putting a plastic drum on the lifting cylinder of the fork-lift truck in such a way that the forks are just shy of the ground. The lifting chains of the fork-lift truck can also be shortened slightly, which has the same effect. Always consult your dealer or manufacturer if you want to carry out such a modification. 13 MEIJER HANDLING SOLUTIONS 2006

8 Inspection and maintenance The MHE functions with a closed self-lubricating hydraulic system. The MHE has been supplied with hydraulic oil which complies with the ISO 4406 17/15/12 standard. The activities that have to be carried out to keep the MHE in good condition are very limited. However, it is important that the activities are carried out in time and correctly. Check the MHE every day for damage and oil leakage. If there is indeed damage or oil leakage, this should be reported to the person responsible. During activities on the forks, the fork-lift truck must be switched off, the key must be removed from the ignition, and there must no longer be any pressure on the system. Consult the maintenance schedule for further inspection. In some cases it can be necessary to adjust the maintenance scheme, for example in very contaminated environments. Plugs should then be replaced more often, in particular the wiper ring. The MHE must be tested every year by a specialist, in accordance with the ISO 5057 standard. The results of the test should be registered in a test book. MEIJER HANDLING SOLUTIONS 2006 14

8.1 Maintenance schedule Table 8.1 displays which parts must be checked, which actions must be taken, and when this must be done. The numbers of the parts correspond with the parts indicated in figure 8.2. Part Daily Weekly 3 months Yearly or 500 hours or 2000 hours 1. Inside U-profile frame IV 2. Hydraulic leakage C 3. Wear of wear strip C V 4. Complete MHE I 5. Check dirt-wipers I IV Grease, C Check, V Replace, I Inspection in accordance with ISO 5057 Table 8.1 Maintenance schedule Figure 8.2 Maintenance points 15 MEIJER HANDLING SOLUTIONS 2006

8.2 Faults table for MHE forks Symptom Possible cause Possible solution Oil leaking from MHE Connections are leaking Tighten again One fork tip hangs lower than the other Cylinder head damaged One of the forks is plastically distorted by overloading AMPCO wear strips are worn Ask your fork-lift truck dealer for advice Ask your fork-lift truck dealer for advice Replace AMPCO wear strips Table 8.2 Faults table for forks with the MHE. 8.3 Ordering spare parts Please look up the article numbers in the specification sheet when ordering spare parts, and state them when ordering. Spare parts drawing MHE MEIJER HANDLING SOLUTIONS 2006 16

Specification sheet article numbers MHE Positie nummer Artikelnummer MHE 1 Socket screw M8x20mm 07090 M8x20 6 2 Screw coupling G3/8 12L RE2017002 2 3 Ring M8 PA6 M00012633 6 4 Socket screw M16x35mm M00013200 2 5 Ring M16 M00013253 2 6 Banjo M16x1,5 12L M00013314 2 7 Screw coupling G3/8 12L M00013318 2 8 Wear strip AMPCO18 U 50 M00013456 4 9 Ring MHE M00013457 2 10 Connecting block MHE M00017060 2 11 Multiseal 10.7 M00017064 8 12 Banjo M14x1,5 M00017073 4 13 Banjo MHE G1/8" M00017079 4 14 Hydraulic internal parts MHE * 2 15 Plug M8 M00017106 4 16 Hose MHE M00017107 4 17 WEO Coupling M12 M00017109 4 18 Caution sticker ST3006200901 3 19 Fork carrier * 1 20 Double-check non-return valve 3/8 M00013160 1 21 Socket screw M12x30 07160 M12x30 1 22 Safety coverplate PC * 1 23 Lower hook M00017093 2 24 Pin QC M00017093 2 25 Locking pin 39660 4,5 2 * When ordering these parts it is important to mention the serial number of the MHE 1 MEIJER HANDLING SOLUTIONS 2006