Manuale posizionatori MZ 2.5 - 3.5 T

FORK POSITIONERS MZ 2.5 – 3.5 T MODEL
Index:
INTRODUCTION
SPECIFICATIONS AND USE OF THE ATTACHMENT
1. RECOMMENDATIONS FOR USING THE EQUIPMENT
1.1
PROHIBITED MOVEMENTS
1.2
CORRECT MOVEMENTS
2. ATTACHMENT CONFIGURATION
3. INSTALLING THE POSITIONER
3.1. Forklift requisites
3.2. Recommended hydraulic system
3.3. Installing the positioner
4. DAILY CHECKS
5. PERIODIC MAINTENANCE
5.1. 100 hours
5.2. 500 hours
5.3. 1000 hours
5.4. 2000 hours
6. HYDRAULIC DIAGRAM
6.1. Versions with separate shifting
6.2. Versions without shifting
7. EXTRAORDINARY MAINTENANCE
7.1. Removing the positioner
7.2. Slide block replacement
7.3. Removing the shifting cylinder
7.4. Removing the guiding tube and fork supports
7.5. Removing the fork positioning cylinders
7.6. Replacing the fork positioning cylinder gaskets
8. TROUBLESHOOTING
9. WARRANTY
10. RECYCLING
11. FACSIMILE OF CERTIFICATE OF CONFORMITY
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INTRODUCTION
This manual includes instructions for installation, periodic maintenance, faults and the list of spare parts for fork positioners model MZ 2.5 - 3.5 T. All
instructions display double units (metric and US). The instructions in this manual do not replace, but rather add to the obligation to obey occupational safety
and accident-prevention regulations. It is the user company's responsibility to adhere to these regulations. The user company is, likewise, required to follow
all the instructions in this manual, including training its personnel to use and maintain the positioner. The positioner was designed and built according to
safety standards; danger stickers on the equipment indicate any potential risks.
SPECIFICATIONS AND USE OF THE EQUIPMENT
The fork positioner is a device that allows shifting and positioning of forks in order to move loads more easily.
It is important to check that the weight and centre of gravity of the load do not exceed the limits marked on the identification plate; if the centre if gravity is
brought forward on the shifting plate, the weight of the load must be reduced accordingly.
The equipment, which is to be attached to a forklift, is made up of a guiding frame for the forks, with ISO 2328 profile hooks that will be attached to the forklift,
with partly incorporated shifting; a hydraulic system for specific movements; sliding fork supports on chrome bars that are driven by opposing linear
actuators, the shape and dimensions of which are suitable for the load to be handled.
1.
RECOMMENDATIONS FOR USING THE EQUIPMENT
1.1.
PROHIBITED MOVEMENTS
- Transporting an unstable or decentralised load; a load that is too bulky, reducing visibility; moving a load with greater weight than the indicated capacity;
moving an already deposited load using the load to be deposited; using the attachment when it presents structural defects or operating anomalies.
Executing movements or manoeuvres with load raised high.
Proceeding at high speed on a rough surface or climbing ramps.
Using the forks to jam loads or to move them sideways.
Handling loads whose height can interfere with visibility during the manoeuvre.
Transporting persons or performing manoeuvres with persons in the vicinity of the forklift.
Parking the forklift with motor running and/or load lifted on a rough surface or on climbing ramps.
Picking up the load with just one fork.
Using the shifting motion when the forklift is turning a corner.
The tips of the forks must support the last crossbeam of the pallet without sticking out beyond it.
Using the equipment for any purpose for which it was not intended.
1.2.
CORRECT MOVEMENTS
Be careful when gripping the load to avoid damage or dangerous movements of the adjacent loads.
The load must be stable, in crossed layers or tied with straps.
When moving with the forklift, keep the mast tilted (the tips of the forks must point up), the load lifted slightly from the ground and centred, adjusting the
speed based on the road surface and any obstacles or the presence of persons on route.
The outside distance of the forks must be 40-80 mm less than the inside distance of the pallet.
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2. ATTACHMENT CONFIGURATION
Lifting hook
Frame.
Power input for fork
positioning.
Power input for incorporated shifting.
Semi-incorporated shifting linear
actuator.
Hydraulic system.
Frame.
Upper sliding frame
for fork carrier plate.
Lower ISO 2328
locking hooks.
Fork support linear actuator.
Fig.01
Fork supports.
Fork screws.
Block for securing fork.
Fork supports guiding tube .
Fig.02
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VERSION WITH STANDARD SIDE PANELS
The right side panel has a hole to extract the fork supports "a" and the forks are inserted from the sides (See Fig. 03)
Fig.03 – Version with standard side panels
VERSION WITH DEDICATED SIDE PANELS
The right side panel does not have a hole to extract the fork supports and the forks are inserted in the middle gap "b" (See Fig. 04)
Fig.04 – Version with dedicated side panels
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3.1.
3.
INSTALLING THE POSITIONER
Forklift requisites
3.1.1.
Supply pressure
80 bar – 1180 psi
average running pressure
250 bar – 3680 psi
maximum
3.1.2.
Oil flow
5 litres/min – 1.5 GPM minimum
7 litres/min – 2 GPM recommended
3.1.3.
forklift plate dimensions
Class II
Class III
ISO 2228 Dimension “A”
Min.
Max.
380 mm – 14.96 in
381 mm – 15 in
474.5 mm – -18.68
476 mm – 18.74 in
in
ISO 2228 Dimension “B”
Min.
Max.
15 mm – 0.59 in
16 mm – 0.63 in
20.5 mm – 0.82 in
21.5 mm – 0.85 in
Fig.05
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INSTALLATION AND MAINTENANCE MUST BE
EXECUTED SOLELY BY SPECIFICALLY TRAINED AND
SPECIALISED TECHNICIANS.
WARNING: Before installing the positioner, clean the forklift's fork carrier plates and check for damage, dents or deformity. If the forklift plate is damaged or
out of shapeit must be replaced before mounting the hooked positioner.
3.2. Recommended hydraulic system
3.2.1.
The equipment requires two independent controls and 4 tubes of auxiliary power with a minimum diameter of 6 mm (1/4 inch).
IMPORTANT: all the slide blocks are pre-greased by the manufacturer.
3.3.
Installing the positioner
Warning: Before any maintenance operation, turn off the forklift and remove pressure from the hydraulic circuit by repeatedly moving the
positioner levers in both directions while the forklift is off. Ensure that no one turns the ignition key or moves the forklift's command lever for
the entire duration of maintenance.
3.3.1.
Remove the lower hooks of the positioner: ISO 3318 24 mm wrench for class 2, 27 mm for class 3;
Fig.06
3.3.2.
Set the positioner (after having secured it with suitable ties to a hook and lifting system that can bear a minimum load of 400 kg (900 lbs) so that
the block or notch of the shifting cylinder (for versions with separate shifting) or of the upper frame (versions without shifting) meets with the central
notch of the forklift's fork carrier plate.
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Fig.07
Ensure that the shifter's support and the notch on the forklift's plate match up correctly.
Fig.08
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3.3.3.
Assemble the lower hooks once more as they were in point 3.3.1, with the components in the correct sequence as per the figure in 3.3.1.
Tighten the screws as prescribed below:
FEM II: 314 Nm – 233 ft-lbs (minimum 240 Nm – 180 ft-lbs)
FEM III: 461 Nm – 233 ft-lbs (minimum 300 Nm – 220 ft-lbs)
Ensure there is play as shown below.
Fig. 09
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3.3.4.
Connect the forklift's system to the shifter, in the case that it is present, at the points shown and tighten the fittings according to their
specifications. The MZ 2.5 – 3.5 T series positioners may have inputs into the sliding cylinder M14x1,5 (ISO 3318 19 mm wrench) or 9/16” 18 UNF.
Fig. 010
Connect the forklift's system to the positioner at the points shown for the positioning of the forks and tighten the fittings according to their
specifications. The MZ 2.5 – 3.5 T series positioners have 10L inputs (ISO 3318 19 mm wrench) for classes 2 and 3. JIC inputs are also available.
Fig. 011 – Standard position fork positioning inputs Fig. 012 – Fork positioning inputs position within frame
3.3.5.
Assembling forks on positioners with standard side panels.
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Position the supports around the middle and remove the side screws (ISO 3926 10 mm wrench) (phase 1 Fig.013). Insert the fork at the side and slide
it onto the support (it is also possible to open the support slightly to slide in the fork) (phase 2 Fig. 013). Replace the external side screws, ensuring the
washers are used, apply threadlocker "Loctite 243" and tighten to 84 Nm - 62 ft-lbs (phase 3 Fig. 013); at this point adjust the internal fork block "a",
placing it against the fork, using the holes suited to the width of the fork (Fig. 014). Apply "Loctite 243" on screws "b" and tighten to 84 Nm - 62 ft-lbs
(ISO 3318 17 mm wrench).
Fig. 013
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Fig. 014
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3.3.6.
Assembling forks on positioners with dedicated side panels.
Position the supports around the middle and remove internal fork blocker "a" (ISO 3318 17 mm wrench) (phase 1 Fig.015). Place the fork in the middle
making use of the gap provided on the lower frame and slide it onto the support (it is also possible to close the support slowly in order to slide in the
fork) (phase 2 Fig. 015). Replace the internal fork block "a", using the holes suited to the width of the fork (Fig. 014). Apply "Loctite 243" on the screws
and tighten to 84 Nm - 62 ft-lbs (phase 3, Fig. 015); apply "Loctite 243" also on screws "b" and tighten to 84 Nm - 62 ft-lbs.
Fig. 015
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4. DAILY CHECKS
At the start of every work shift, check the following points and inform maintenance personnel of any problems:
• check that the nuts of the cylinder rod head are secure and the pins and split pins of the base of the support movement cylinders are correctly
positioned;
• check the tightness of the nuts fastening the forks:
• check that the screws of the fork supports bushings are tight;
• check that the screws of the guiding tube are tight;
• check for any leaks from the fork movement cylinder supports;
• check that the guiding tube of the fork supports are clean and greased;
• thecentre tooth of the upper slide block guide must engage in the centre notch of the forklift's fork carrier plate;
• check for any leaks from the shifting cylinder;
• check the correct positioning and fastening of the slide blocks and lower hooks.
Screw of the guiding
tube.
Shifting cylinder.
Guiding tube.
Nut of
cylinder
of head.
Pin and split pin for securing
base of cylinder.
Fork support
bushing screw.
Fig. 016
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Fork blocking
screws
Fork blocking
screws
Fig. 017
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5. PERIODIC MAINTENANCE
5.1. 100 hours
Check the tightness of screws "a" on the lower hooks (for tightness see point 3.3.3); check for any damage on the tubes or the hydraulic system's
fittings and that the fittings are tightened correctly. Check the tightness of the nuts fastening the forks.
Check for play between the forklift's lower bar and the lower hooks of the positioner as described in section 3.3.1. In the event that there is too much
play, adjust the hooks and tighten the screws as described in point 3.3.1.
5.2. 500 hours
In addition to the checks in section 5.1:
grease the guiding tube of the fork supports "e" (or apply specific lubricating spray); grease the upper slides "b" and the lower slides "c". Grease the
lower bar of the forklift in the region of the positioner slides.
5.3. 1000 hours
In addition to the checks in section 5.1 and 5.2:
Check the condition of the hydraulic actuators "d"; any oil leaks from the cover and the condition of the chromed surface of the rod. Check the
condition of the guiding tube of the fork supports "e" and the superficial coating.
Check the thickness of the upper sliding blocks; if thinner than 4mm (0.15 in) replace them as described in section 7.2. Check the thickness of the
lower sliding blocks; if thinner than 5mm (0.2 in) replace them as described in section 7.2.
Check and if required replace the sliding bushings of supports "f" (Fig. 018), if the diameter is less than 29.5mm as laid out in section 7.4.
5.4. 2000 hours
In addition to the checks in section 5.1, 5.2 and 5.3:
Replace the upper and lower sliding blocks as described in section 7.2. Replace self-locking nuts to secure the lower hooks.
Fig. 018
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Fig. 019
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6. HYDRAULIC DIAGRAM
6.1.
Versions with separate shifting
Fig. 020 – Hydraulic system for versions with separate shifting with fork power inputs in standard position
Fig. 021 – Hydraulic system for versions with separate shifting with fork power inputs positioned in the inside of the frame
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Fig. 022 – Hydraulic diagram for versions with separate shifting
6.2.
Versions without shifting
Fig. 023 – Hydraulic system for versions without shifting with fork power inputs in standard position
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Fig. 024 – Hydraulic system for versions without shifting with fork power inputs positioned in the inside of the frame
Fig. 025 – Hydraulic diagram for versions without shifting
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7. EXTRAORDINARY MAINTENANCE
7.1. Removing the positioner.
Warning: Before any maintenance operation, turn off the forklift and remove pressure from the hydraulic circuit by repeatedly moving the positioner
levers in both directions while the forklift is off. Ensure that no one turns the ignition key or moves the forklift's command lever for the entire duration of
maintenance.
7.1.1.
Dismantle for forks (for the required wrench, refer to point 3.3.5.)
Fig. 026 – Removal of forks for positioners with standard side panels
Fig. 027 – Removal of forks for positioners with dedicated side panels
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7.1.2.
Removing the lower hooks.
Remove split pins “a” which block the sliding cylinder on the movable frame as shown in Fig. 028. Thereafter, remove the lower hooks (for the
required wrench, refer to point 3.3.1.)
Fig. 028 – Removing the lower hooks.
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7.1.3.
Remove the movable frame from the FEM plate of the forklift using a hook and a lifting system that can lift at least 400 kg (900 lbs).
Fig. 029
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7.2. Slide block replacement
7.2.1.
Follow the instructions in section 7.1
7.2.2.
Remove the upper slide block(s) as indicated
Replace with new ones ensuring that the pegs of the block(s) fit correctly into the right place on the moveable frame. Grease with a good
quality grease.
Fig. 030
7.2.3.
Replacement of lower sliding blocks
Remove the lower blocks as per Fig. 031. Mount the new blocks and grease with a good quality grease.
Fig. 031
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7.3. Dismantling the shifting cylinder (for versions with separate shifting)
Warning: Before any maintenance operation, turn off the forklift and remove pressure from the hydraulic circuit by repeatedly moving the positioner
levers in both directions while the forklift is off. Ensure that no one turns the ignition key or moves the forklift's command lever for the entire duration of
maintenance.
7.3.1.
7.3.2.
7.3.3.
Follow the instructions in section 7.1.
Remove the hoses.
Remove the cylinder from the support.
Fig. 032
7.3.4.
7.3.5.
7.3.6.
Block the housing and loosed the cap with a wrench until the retaining ring comes out.
Remove the retaining ring.
Remove the cap.
Fig. 033
7.3.7.
To replace the cylinder, follow the above instructions backwards. At the end of the steps, remount the positioner on the forklift's plate starting
from point 3.3.2.
WARNING: When replacing the seals, follow the right sequence of assembly.
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Fig. 034
7.4. Removing the guiding tube and fork supports
7.4.1.
For positioners with standard and dedicated side panels
7.4.1.1. Remove the forks as described in section 7.1.1.
7.4.1.2. Open the fork supports to the minimum setting (retracted cylinders).
7.4.1.3. At this point, turn off the forklift and remove pressure from the hydraulic circuit by repeatedly moving the positioner levers in both directions
while the forklift is off. Ensure that no one turns the ignition key or moves the forklift's command lever for the entire duration of maintenance.
7.4.1.4. Remove nuts "a" of the ball joints of the cylinder rods "b", Fig. 035 (ISO 3318 19 mm wrench for blocking the fork support pins and loosening
the nut). Disengage the spherical joints of the cylinder rods "b" from the fork support pins.
7.4.1.5. Remove block "e" of the guiding tube, Fig. 036 (ISO 1174 13 mm socket wrench for removing screw “c” and the lock washer “d”); when
reassembling, replace lock washer “d” and tighten the screw “c” to 25 Nm - 18 ft-lbs, applying “Loctite 270” lockthread.
7.4.1.6. Move the fork supports sideways, to a distance of about 10mm from the side panel, as in Fig. 037 (to move the supports, the guiding tube must
be rotated in its place).
7.4.1.7. Rotate the guiding tube about 90° and extract it from its place with the fork supports, as per Fig. 038; if required, remove the cylinder, as
described in section 7.6.
7.4.1.8. It is now possible to extract the fork supports from the guiding tube by sliding them out.
7.4.1.9. To replace the guiding tube and fork supports, follow the above instructions backwards.
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Fig. 036
Fig. 035
Fig. 037
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Fig. 038
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7.4.2. Disassembly of the guiding tube and fork supports (only for positioners with standard side panels)
7.4.2.1. Remove the forks as described in section 7.1.1.
7.4.2.2. Open the fork supports to the minimum setting (retracted cylinders).
7.4.2.3. At this point, turn off the forklift and remove pressure from the hydraulic circuit by repeatedly moving the positioner levers in both directions
while the forklift is off. Ensure that no one turns the ignition key or moves the forklift's command lever for the entire duration of maintenance.
7.4.2.4. Remove nuts "a" of the ball joints of the cylinder rods "b", Fig. 039 (ISO 3318 19 mm wrench for blocking the fork support pins and loosening
the nut). Disengage the spherical joints of the cylinder rods "b" from the fork support pins.
7.4.2.5. Remove pins "e" of the fork supports, Fig. 040 (ISO 3318 22 mm wrench “c” for holding the fork support and ISO 3318 19 mm wrench “d” for
loosening pin “e”). The pins are secured with "Loctite" lockthread; to remove it, they may need to be heated up. For reassembly, tighten them to 84
Nm - 62 ft-lbs, applying “Loctite 270” lockthread.
7.4.2.6. Remove block "h" of the guiding tube, Fig. 041 (ISO 1174 13 mm socket wrench for removing screw “f” and the lock washer “g”); when
reassembling, replace lock washer “g” and tighten the screw “f” to 25 Nm - 18 ft-lbs, applying “Loctite 270” lockthread.
7.4.2.7. Extract the fork supports, sliding them out of the gap in the right side panel, Fig. 042 (to move the supports, the guiding tube must be rotated in
its place).
7.4.2.8. Rotate the guiding tube about 90° and extract it from its place, as per Fig. 043.
7.4.2.9. To replace the guiding tube and fork supports, follow the above instructions backwards.
Fig. 039
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Fig. 040
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Fig. 041
Fig. 042
Fig. 043
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WARNING: When replacing the bushings of the fork supports, assemble them as shown in Fig. 044; the screws pos.1 must be mounted using “Loctite
270” threadlock and tightened to 84 Nm - 62 ft-lbs; replace the lock washers pos. 2 when reassembling.
Fig. 044
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7.5.
Removing the fork positioning cylinders
7.5.1.
Remove the forks as described in section 7.1.1.
7.5.2.
Open the fork supports to the minimum setting (retracted cylinders).
7.5.3.
At this point, turn off the forklift and remove pressure from the hydraulic circuit by repeatedly moving the positioner levers in both directions
while the forklift is off. Ensure that no one turns the ignition key or moves the forklift's command lever for the entire duration of maintenance.
7.5.4.
045 (ISO 3318 19 mm wrench for blocking the fork support pin and loosening the nut). Disengage the spherical joints of the cylinder rods from
the fork support pins.
7.5.5.
Disconnect the flexible and rigid tubes from the cylinders (ISO 3318 17 mm wrench)
7.5.6.
Remove the split pins from the bottom of the cylinders, "b", Fig. 045 and extract pins “c” from the bottom of the cylinders.
7.5.7.
Remove the cylinders.
7.5.8.
To replace the cylinders, follow the above instructions backwards.
Fig. 045
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7.6.
Replacing the fork positioning cylinder gaskets
7.6.1.
7.6.2.
7.6.3.
Remove the cylinders as shown in section 7.5.
Remove the cylinder cap with a wrench.
Place the seals as shown in Fig. 046.
Fig. 046
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8. TROUBLESHOOTING
8.1. Side shifting does not occur
• Check that the supply pressure conforms to the requirements in point 3.1.1 and the load conforms to the requirements in point 3.1.2.
• Check that the moveable frame of the positions is not out of shape due to bumping.
• Check that the play between the lower hook and the forklift's bar is correct (point 3.3.3)
• Check that there are no oil leaks from the shifting cylinder's hydraulic system.
8.2. Side shifting occurs too slowly
• Perform all the checks in section 8.1
• Check the oil level in the forklift's tank.
• Check the wear of the sliding blocks section 5.3
8.3. Side shifting is irregular
• Check that there is no air in the hydraulic system
• Check the wear of the sliding blocks section 5.3
8.4. The jaws do not open and close
• Check that the supply pressure conforms to the requirements in point 3.1.1 and the load conforms to the requirements in point 3.1.2.
• Check that there are no obstructions or leaks in the positioning cylinder hydraulics
• Check that there are no obstructions, breakages or leaks in the positioning hydraulic cylinders
• Check the condition of the support guiding tube and whether it is clean and check that there are no deformities or obstructions.
8.5. The jaws open and close too slowly
• Perform all the checks in section 8.4
• Check the oil level in the forklift's tank.
• Check the wear of the support bushings section 7.4
8.6. The jaws open and close irregularly
• Check that there is no air in the hydraulic system
• Check the wear of the support bushings section 7.4
9. WARRANTY
All the products by BOLZONI S.p.A are provided with a 12-month warranty, when used for 8 hours per working day beginning from the date of shipment. If
used for more than 8 hours per day, the warranty period will be reduced proportionally.
The guarantee is limited to the replacement of of parts at the Bolzoni SpA factory and is valid only for those parts that the company recognises to be defective
owing to material or processing faults and does not include the labour cost or transfer cost for the replacement of such parts.
In case the equipment has been used inappropriately, has been placed in operation without following the instructions provided by BOLZONI S.p.A or if
replacement parts have been installed that were not made by BOLZONI S.p.A, the warranty is void.
BOLZONI S.P.A. products are not guaranteed for uses beyond the performance indicated on the plates and in the documentation.
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All equipment produced by BOLZONI S.P.A. is covered by insurance for any damage caused to third parties owing to defective parts or the incorrect
operation of the same; damage deriving from the incorrect or improper use of the platforms is excluded.
10. RECYCLING
Moveable frame
Lower hooks
Slide blocks
Enamel
Cylinder
Supports
Belts for fixing and protective
covering for shipping
Gaskets
Guiding tube
Hydraulic oil
11.
Steel
Cast iron
Nylon
Polyester epoxy
Steel
Steel
Polyester and heat-shrink
Polyurethane and NBR
Steel
Dispose of in conformity with local law
FACSIMILE OF CERTIFICATE OF CONFORMITY
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