USE AND MAINTENANCE MANUAL

FORKS POSITIONER Mod. FZ ORIGINAL INSTRUCTIONS

WITH SIDE-SHIFT MOVEMENT
INTRODUCTION
This manual includes instructions for assembly, maintenance (regular and extraordinary), and for possible faults with remedies.
The instructions provided in this manual do not replace but complement obligations for compliance with existing legislation on safety and accident prevention, which are the obligation of
the User. The User is also bound to follow all instructions in this manual including training of personnel both in the use of the equipment and its maintenance.

SPECIFICATIONS AND USE OF EQUIPMENT

Equipment attached to forklifts to position the forks when handling pallets of different sizes. Consisting of a frame with FEM profile at the front and sliding shoes supports and hooks to the
rear that, when controlled by a linear hydraulic actuator, moves laterally to the right and left.
The positioning of the forks is obtained by means of two hydraulic actuators attached opposite the frame, and connected to the forks via special screw clamps.The positioning of the forks
must be made before picking up the load based on the opening of the pallets and, when raised, the forks should not be moved or forced against the pallet to prevent damage to the equipment
or dangerous movements of the load itself.

Situation with possible risk to the Mandatory procedures Notes to be read

SYMBOLS USED operator's safety. to be carried out. carefully.

INDEX
1. TIPS FOR USE OF THE EQUIPMENT Page 2 5.3. FIXING Page 5 9.4. CYLINDER DISASSEMBLY Page 8
1.1. PROHIBITED HANDLING Page 2 5.4. ALIGNMENT CONTROL Page 5 9.5. REPLACEMENT OF SEALS Page 8
1.2. CORRECT HANDLING Page 2 5.5. MINIMUM WIDTH OF FORKS Page 5 9.6. ELIMINATION OF SIDE-SHIFTER Page 8
EXTRAORDINARY MAINTENANCE OF FORKS
2. FORKLIFT CONTROLS Page 2 6. HYDRAULIC SYSTEM Page 6 10. Page 9
POSITIONER
3. EQUIPMENT DESCRIPTION Page 3 6.1. HYDRAULIC LAYOUT AND CONNECTION Page 6 10.1. DETACHMENT OF CYLINDERS Page 9
3.1. SHIPPING LAYOUT Page 3 6.2. MOVEMENTS CONTROL Page 6 10.2. DETACHMENT OF POSITIONERS Page 9
3.2. DESCRIPTION Page 3 6.3. ADJUSTMENTS AND CONTROLS Page 6 10.3. BALL JOINTS DISASSEMBLY Page 9
4. FASTENING TO THE FORKLIFT Page 4 6.3.1. SPEED AND SYNCRONY Page 6 10.4. REPLACEMENT OF SEALS Page 10
4.1. COUPLING Page 4 7. DAILY CONTROLS Page 6 10.5. CONTROL OF INTERNAL VALVE Page 10
LIST OF POSSIBLE FAULTS WITH CAUSES AND
4.2. HOOKS ADJUSTMENT Page 4 8. ROUTINE MAINTENANCE Page 7 11. Page 10
REMEDIES
EXTRAORDINARY MAINTENANCE OF SIDE-
4.3. HOSE CONNECTIONS Page 4 9. Page 7 12. NOISE EMISSION Page 11
SHIFTER
5. FORK ASSEMBLY Page 5 9.1. DETACHMENT FROM THE FORKLIFT Page 7 13. RECYCLING Page 11
SHOES REPLACEMENT AND CYLINDER Page 7
5.1. PREPARATION FOR ASSEMBLY Page 5 9.2. 14. WARRANTY Page 11
DETACHMENT
5.2. ASSEMBLY Page 5 9.3. SHOES CONTROL Page 8 15. FACSIMILE OF THE EC CONFORMITY CERTIFICATE Page 11

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1. ADVICE FOR THE EQUIPMENT'S USE
1.1. PROHIBITED HANDLING
Carry a load that is unstable, decentralised or on a single
fork, too bulky reducing visibility, with a weight greater
than the specified lifting capacity. Move a load already
deposited using the load to be deposited. Using the
equipment for purposes other than those specified, or when
the equipment is structurally defective or malfunctioning.
Performing movements or Proceeding at high speed in
manoeuvres with the load the presence of the uneven
lifted high. ground or uphill ramps.
Transporting people with the forklift or the equipment or
performing manoeuvres with people in the operating range.
Parking the forklift truck with the engine running
and/or load lifted on uneven ground or ramps.
Side-shifting manoeuvres or moving the forks
with the load and the forklift moving.
USE OF THE EQUIPMENT FOR
PURPOSES OR HANDLING OTHER
THAN INDICATED IS PROHIBITED.
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1.2. CORRECT HANDLING 2. FORKLIFT CONTROLS
The load must be stable, with crossed layers or The hydraulic pump of the forklift must have a minimum
shrink wrapped and centred in relation to the capacity of 1 GPM (2 GPM recommended) with average
forklift during handling. pressure of 1000 psi (max. 3200 psi).
The recommended internal diameter for any
additional supply system is min. 6.5 mm.
4-lever distributor for movements control.
The fork positioning slots must
be intact and not clogged.
The fork carriage must be flat
without protrusions on the
front.
Before introducing the forks, position them so that no
force is exerted against the foot of the pallet.
When moving with the forklift truck, keep the mast
tilted (the tip of the fork up), the load slightly off the
ground, adjusting the speed according to the state of
the road surface and any obstacles or presence of
people along the route.
Dimension « A » ISO 2228 (mm) :
Class I = min. 304 – max. 305
Handle loads of appropriate Class II = min. 380 – max. 381
height to avoid undermining Class III = min. 474.5 – max. 476
visibility during manoeuvres.
Class IV = min. 595,5 – max. 597
The tips of the forks
THE EFFECTIVE COMBINATION CARRYING CAPACITY
should rest on the last
BETWEEN THE FORKLIFT TRUCK AND THE
cross member of the
EQUIPMENT IS THE RESPONSIBILITY OF THE
pallet without
FORKLIFT TRUCK MANUFACTURER AND MAY NOT
protruding from it.
CORRESPOND TO THAT INDICATED ON THE RATING
PLATE.
CONTACT THE MANUFACTURER OF THE FORKLIFT
TRUCK FOR THE DEFINITIVE CARRYING CAPACITY.
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3. EQUIPMENT DESCRIPTION

3.1 SHIPPING LAYOUT 3.2 DESCRIPTION

Straps fastening equipment to the pallet.
Envelope with documents.
Transport pallet.

Safety stickers.

Sling and lifting ring.

Side-shifting cylinder
support.
The equipment is protected
with heat-shrink wrapping.

Fork sliding and hooking profile.

Identification plate.
Side-shifting cylinder.
Positioners adaptation ball
joint.

Forks movement cylinders feed

hoses.

Forks approach speed Front support sliding

regulator. shoe.
Forks movement cylinder. Side-shift cylinder feed
hoses.
Cylinders central fixing.
Lower hooks.
Forks assembly lower
opening.
Forks fixing screw. Vertical support sliding
Forks positioner. shoe.

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4. FASTENING TO THE FORKLIFT
4.1. COUPLING
Remove the straps that secure the
equipment and the plastic sheeting.
Remove the lower hooks,
ISO 3318 class2 24 mm, class3 27 mm wrench.
Make sure the hoses are not damaged during hooking to the forklift.
4.2. HOOKS ADJUSTMENT
Position the lower hooks keeping the
distance indicated below 1 mm – 2 mm.
Bolts tightening class2 240 Nm,
class3 300 Nm.
Check that the vertical guide
shoe is inserted into its housing.
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Lift with appropriate ring with UNI ISO 4779 hook. Connect the equipment to the forklift so
that the central stop of the cylinder
support engages the central notch of the
fork carriage. If necessary tilt the mast
forward
Reposition the lower hook, ISO 3318
class2 24 mm, class3 27 mm wrench.
4.3 HOSE CONNECTIONS
Before connecting the hydraulic hoses, follow the manufacturer's instructions to remove the pressure in the forklift's circuit.
Possible leakage of oil from pipelines. Prepare a container to collect fluid.
Forks opening. Left side-shift.
To check the connection,
perform 5 complete
movements, with and without
the load.
Forks closure.
Right side-shift.
The frame with the fork positioning cylinder, move sideways left and right; during the pipe connection of the
hoses, ensure that the hoses allow the movement and do not rub against fixed parts.
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5. ASSEMBLY OF THE FORKS
Forks safety catch.
5.1. PREPARATION AND ASSEMBLY Fork lower sliding zone.

1) Control, cleaning and greasing of the forks sliding zone.

2) Position the positioners at maximum opening and rotate in the indicated direction by 90°.
The positioners are released and during the opening
movement are free to rotate or oscillate.
3) Position the upper locking pin on the fork so as not to impede sliding.
4) Hook the forks to the centre of the upper profile and, using the appropriate lower
opening, resting against the lower profile, slide towards the outside of the frame. Fork positioner. Fork assembly lower opening.

5.3. FIXING 5.4. ALIGNMENT CONTROL 5.5. MINIMUM WIDTH OF FORKS

5) Reposition the positioners clasping Screw locking nut.
the mast of the forks.
6) With two ISO 3318 mm 27
wrenches, hold the positioners in place
and tighten the bolts (60-65 N/m).
Check that the "PLUG" of the cylinder Fork positioner.
7) With the same wrenches, fasten the is in axis with the "HOLE" of the
bolt with the locking nut central support, both with the forks at With the forks at minimum width, move
(250-300 N/m). maximum and minimum opening. the nut inside the positioner.

6. HYDRAULIC SYSTEM Before connecting the hydraulic hoses, follow the manufacturer's instructions to remove the pressure in the forklift's circuit.

Possible leakage of oil from pipelines. Prepare a container to collect fluid.

6.1. HYDRAULIC LAYOUT AND CONNECTION System present on the forklift truck. 6.2. MOVEMENTS CONTROL

lever 1 (lifting).

lever 2 (tilt).
lever 4.
lever 3.

To check the connections, perform 5 complete movements, with and without the load.

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6.3. CONTROLS AND ADJUSTMENTS 7. DAILY CONTROLS
The equipment is not fitted with a pressure relief valve.Check that the
pressure does not exceed 3200 PSI with the application of pressure At the beginning of each shift check
gauges on the distributor or consulting the specifications of the forklift. the points indicated and report any
Contact our Aftersales service in the event of problems. problem to the maintenance
personnel.
6.3.1. SPEED AND SYNCRONY Check the tightness of the screws
between the cylinder stem and positioner.
Act on the regulators of the cylinders to increase
or decrease the opening or closing speed.Screw The centre stop of the cylinder support must engage
to decrease, unscrew to increase. the central notch of the fork carriage.
To restore the synchronism, act on the Check for oil leaks from the cylinders or from the system.
regulator of the slow cylinder, to avoid a The forks must be correctly attached to the upper
reduction in the total closure speed. profile and blocked by the positioner.
Recommended speed 8.0 m/min. Max. 13 mm.
ISO 3318 12 and Lower hooks correctly positioned and secured, see point
Recommended time to bring the ISO 2380 16 mm wrench. 4.2. HOOKS ADJUSTMENTS AND CONTROLS.
forks together by 600 mm: 2.5 sec. screwdrivers.

8. ROUTINE MAINTENANCE Before connecting the hydraulic hoses,

follow the manufacturer's instructions to
PERIODIC MAINTENANCE SCHEDULE remove the pressure in the forklift's
Working circuit.
OPERATIONS
hours
Lubrication in point “a”.
Cleaning and lubrication of the shoes sliding tracks “b”.
Control of bolts tightness and hydraulic connections.
500
In addition to the operations every 500 working hours, carry out:
Verify the thickness of the upper and lower sliding shoes (point 7.1.1).
Check cylinder stems “c” and tightness of seals.
Check the position of the lower hooks (point 4.3.). 1000
Control the condition of the mobile hoses.
In addition to the operations every 500 and 1000 working hours, carry out:
Replacement of shoes “a” (point 7.1.1.).
Check ball joints “d”.
Examination for deformation or break in the structure or welds.
2000
Position “a” grease nipple UNI 7763-AM6-5.8

Recommended lubricant: for internal ISO X M2 (SHELL ALVANIA GREASE R2), for external ISO CB 32 (ESSO NUTO32).
THE WORKING HOURS SHOULD BE HALVED WHEN USING THE EQUIPMENT IN DUSTY, DAMP OR CORROSIVE ENVIRONMENTS.

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9. EXTRAORDINARY MAINTENANCE OF SIDE-SHIFTER
The equipment must be disconnected from Before disconnecting the hydraulic hoses, follow the manufacturer's instructions to remove the pressure in the forklift's circuit.
the forklift in order to proceed with
maintenance. Possible leakage of oil from pipelines. Prepare a container to collect fluid.

9.1. DETACHMENT FROM THE FORKLIFT 9.2. SHOES REPLACEMENT AND CYLINDER DETACHMENT
Lifting hook. 1) Disconnect the 4 forklift feed hoses, ISO Upper shoe.
3318 17 mm wrench. Cylinder support and shoes guide.
2) Remove the lower hook, ISO 3318
class2 24 mm, class3 27 mm wrench. 5) Disconnect the cylinder feed hoses,
Cylinder stem stop.
3) Use the special ring to remove ISO3318 17 mm wrench.
the equipment from forklift. 6) Remove the cylinder block and support,
Feed. Before lifting the equipment, make sure and remove the cylinder.
the rings are intact, without deformations
or the beginning of fractures. 7) To extract the upper shoes, use a
DIN 6450 5mm punch.
4) Remove the side-shift
cylinder stem stop springs. 8) To disconnect the lower shoes, use a ISO
Hook and lower shoe. 2380 screwdriver.
In this phase the cylinder block
and shoes support are free to drop. Lower shoe.

CARRY OUT THE PROCEDURE IN REVERSE ORDER TO RESTORE THE DISMANTLED PARTS.

9.3. SHOES CONTROL 9.4. CYLINDER DISASSEMBLY 9.5 REPLACEMENT OF SEALS

Rotate the cap until the circlip is

completely out.

Replace the shoes if there are cracks, Follow the order of assembly when
permanent deformations or the thickness Cylinder cap replacing the gaskets.
is less than: s1 2 mm, s2 3 mm. circlip.
Perform the replacement of the seals in a
dust free environment.

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9.6. ELIMINATION OF SIDE-SHIFTER

The equipment must be disconnected from the forklift

in order to proceed with maintenance. Possible leakage of oil from pipelines. Prepare a container to collect fluid.

Before disconnecting the hydraulic hoses, follow the manufacturer's instructions to remove the pressure in the forklift's circuit.
1) Disconnect the 4 forklift feed hoses, ISO
3318 17 mm wrench.
Side-shifter cylinder.
Central tooth.
2) Remove the lower hooks, Upper cylinder support.
ISO 3318 class2 24 mm, class3 27 mm wrench.
Upper shoe. Spacer.
3) Use the special ring to lift the equipment. Lifting hook.

Before lifting the equipment, make sure the rings are intact, Side stop.
without deformations or the beginning of fractures.
4) Remove the cylinder stems retainers.

In this phase the cylinder block

and shoes support are free to drop.

5) Disconnect the cylinder feed hoses,

ISO3318 17 mm wrench.

6) Dismantle the cylinder support block and upper shoes.

7) Attach the spacer to the ISO 2328 carriage of the forklift with the central
tooth inserted into the notch at the centre of the carriage.
Feed.
8) Attach equipment to the spacer, making sure that the
side retainers of the spacer are inside the side-shifter
cylinder thrust dowels. Cylinder stem stop.

9) Reposition the lower hooks and make adjustments as Hook and lower shoe.
per point 4.2. HOOKS ADJUSTMENT.

10) Connect the hoses to the forklift's system.

To check the connections, perform 5 complete movements, with and without the load.

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10. FORKS POSITIONER EXTRAORDINARY MAINTENANCE
10.1. DETACHMENT OF CYLINDERS
1) Open the equipment to its maximum. Before disconnecting the hydraulic hoses, follow the manufacturer's instructions to remove the pressure in the forklift's circuit.

2) To release the forks, loosen the side screws and rotate the positioners.
Possible leakage of oil from pipelines. Prepare a container to collect fluid.
3) To remove the forks, move them to the centre of the frame.
Cylinder pin retainer screw.
4) Open the positioners to their minimum +200 mm.
Cylinders central supports.
The positioners are released and are free to
rotate or oscillate during the opening.

5) Disconnect the 4 cylinder feed hoses,

ISO 3318 17 mm wrench.
6) Remove the retaining screw with ISO 3318
10 mm wrench; extract the cylinder retainer pin
with DIN 6450 5 mm diameter punch.
7) Remove the cylinders central supports with ISO 2936 6 mm wrench.
The cylinders fall when released from their central support. Fork assembly lower opening.

8) Disconnect and place the cylinders on a work bench.

10.2. DETACHMENT OF THE POSITIONERS 10.3. BALL JOINTS DISASSEMBLY

Cylinder stem. To remove the ball joints, use spacers

with diameters, in millimetres, as
Fork positioner. indicated in the figure.

Ball joint support.

Positioner fixing screw.

Disconnect the positioner with ISO 3318 15 mm wrench.

Fasten the cylinder stem with ISO 3318 14 mm wrench, disconnect
the ball joint support with ISO 3318 19 mm wrench.

During assembly, apply "LOCTITE" No. 243 brake fluid to

the threads of the positioner and cylinder stem fixing CARRY OUT THE PROCEDURE IN REVERSE ORDER
screws, (follow the instructions on the package). TO RESTORE THE DISMANTLED PARTS.

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10.4. REPLACEMENT OF SEALS 10.5. CONTROL OF INTERNAL VALVE

Follow the order of assembly when

replacing the seals.

ISO2936 6 mm wrench for valve cap. ISO

3318 12 mm wrench for piston.

Check the integrity of the valve slider.

Replace the spring if free length is less than
22.5 mm.

Replace the internal seals and the valve control in a dust free environment.

Possible leakage of oil from pipelines. Prepare a container to collect fluid.

11. LIST OF POSSIBLE FAULTS WITH CAUSES AND REMEDIES

Side-shift does not occur.
The side-shift is performed slowly
and/or irregularly.
The positioning of the forks does
not occur.
The positioning of the forks is
performed slowly or irregularly.
The forks approach only.
Insufficient oil pressure and/or flow rate
Sliding tracks dirty or obstructed
Hydraulic circuit blocked or broken
Lower hooks not secured or not adjusted
Defective cylinder
Insufficient oil pressure and/or flow rate
Sliding shoes tracks dirty or obstructed.
Faulty cylinders
Residual air in the hydraulic circuit
Insufficient oil pressure and/or flow rate
Forks sliding tracks dirty or obstructed.
Hydraulic circuit blocked or broken
Faulty cylinders
Insufficient oil pressure and/or flow rate
Forks sliding tracks dirty or obstructed.
Faulty cylinders
Residual air in the hydraulic circuit
Malfunction of the regulator on the cylinder bulkhead.
Malfunction of the internal valve.
Control and/or regulation of the forklift's hydraulic pump
Clean, eliminate the obstruction and grease
Eliminate obstruction or replace damaged hose
Re-establish the play and tightness of the screws as shown in point 4.3.
Control or replacement of the seals and of the cylinders or stem guides
Control and/or regulation of the forklift's hydraulic pump
Clean, eliminate the obstruction and grease
Control or replacement of the seals and of the cylinders' stem guides
Control of the oil level in the tank of the forklift. Bleed the residual air in the
hydraulic circuit.
Control and/or regulation of the forklift's hydraulic pump
Clean, remove blockages and grease see point 4.2.1.
Eliminate obstruction or replace damaged hose
Control or replacement of the seals and of the cylinders or stem guides
Control and/or regulation of the forklift's hydraulic pump
Clean, remove blockages and grease see point 4.2.1.
Control or replacement of the seals and of the cylinders' stem guides
Control of the oil level in the tank of the forklift. Bleed the residual air in the
hydraulic circuit.
Control and/or adjustment see point 7.2.4.
Control of the internal valve see point 7.2.3.

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IN CASE OF PROBLEMS OTHER THAN THOSE DESCRIBED ABOVE, PLEASE CONTACT OUR SERVICING DEPT.

12. NOISE EMISSION 13. RECYCLING

THE FOLLOWING SPECIFICATIONS APPLY TO THE Transport pallet Wood
Replaced parts should be
FORKLIFT-EQUIPMENT UNIT. Straps and protection Heat shrink polyester
disposed of, as in the case of
complete destruction, during shipping
- Sound pressure level of the weighted emission A in the workplace, where this
exceeds 70 dB (A); if said level does not exceed 70 dB(A), it must be indicated. separately depending on the Side-shifter shoes Nylon
nature of the material and in Bushings Bronze
-Maximum weighted instantaneous sound pressure C in the workplace, where this compliance with the Hoses / connectors Polyester / steel
exceeds 63 Pa (130 dB relative to 20 µPa). requirements of the law on the
disposal of industrial waste. Cylinder gaskets Polyurethane and NBR
NB: The pieces not mentioned Cylinder caps Cast iron
- Weighted sound power level A emitted by the machine, if the sound pressure level
of the weighted emission A in workplaces exceeds 80 dB (A). in the table are made of steel. Hose fastening Nylon
Paint Epoxy polyester
Gearmotor oil and grease Dispose of in compliance
with local regulations
14. WARRANTY 15. FACSIMILE OF THE EC CONFORMITY CERTIFICATE
The manufacturer guarantees all its products for 12 months or 2000 working
hours (whichever situation occurs first) from the date of shipment.
The warranty is limited to the replacement, ex-factory of the manufacturer, of
those parts identified as being defective due to defects of processing materials;
it does not include the cost of labour or travelling expenses for the replacement
of such parts.
It is further understood that recognition of the warranty is void if the anomaly
results from the inappropriate use of the product, if the implementation was not
carried out according to the manufacturer's specifications or if non-original
parts have been used for modifications or replacement.
The equipment is not guaranteed for uses that exceed the performance indicated
on the rating plate and in the documentation.
All equipment is covered by insurance for any damage caused to third parties
by defective parts or their malfunction; damage caused by improper use or
misuse is not included.

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