Allied Systems LONG REACH CCHA Manual

145-034, REV. 5/18
Installation, Maintenance and
Service Manual
CCHA
Carton Clamp with Load Stabilizer

245-034, REV. 5/18
TABLE OF CONTENTS
SECTION 1 NAMEPLATE LOCATION
.......................................................Date received:
3
SECTION 2 MODEL NUMBER DESCRIPTION
.......................................... Series Model Number:
4
SECTION 3 SAFETY SUMMARY
3.1 Safety Information.........................................5
3.2 Safety Regulations........................................5
3.3 Safety Symbols.............................................5
3.4 Labeling ........................................................6
3.5 Training..........................................................6
3.6 Personnel Safety...........................................6
3.7 Pre-start Checks...........................................7
3.8 Operation Warnings......................................7
3.9 Hydraulic Hazards .......................................7
3.10 Electrical Hazards.......................................7
3.11 Maintenance Warnings ...............................8
3.12 Load Handling ............................................8
3.13 Load Positioning .........................................9
3.14 Operator’s Controls ...................................9
3.15 Industry Standards ...................................10
3.16 Clamp Open Control.................................10
SECTION 4 INSTALLATION PROCEDURE
4.1 Truck Requirements....................................12
4.2 Attachment Installation ...............................12
4.5 Hydraulic Connections................................13
SECTION 5 SERVICE PROCEDURE
5.1 Attachment Removal ..................................14
5.2 Arm Removal..............................................14
5.3 Arm Installation...........................................14
5.4 Cylinder Removal .......................................14
5.5 Cylinder Installation ....................................14
5.6 Cylinder Disassembly .................................15
5.7 Cylinder Inspection .....................................16
5.8 Cylinder Assembly......................................16
5.9 Hydraulic Valve Removal............................17
5.10 Hydraulic Valve Installation.......................17
5.11 Camber Adjustment..................................17
5.12 Toe Adjustment ........................................18
5.13 Rotating Contact Pads..............................18
SECTION 6 MAINTENANCE SCHEDULE
6.1 Schedule.....................................................19
6.2 Torque Specifications..................................19

345-034, REV. 5/18
- -
Date received:
SECTION 1 NAMEPLATE LOCATION
NOTICE
When you receive your attachment, locate
the Long Reach nameplate (upper left
corner on the body). Record the infor-
mation from the nameplate, along with
the date received, at the bottom of this
page. If the nameplate is missing, look for
the serial number stamped directly into
the metal at the nameplate location and
consult the factory for details.
A

445-034, REV. 5/18
SECTION 2 MODEL NUMBER DESCRIPTION
Each clamp is identified by a model number and a serial number located on the name plate attached to the unit
prior to shipment. Long Reach’s model numbers are designed to describe how an attachment is equipped. The
guide below illustrates the information that is represented in an 18-digit model number. Always include model and
serial number when ordering parts or requesting service information.
Series Model Number:
SERIES
CCHA = Citrus
clamp; carton
clamp with
stabilizer
CAPACITY
030 = 3,000 lbs
FUNCTION
06 = Clamp range:
24.0" - 33.0"
Stabilizer range:
80.0" - 130.0"
Sideshift
STABILIZER
DIMENSIONS
40 = 40" long x 24.5"
wide stabilizer pad
MOUNTING
A = ITA Class II
CLAMP
DIMENSIONS
41 = 41.5" long x 21.5"
high clamp pads
0 A 4 10 0 C C A 0 3 4 6 H

545-034, REV. 5/18
SECTION 3 SAFETY SUMMARY
CAUTION
Indicates a hazardous situation which,
if not avoided, could result in minor or
moderate injury, or equipment damage or
void the machine warranty. Carefully read
the message that follows to prevent minor
or moderate injury.
Notice
Describes information that is useful but
not safety related.
WARNING
Multiple hazards.
Ignoring safety warnings may cause equip-
ment damage, personal injury or death.
All possible safety hazards cannot be
foreseen and included in this manual. The
operator must always be alert to possible
hazards that could endanger personnel or
damage the equipment.
3.4 Labeling
• Change capacity, operation, and maintenance
instruction plates, tags, or decals when a forklift
truck is equipped with an attachment. If the truck
is equipped with front-end attachments other than
factory installed attachments, truck must be marked
to identify the attachments and show the approxi-
mate weight of the truck and attachment combination
at maximum elevation with load laterally centered.
3.5 Training
• Make sure all operators are trained in the fork and
attachment adaptation, operation, and use limita-
tions. Retrain an operator if a new attachment is
added to the forklift. Consult the operator’s manual
for instructions on how to use the new equipment.
• Know the mechanical limitations of your forklift.
3.1 Safety Information
Safety is Everyone’s Responsibility
Whether you are new on the job or a seasoned veteran,
these safety tips may prevent injury to you, to others, or
to the materials you are handling. Always be alert, watch
out for others, and follow these suggestions:
Attachments handle material, not people.
Safety starts with common sense, good
judgement, properly maintained equip-
ment, careful operation, and properly
trained operators.
The safety instructions and warnings, as documented
in this manual and shipped with the machine, provide
the most reliable procedures for the safe operation and
maintenance of your Long Reach attachment. It’s your
responsibility to see that they are carried out.
3.2 Safety Regulations
Know your company’s safety rules. Some companies
have site-specific directions and procedures. The
methods outlined in your operator’s manual provide a
basis for safe operation of the machine. Because of
special conditions, your company’s material handling
procedures may be somewhat different from those
shown in this manual.
3.3 Safety Symbols
The following terms define the various precautions and
notices:
DANGER
Indicates a hazardous situation which, if
not avoided, will result in death or serious
injury. Carefully read the message that
follows to prevent serious injury or death.
WARNING
Indicates a hazardous situation which,
if not avoided, could result in death or
serious injury. Carefully read the message
that follows to prevent serious injury or
death.

645-034, REV. 5/18
• Modifications or additions that affect capacity or safe
operation must have prior written approval from the
forklift truck manufacturer. Capacity, operation, and
maintenance instruction plates, tags, or decals shall
be changed accordingly.
• Never use free rigging for a below-the-forks lift. It
could affect the capacity and safe operation of a lift
truck.
3.6 Personnel Safety
• When removing or installing dismountable attach-
ments always keep hands and feet free from
dangerous positions or pinch points. Never leave a
dismounted attachment in a dangerous position.
• Keep hands, feet, long hair and clothing away from
power-driven parts. Do not wear loose fitting clothing
or jewelry while performing maintenance and lubrica-
tion in these areas.
• Never jump on or off the machine.
• Never stand on top of material being raised, lowered,
or transported. (Figure 3-1)
Figure 3-1 Figure 3-2
Figure 3-3
• Never use the attachment or its load to support a
man-carrying device.
• Never allow anyone under a load or under the
carriage. (Figure 3-2)
• Never stand in front of or beside an attachment
that is being operated. Never allow another person
to approach an attachment that is being operated.
(Figure 3-3)
• Never leave an attachment or load in an elevated
position.
• Never reach through the mast of the truck. Keep all
parts of the body within the driver’s compartment.
• Always operate an attachment from the operator’s
seat, never while standing next to the lift truck.
• Do not allow riders on the truck at any time.
• Always use reverse when carrying a load that
impedes full vision. Watch for pedestrians when
transporting.
• Always use personal protective equipment (PPE)
appropriate to the situation.
3.7 Pre-start Checks
• Check your equipment before you operate it. If
anything looks wrong, unusual or different, report it
before using the attachment.
• Do not operate this machine if you know of malfunc-
tions, missing parts, and/or mis-adjustments. These
situations can cause or contribute to an accident or
damage to the machine. Stop the machine immedi-
ately if problems arise after starting.
• Check to make sure the attachment on your truck is
the same as on the truck capacity plate.
• Check for hydraulic leaks and cracked hoses or
fittings. Check the hydraulic oil level in the lift truck
hydraulic reservoir.
• All electrical cables and connectors must be in good
condition. Use caution in wet weather to avoid danger
from electrical shock.
• Always check the attachment for proper fit and
engagement of the truck carriage.
3.8 Operation Warnings
• You must be trained to operate this equipment prior
to operation. Be extremely careful if you do not
normally operate this machine. Reorient yourself to
the machine before starting, then proceed slowly.
• Always operate an attachment from the driver’s seat.

745-034, REV. 5/18
• Always lower the attachment if you need to leave
the lift truck. A lift truck supporting a load requires
your full attention.
3.9 Hydraulic Hazards
DANGER
Injection hazard.
Infection and gangrene will result
when hydraulic oil penetrates the
skin. See a doctor immediately to
prevent loss of limb or death.
Use a piece of cardboard to check for
hydraulic leaks.
• Wear personal protective equipment, such as gloves
and safety glasses, whenever servicing or checking
a hydraulic system.
• Assume that all hydraulic hoses and components
are pressurized. Relieve all hydraulic pressure before
disconnecting any hydraulic line.
• Never try to stop or check for a hydraulic leak with
any part of your body; use a piece of cardboard to
check for hydraulic leaks.
3.10 Electrical Hazards
WARNING
Electrocution hazard.
Contact with energized equipment may
result in injury or death and will damage
equipment.
Remain at least 25 feet from high voltage
electrical wires.
• All electrical cables and connectors must be in
good condition (free of corrosion, damage, etc). Use
caution in wet weather to avoid danger from electrical
shock. Never attempt electrical testing or repair while
standing in water.
• Do not wear electrically conductive jewelry, clothing,
or other items while working on the electrical system.
3.11 Maintenance Warnings
Maintenance, lubrication and repair of this machine can
be dangerous unless performed properly. You must have
the necessary skills and information, proper tools and
equipment. Work in a method that is safe, correct, and
meets your company’s requirements.
• Do not attempt to make adjustments, or perform
maintenance or service unless you are authorized
and qualified to do so.
• Include attachments in a scheduled maintenance
and inspection program. Tailor inspection steps to
the attachment.
• Unless specified in service procedures, never attempt
maintenance or lubrication procedures while the
machine is moving or the engine is running.
• Always perform all maintenance and lubrication
procedures with the machine on level ground, parked
away from traffic lanes.
Notice
Local laws and regulations may require
that additional safety measures be taken.
• Never rely on the hydraulic system to support any
part of the machine during maintenance or lubrication.
Never stand under a component that is supported
only by the hydraulics. Make sure it is resting on its
mechanical stops or appropriate safety stands.
• Use caution when working around hot fluids. Always
allow lubricating and hydraulic oils to cool before
draining. Burns can be severe.
• Use extreme caution when using compressed air to
blow parts dry. The pressure should not exceed 30
psi (208 kPa) at the nozzle. Never use compressed
air on yourself. Air pressure penetrating your skin
can be fatal.

845-034, REV. 5/18
WARNING
Suffocation hazard.
Engine exhaust fumes can cause death.
Remove the exhaust fumes from the area
with an exhaust pipe extension, or use
ventilation fans and open shop doors to
provide adequate ventilation.
• Before disconnecting hydraulic lines, be sure to lower
all loads and relieve all hydraulic pressure. The load
could fall on you, or escaping hydraulic oil could
cause severe personal injury.
• Prevent personal injury or equipment damage by
using a lifting device with a lifting capacity greater
than twice the weight of any equipment to be lifted.
3.12 Load Handling
• Treat an unloaded forklift with an attachment as
partially loaded.
CAUTION
Equipment overload hazard.
Injury or equipment damage may result if
the capacity of the truck and attachment
combined are less than the attachment
capacity.
Consult truck nameplate for truck
capacity with an attachment installed.
• Never overload the attachment. Refer to the attach-
ment nameplate for the rated capacity of the
attachment. Refer to the truck nameplate for the
maximum net working capacity of the truck/attach-
ment combination. Never use a load to support or
move another object. Doing so can easily exceed the
holding capacity of the attachment.
• Always check loads to be handled. Correct loads that
are broken, unbalanced, loose, or too heavy.
• Never lift, lower, side shift, pivot, rotate, or tilt loads
while traveling. Repositioning loads while traveling
affects the stability of the truck and may impede
vision or clearances.
• Do not use an attachment to open or close boxcar
doors. Doing so can severely damage the attachment
and cause loss of warranty. Damage to clamp arms
may result in product damage.
• Do not carry loose items or unsupported loads on
top of a clamped load.
• Never use chains, cables, or other devices in conjunc-
tion with an attachment for load handling.
• Never clamp loads other than what the attachment
was designed to handle.
• Always carry cylindrically shaped loads in the vertical
position, not the horizontal.
• Always clamp loads with the contact pads, if appli-
cable, not the arm or arm base.
• Never rotate a load that is off center to the centerline
of rotation. Severe damage to the rotator could result.
• Always ensure that the load is the same width as the
pallet and neatly stacked when using a carton clamp.
3.13 Load Positioning
• Be accurate in load placement. It’s important to know
what the load will do when it’s released.
• Always carry loads as close to the floor as possible,
consistent with the surface being traversed. Scraping
or bumping the floor surface with the load or the
attachment can severely damage the attachment and
cause product damage. The mast should be tilted
back.
• Always keep the load positioned as close as possible
to the horizontal center of the lift truck.
• Always back down ramps or inclines. Driving forward
down a ramp or incline with a clamped load will
lessen the stability of the truck. (Figure 3-4)
Figure 3-4

945-034, REV. 5/18
• Do not cross dock boards or dock levelers with the
attachment or carriage fully lowered. Ramming the
front or rear of the attachment against a dock board
can cause severe damage.
• Limit lift truck movement to a minimum when high
stacking. Limit sideshift movement to a minimum
when high stacking.
• Always be observant when high stacking. Look for
poorly stacked loads, overhead obstacles, broken
cartons, or damaged products in the stack.
• Travel slowly around corners. Sound horn on blind
corners. Be careful of tail swing and overhead clear-
ances. Watch in all directions. Avoid sudden stops.
3.14 Operator’s Controls
Some lift trucks are equipped with a single lever to
control both hoist and tilt functions, others have separate
levers for each function. Refer to your lift truck manual
for more information.
For clarity, the direction of arm movement is shown on
the control handle. To move the arms in the direction
shown, pull the handle towards the operator. To move
the arms in the opposite direction, the push the handle
away from the operator. (Figure 3-5)
Clamp Fork position
Push/pull Rotate Sideshift
Figure 3-5 Operator controls
Lifting speed is controlled by the speed of the engine
and the position of the control lever. Engine speed has
no effect on lowering speed.
Before going on the job, shift the truck control levers
one way and then the other to determine which direc-
tion the attachment moves when the levers are shifted.
Make sure the attachment moves smoothly throughout
its travel, without binding or pinching hoses.
CAUTION
Equipment damage hazard.
Injury or equipment damage may result
if the attachment does NOT operate
smoothly.
Do not take malfunctioning equipment on
the job. Check with your supervisor about
needed repairs.
3.15 Industry Standards
ANSI/ITSDF B56.1-2016 is the published sequence and
direction standard for lever- and hand-type controls.
Notice
The chart on the following page shows
industry standards. Your equipment may
be different. If you do not routinely operate
this equipment, refresher training is
recommended. You must reacquaint your-
self with this manual and the equipment
before starting, and then proceed slowly.
Special controls such as automatic devices should be
identified, preferably according to the recommendations
in Figure 3-6.
When a function is controlled by a pair of push buttons,
they should operate in the same sense as the lever
controls. For example, pushing a button located to the
rear (relative to the operator’s position) should serve
the same function as moving a control lever to the rear.

10 45-034, REV. 5/18
3.16 Clamp Open Control
Effective October 7, 2010, safety standard ANSI/ITSDF
B56.1, Section 7.25.7 covers all lift trucks with a load
bearing clamp (paper roll clamp, carton clamp, etc.),
and requires the driver to make two distinct motions
before opening or releasing the clamp. For example,
you must press a switch and then move a lever to
unclamp the load. This requirement applies to new
and used attachments being mounted on trucks which
shipped from the factory after October 7, 2010, and is a
recommended feature to be installed on dealer orders
and existing applications.
WARNING
Load loss hazard.
Injury or equipment/load damage may
result if a fork positioner attachment is
used to clamp a load. The fork positioner
does not have enough clamping force to
safely hold a load.
Always support the load with the forks.
Do not use fork positioning attachments
as clamps.

1145-034, REV. 5/18
Function Direction of motion
Load Operator's hand on control handle, facing the load*
Hoist
Up
Down
Rearward or up
Forward or down
Reach Retract
Extend
Rearward or up**
Forward or down
Tilt Rearward
Forward
Rearward or up**
Forward or down
Sideshift Right
Left
Rearward or up
Forward or down
Push-pull Rearward
Forward
Rearward or up**
Forward or down
Rotate, lateral
Clockwise
Counter-
clockwise
Rearward or up
Forward or down
Rotate, longitude Rearward
Forward
Rearward or up
Forward or down
Load stabilizer Down
Up
Rearward or up
Forward or down
Swing Right
Left
Rearward or up
Forward or down
Slope
Clockwise
Counter-
clockwise
Rearward or up
Forward or down
Fork position Together
Apart
Rearward or up
Forward or down
Tr i p Engage
Release
Rearward or up
Forward or down
Grip Engage
Release
Rearward or up
Forward or down
Truck stabilizer Raise
Lower
Rearward or up
Forward or down
Clamp Clamp
Release
Rearward or up
Forward or down
Figure 3-6 ANSI/ITSDF Sequence of location and direction of motion for lever- or hand-type controls
* For high lift order picker trucks and center control pallet trucks, predominant motion of the operator’s hand when actuating the control
handle while facing away from the load.
** The sense of rotation of the control handle is intended to be in the same direction as the desired motion of the mast or load.

12 45-034, REV. 5/18
SECTION 4 INSTALLATION PROCEDURE
4.1 Truck Requirements
Long Reach attachments have been designed to
operate within specific limits. Operating pressures above
the recommended maximum may cause damage to the
attachment and may void the warranty.
Hydraulic flow less than the recommended rates, or the
use of small I.D. hoses may reduce operating speed.
Higher flow can result in excessive heat buildup, erratic
operation and damage to the truck/attachment hydraulic
system.
Notice
The dealer and/or the user must provide
and install the valving required to meet
the recommended hydraulic pressures
and flow, or must arrange installation of
the required valving at the truck factory.
The attachment model description, found
on your shipped invoice, will state the
following truck requirements: flow (gpm),
psi, and minimum truck carriage width.
1. The truck carriage must conform to the American
National Standard (ANSI) dimensions shown in
ANSI/ITSDF B56.11.4-2005, reaffirmed 2000.
2. Make sure the truck carriage is clean, conforms to
ANSI recommendations, and the notches are not
damaged.
CAUTION
Any alterations to the original attachment
may affect performance or safety and
result in loss of warranty.
3. The truck hydraulic system must supply to the
attachment hydraulic oil that meets the specifica-
tions required to operate the attachment properly.
4. When the truck hydraulic system pressures exceed
this maximum, a relief valve is recommended in the
attachment auxiliary system of the truck or on the
attachment.
5. Consult the truck factory and/or Long Reach for
guidance.
4.2 Attachment Installation
WARNING
Equipment overload hazard.
Overloading the truck may cause equip-
ment damage.
Consult truck nameplate to determine
the capacity of the truck and attachment
combination, as it may be less than the
capacity shown on the attachment alone.
3. Remove the lower bolt-on hooks and, if applicable,
make a note of any factory installed shims. Shims
are used to create clearance between the hook and
carriage.
4. Center the truck behind the attachment and drive
toward the attachment with the mast tilted forward
approximately 4 degrees.
5. Line up the locking lug (under the hanger plate, if
applicable) with the appropriate notch on the truck’s
carriage. Check that the bronze side shifting wear
strips are in the proper place, if applicable.
6. Slowly raise the truck carriage completely to engage
the top hooks with the truck carriage. Tilt carriage
back until the unit is against the carriage bottom
fork bar (0 degrees).
7. Inspect for proper engagement of the locking lug
in the corresponding notch of the truck’s carriage.
Inspect any wear strips, if applicable, to insure they
are properly aligned in the top hooks.
8. Install the bolt-on lower hooks. Inspect clearance to
the carriage on lower hooks. Adjust the lower hooks
for a maximum clearance of 3/32" (see Figure 4-1).
Tighten the bolts to 40-50 ft-lbs.

1345-034, REV. 5/18
Maximum
clearance
1/8"
Maximum
clearance
1/32"
Maximum
clearance
3/32"
(consult factory
if over)
Shim(s)
as required
Shim(s)
as required
Figure 4-1, Lower Hook Clearance
9. Check all fittings, connections and bolts for any
interference.
4.5 Hydraulic Connections
1. Prior to connecting the truck hydraulic system to the
attachment, the system must be purged through the
filtration system. This will eliminate any contamina-
tion that might exist in the auxiliary hydraulic system
of the truck.
2. Purging can be accomplished by installing a jumper
line and operating each hydraulic function (clamp,
rotate and side shift if equipped) in each direc-
tion for a minimum of 30 seconds. (Figure 4-2)
Hoses should meet or exceed SAE100 RI Type AT,
with maximum working pressure of 3,000 psi for all
attachment functions.
To Truck
To Clamp
Figure 4-2, Jumper Line
3. Install the lines from the truck’s hydraulics to the
hydraulics of the attachment.
Figure 4-3, Hydraulic Connection
4. Inspect installation to ensure hoses are not kinked or
pinched between the truck carriage and attachment.
5. Operate the attachment continuously for several
minutes to determine that all hydraulic connections
are secure with no leaks.
6. With the mast in the vertical position, rotate the
attachment fully 360°. After this procedure, check
that the truck’s hydraulic reservoir oil level is at the
recommended level.
7. Before placing the attachment in operation inspect
all hoses and fittings for leaks and routing clearance.
Be sure to include clearance of jumper hoses to the
mast.
6. After completing the installation, operate the attach-
ment without a load for several cycles to remove
any air in the hydraulic system. Test the attachment
with a load to make sure the attachment operates
correctly.

14 45-034, REV. 5/18
SECTION 5 SERVICE PROCEDURE
5.1 Attachment Removal
1. Position the attachment arms to the width of the
unit’s body. Turn off lift truck. Relieve pressure in
the hydraulic circuit to the attachment by cycling
the lever back and forth several times.
WARNING
Crush hazard.
Serious injury could result if residual
hydraulic pressure causes equipment to
drift during service procedures.
Cycle the hydraulic circuit as described
above to relieve all system pressure.
2. Slightly raise the truck carriage to remove the bottom
mounting hooks.
3. Position the attachment on the edge of a pallet.
Lower the attachment so that the lower carriage
bar misses the pallet when lowered. Tilt the mast
forward to allow the carriage to disengage from the
upper mounting hooks and back away. If lowering
onto a floor, blocks of wood can be place under the
body of the attachment to raise the rear.
4. To reinstall, follow the installation procedure in this
manual.
Notice
Equipment damage and loss of perfor-
mance could result if air is trapped in the
hydraulic system.
Activate the hydraulic functions several
times after hydraulic service has been
performed, to bleed trapped air out of the
system before returning attachment to
service.
5.2 Arm Removal
1. Extend the arms outside the body. Remove the hair pin
and cotter pin from the rod end of the cylinder. (Figure
5-1)
Clevis Pin
Hair
Pin
Arm
Weldment
Cylinder
Figure 5-1, Arm/Cylinder
2. Tie the cylinder up to support the weight when
removed from the arm lug. Activate the hydraulics
and retract the cylinder from the arm lug.
3. Attach a suitable overhead hoist to the arm weld-
ment. Pull the arm assembly out of the body.
5.3 Arm Installation
1. Attach a suitable overhead hoist to the arm weld-
ment. Line up the slide bar with the body channel
and slide into place.
2. Activate the hydraulics and extend the cylinder rod
out until it is at the arm lug. Insert the clevis pin and
hair pin.
5.4 Cylinder Removal
1. Remove the cylinder rod end cotter pin and clevis
pin.
2. Disconnect the hydraulic connections.
3. Remove cotter pin and clevis pin at the base end
of the cylinder.
5.5 Cylinder Installation
1. Install the clevis pin and cotter pin into the base end
of the cylinder.
2. Attach the hydraulic connections to the cylinder.
3. Extend the cylinder until the rod end hole lines up
with the mounting hole. Install the clevis pin and
cotter pin into the rod end of the cylinder.

1545-034, REV. 5/18
4. Turn on the truck’s power and activate the posi-
tioning cylinders several times to bleed out trapped
air.
Notice
Equipment damage and loss of perfor-
mance could result if air is trapped in the
hydraulic system.
Activate the hydraulic functions several
times after hydraulic service has been
performed, to bleed trapped air out of the
system before returning attachment to
service.
5.6 Cylinder Disassembly
1. Remove the cylinder from the attachment. See
removal instructions.
2. Clamp the cylinder lightly at the base end in a soft
jawed vise. Use a block or other support under the
rod end of the cylinder. (Figure 5-2)
Figure 5-2, Cylinder Vise
3. Spread and remove the retaining ring from the gland
cap.
4. Push gland inward 1 inch and pry out lock ring.
5. Remove the rod assembly from the cylinder tube.
6. Clamp the rod assembly in a soft jawed vise on the
wrench flats, not on the rod surface. If the rod
does not have wrench flats use two pieces of wood
on both sides of the rod to prevent scaring. (Figure
5-3)
Figure 5-3, Cylinder Shaft
7. Remove the piston retaining nut and remove the
piston. (Figure 5-4)
Piston Nut
Piston
Gland Cap
Lock Ring
Retaining Ring
Figure 5-4, Rod Assembly
8. Carefully pry up on the piston seals using a blunt
tip screw driver being careful not to scratch the seal
grooves. Cut the seals to remove from the piston.
(Figure 5-5)
Figure 5-5, Piston Seal

16 45-034, REV. 5/18
9. Use the same procedure as above to remove the
seals from the gland cap.
5.7 Cylinder Inspection
Inspect the cylinder tube bore for:
1. Deep scratches or nicks.
2. Signs of galling or excessive wear.
3. Out-of-roundness or deformities of the barrel.
Inspect the piston for:
1. Scratches or nicks on seal grooves.
2. Wear on outside diameter.
Inspect the cylinder rod for:
1. Scratches or nicks on the rod surface.
2. Straightness of the rod.
3. Damaged threads.
Inspect the gland cap for:
1. Scratches or nicks in seal grooves.
2. Damaged threads or spanner wrench holes.
3. Excessive wear in bore.
Replace any component found to be defective.
5.8 Cylinder Assembly
1. Spray the piston, gland cap, and seals with WD40
or other similar product to ease slipping of the seals
in place.
2. Note the direction of the seal on the piston. Improper
installation will result in poor performance. The
cupped side or O-ring side of the seal should be
facing the gland cap. (Figure 5-6)
O-Ring
Seal
Piston nut
Piston
Cylinder
rod
Figure 5-6, Piston Seal
3. Install the seals and wipers in the gland cap. Note
the direction of the seals. The cupped side or O-ring
side of the seal should be facing the piston. (Figure
5-7)
Wiper ri
ng
Lock ring
Retaining
ring
O-Ring
Backup ring
Seal
Gland
cap
Cylinder
rod
Figure 5-7, Gland Cap Seal
4. Install the gland cap on the cylinder rod being
extremely careful not to cut the rod seal on the
threads of the rod or rod shoulder. If available use
a sleeve to cover the rod threads or plastic electrical
tape.
5. Install the piston on the rod and tighten the locknut
to 90 ft-lbs (0.56 UNF), 22 ft-lbs (0.75 UNF).
6. Spray the inside of the cylinder tube with lubricant
to ease inserting the rod and piston. Insert the rod
and piston into the cylinder tube. Tap the rod in with
a rubber mallet if resistance is encountered.

1745-034, REV. 5/18
7. Press on the lock ring and spread retaining ring to
install onto the gland cap.
5.9 Hydraulic Valve Removal
1. Turn off the truck’s power and activate the hydraulic
functions in both directions several times to relief
the built up hydraulic pressure.
2. Disconnect the hydraulic hoses from the truck at the
attachments valve ports V1 (open) and V2 (close).
(Figure 5-8)
Figure 5-8, Valve Removal
3. Disconnect the hydraulic hoses at the valve ports
C1 and C2.
4. Remove the valve mounting bolts and remove valve.
5.10 Hydraulic Valve Installation
1. Reassembly in the reverse order above.
2. Turn on the truck’s power and activate the hydraulic
functions several times to bleed out trapped air.
Notice
Equipment damage and loss of perfor-
mance could result if air is trapped in the
hydraulic system.
Activate the hydraulic functions several
times after hydraulic service has been
performed, to bleed trapped air out of the
system before returning attachment to
service.
5.11 Camber Adjustment
1. The term camber refers to the tilt of the contact
pads as viewed directly from the front or rear of the
attachment.
2. Positive camber, the desired configuration, means
that the contact pads are closer together at the
bottom than the top.
3. Negative camber means that the contact pads are
closer together at the top than at the bottom.
4. To help prevent loss of cartons from the lower tier,
Long Reach recommends a positive camber of 0.0
to 0.50 inch for pads up to 48 inches high and 0.0
to 0.75 inch for pads over 48 inches high.
5. Camber is adjusted by using 1/8 inch spacers, P/N
Y156057, to increase or decrease camber approxi-
mately 1/4 inch on a 48 inch high pad.
6. To increase camber positively, add one or more
spacer(s) between the pad and the lower platen
support. (Figure 5-9)

18 45-034, REV. 5/18
7. To decrease camber negatively, add one or more
spacer(s) between the pad and the upper platen
support.
8. Use existing capscrews only if one spacer is used. If
two or three spacers are used use P/N Y96G-0820
capscrew.
9. As the clamp arms and slides wear it may be neces-
sary to increase the positive camber.
5.12 Toe Adjustment
1. The term toe adjustment refers to adjusting the
difference in the distances between the front edge
and the rear edge of the contact pads.
2. Toe out, the preferred configuration, means that the
front edges are farther apart than the rear edges.
3. Toe in means that the front edges are closer
together than the rear edges.
4. To adjust the toe out, first loosen the lock nuts and
then screw the adjustment screws out (counter-
clockwise) for greater toe out, in for less. Be sure
to adjust both the top and bottom adjustment screws
found on each platen support. (Figure 5-9)
5.13 Rotating Contact Pads
1. As the contact pads wear it may be necessary to
rotate or replace them. Pad surfaces may wear
uneven, more or less, depending on the distribu-
tion of weight in the loads.
2. Before rotating, check flatness and deflection of the
pad. The pads surface flatness should not vary more
than 1/8 inch. The horizontal and vertical deflection
of the pad should not be more than 1/4 inch.
3. Pads can be rotated left to right.
Adjustment Screw
Adjustment Screw
Front Edge/Toe Out
Rear Edge/Toe Out
Figure 5-9, Camber and Toe Adjustment

1945-034, REV. 5/18
SECTION 6 MAINTENANCE SCHEDULE
6.1 Schedule
Daily Maintenance:
1. Check level of hydraulic oil in the truck reservoir
and add oil if necessary.
2. Visually inspect all hoses and fittings for wear or
damage. Inspect for signs of hydraulic leaks.
3. Visually inspect for external damage or cracks.
4. Inspect lower hooks for proper clearance. Maximum
clearance is 3/32 of an inch.
Weekly 40 Hour Maintenance:
1. Inspect all hoses and fittings for wear or damage.
Inspect for hydraulic leaks.
2. Check for loose or missing bolts.
3. Check for foreign matter between the arm slides
and the body. Foreign matter may lead to uneven
arm movement or galling of the slides or body.
4. Check that arm and slides are clean and lubricated.
Keeping the arm slides greased with a multipur-
pose, polymer fortified grease such as DuBois
Chemical MPG-2 will prevent excess wear. “Gun
barrel” grease the insides of the body sections, wipe
off excess.
500 Hour Maintenance:
1. Inspect base and lower retainer for hairline cracks or
signs of structural failure, particularly at the welds.
6.2 Torque Specifications
The following torque values are to be used on all
fasteners unless otherwise specified.
Lubricated refers to fasteners in the “As Received”
condition, which is normally a light preservative oil
coating on unplated fasteners and no oil coating on
plated fasteners. No special steps are taken to add
further lubrication prior to assembly.
GRADE 8 COARSE THREAD GRADE 5 COARSE THREAD SOCKET HEAD COARSE THREAD
Bolt Size Lubricated Torque Bolt Size Lubricated Torque Capscrew Size Lubricated Torque
1/4" 11 ft-lbs 1/4" 7.5 ft-lbs 1/4" 12.5 ft-lbs
5/16" 23 5/16" 16 5/16" 26
3/8" 40 3/8" 28 3/8" 46
7/16" 63 7/16" 45 7/16" 74
1/2" 96 1/2" 68 1/2" 115
9/16" 140 9/16" 98 9/16" 160
5/8" 195 5/8" 140 5/8" 215
3/4" 340 3/4" 240 3/4" 385
7/8" 550 7/8" 390 7/8" 615
1" 820 1" 580 1" 920
1-1/8" 1,160 1-1/8" 715 1-1/8" 1,305
1-1/4" 1,640 1-1/4" 1,010 1-1/4" 1,840
1-3/8" 2,150 1-3/8" 1,330 1-3/8" 2,415
1-1/2" 2,850 1-1/2" 1,760 1-1/2" 3,205
Figure 5-1, Torque Chart