Engcon GH1000 User manual

User manual
PALLET FORK
GH1000 | GHH1000 | GH1200 | GHH1200 | GHH1200L | GH1500 | GHH1500
Article 9000122 | Version 1.6
Language
Country
Original Instructions

Preface
Preface
Dear Customer,
Thank you for choosing a product from engcon.
engcon is the market leader in tiltrotators and tools for excavators. We represent
innovation, knowledge and experience, and we develop our products with a focus on the
customer's needs. Please visit our website for contact information and details about the
rest of our product range.
www.engcon.com
2

Table of Contents
Table of Contents
1. Introduction
1.1. General............................................................................................................ 5
1.2. Scrapping and recycling.................................................................................. 5
1.3. Warranty.......................................................................................................... 6
1.4. Technical support and spare parts.................................................................. 6
1.5. Product approval............................................................................................. 7
1.5.1. EU Declaration of Conformity.................................................................. 7
2. Safety
2.1. General............................................................................................................ 8
3. Design and function
3.1. General............................................................................................................ 9
3.2. EC-Oil.............................................................................................................. 10
4. Installation
4.1. Identification.....................................................................................................11
4.2. Mechanical.......................................................................................................12
4.3. Electrical and hydraulics..................................................................................12
4.4. On completion................................................................................................. 13
5. Operation
5.1. Before and during use.....................................................................................14
5.1.1. Before use............................................................................................... 14
5.2. Excavator/Backhoe loader...............................................................................15
5.3. Tiltrotator..........................................................................................................15
5.4. Attachment.......................................................................................................16
5.4.1. After attachment.......................................................................................16
5.5. Handling loads.................................................................................................17
5.6. Driving..............................................................................................................18
5.7. Detaching.........................................................................................................18
6. Maintenance
6.1. General............................................................................................................ 19
6.2. Daily inspections..............................................................................................20
6.3. Special maintenance....................................................................................... 21
6.3.1. EC-Oil.......................................................................................................21
6.4. Checks every 500 operating hours................................................................. 22
6.5. Lubricate every 40 operating hours.................................................................23
6.5.1. Pallet fork greasing..................................................................................23
6.6. Tightening torque.............................................................................................23
7. Decals
7.1. Warning decals................................................................................................24
7.1.1. Warning decals in cab............................................................................. 24
7.1.2. Symbol legend......................................................................................... 24
3

Table of Contents
8. Technical data
8.1. Pallet forks.......................................................................................................26
9. Glossary
9.1. Designations.................................................................................................... 27
9.2. Abbreviations................................................................................................... 27
4

1 Introduction
1. Introduction
1.1. General
This user manual contain important information about your product's functions and
characteristics, and how to use it in the best way. Before you begin using the product, it is
important that you read and understand the content of these instructions, especially the
sections that address safety.
In addition to these instructions, you must study and understand the applicable safety
information for the relevant base machine as well as any other equipment involved.
The user manual is supplied with supplementary documentation providing more detailed
descriptions of the installation, fitting, operation and maintenance of control systems and
custom modifications for your specific product.
Information, images, illustrations and specifications used in the instructions are based
on product information that was available at the time of going to press. Images and
illustrations used in the instructions are typical examples and not intended to be exact
depictions of various part of the product. We reserve the right to make changes without
prior notice.
Always store the user manual together with any other supplementary information in a safe
manner and such that it is always available.
1.2. Scrapping and recycling
engcon makes constant efforts to reduce its environmental impact. engcon's products
comprise at least 99 per cent recyclable material. All assembly and service work must
take place in compliance with legislation and ordinances governing the environment,
health and occupational safety. This refers to all work with residual materials including
handling, storage and processing. To prevent contamination of soil and water, spillages
must be avoided. Should a spillage occur, it must be dealt with.
Hazardous waste may only be disposed of by those authorized to do so. All waste
produced must be disposed of in compliance with applicable legislation and ordinances:
- Metal and plastics to be recycled.
- Hydraulic hoses are normally used for energy recovery (sort as hazardous waste).
- Oils and greases are normally used for energy recovery (sort as hazardous waste).
- Electronic components to be recycled for materials (sort as hazardous waste).
- Packaging to be sorted at source and recycled for materials.
- Paper to be sorted at source and recycled for materials.
If in doubt, contact the environmental manager at engcon.
5

1 Introduction
1.3. Warranty
This product was designed, dimensioned and manufactured by engcon. It is forbidden
to modify, alter or convert this product such that it no longer corresponds to the
manufacturer's specifications. When replacing parts or making repairs, contact an
authorized workshop.
Warranty: One (1) year providing the product has not been subjected to abuse or other
abnormal operation.
1.4. Technical support and spare parts
Contact information for support and spare parts can be found at www.engcon.com.
6

1 Introduction
1.5. Product approval
1.5.1. EU Declaration of Conformity
Manufacturer:
engcon Nordic AB
Address:
Box 111, SE 833 22 Strömsund, SWEDEN
Telephone:
+ 46 670 178 00
Email:
[email protected]
engcon hereby declares that the below is manufactured in conformance with Machinery Directive 2006/42/
EU.
Type designation:
Part no:
Serial No:
Max jacking point:
Max hydraulic pressure:
Date:
Other:
Because the following standards and regulatory directives are also applied, the product complies with the
requirements for CE marking.
-SS-EN ISO 12100:2010, SS-EN 474-1:2006+A5:2018 and SS-EN 474-5:2006+A3:2013
dold text
This declaration and engcon's warranties will cease to be valid immediately if spare parts other than engcon
original spare parts are used, or if any changes or other interventions are made without engcon's permission.
Osynlig fras
Krister Blomgren - Signatory for engcon Nordic AB
Osynlig fras
Qualified person authorized to compile the technical documentation:
Fredrik Jonsson, Head of R&D, engcon AB
7

2 Safety
2. Safety
2.1. General
It is important that you read and understand all warnings prior to installation work on this
product or before you use it and any accessories supplied. The warning texts highlight
potential risks and describe how to avoid them. The following warning levels are used in
this user manual:
DANGER
Indicates that an accident will occur if the regulation is
not followed. Risk of personal injury or death.
WARNING
Indicates that an accident may occur if the regulation
is not followed. Risk of personal injury or death.
CAUTION
Indicates that an accident may occur if the regulation
is not followed. Risk of personal injury.
IMPORTANT
Indicates that an accident may occur if the regulation is
not followed. Risk of damage to property, process or the
surroundings.
REMARKS
Specifies additional information that may make performance or
understanding of specific operations easier.
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3 Design and function
3. Design and function
3.1. General
The engcon pallet fork make pallet handling easier and more efficient. It has a robust,
well-conceived design for best visibility.
DANGER
Do not exceed tipping load limits. The weight of the
product and the increased reach may impair stability.
Risk of personal injury and damage to property.
The pallet fork is available in two different versions – hydraulic and mechanical.
Hydraulic
The pallet fork is connected to the machine hitch/quick coupler. Its hydraulic hoses are
connected to the base machine's hydraulic system. The fork carriage is equipped with two
hydraulic cylinders that each operate one blade. The blades can be moved apart or closer
together by means of the base machine's hydraulic system.
The hydraulic assembly includes a flow divider for the smoothest possible fork spreading.
Fork spreading – use hoses A + B.
GHH = Hydraulic spreading.
Pos.
Designation
1
Fork carriage
2
Blades
3
Hydraulic cylinders
12
3
Figure 1.
9

3 Design and function
Mechanical
The pallet fork is connected to the machine hitch/quick coupler. The pallet fork blades are
fitted with locks to enable the correct distance to be set between the blades. The blade
carriage is fitted with end stops to prevent the blades from sliding off.
GH = Mechanical spreading.
Pos.
Designation
1
Fork carriage
2
Locking
3
Blades
1
2
3
Figure 2.
3.2. EC-Oil
engcon’s system for more efficient tool changes. It provides the ability to switch hydraulic
tools without leaving the cab. The system is designed for maximum reliability in harsh
environments. It is a fully hydraulic system that handles the connection of tools under full
system pressure.
Figure 3.
10

4 Installation
4. Installation
It is important to check the necessary additional documentation before installation. At time
of delivery, your product and supplementary documentation are as far as possible adapted
to your base machine.
WARNING
Never attempt to increase the maximum capacity
of the equipment by modifications not approved by
the supplier. Risk of personal injury and damage to
property.
WARNING
If you have any doubts concerning the safety aspects
of your knowledge, the equipment or work, contact
a dealer or engcon Nordic AB. Incorrect installation
affect safety.
WARNING
Welding is not permitted. It can have a negative
impact on safety. Risk of personal injury and damage
to property. For welding, contact your dealer or
engcon Nordic AB.
WARNING
Beware of moving parts. A lack of awareness may lead
to crush injuries. Risk of personal injury.
IMPORTANT
Ensure miscibility with the base machine's hydraulic oil
prior to installation. If you are in any doubt, contact your
lubricant supplier. An incorrect mixture could damage hydraulic
components.
4.1. Identification
Check that your product's rating plate matches the information on the EC Declaration
of Conformity. If there is any deviation, contact the supplier before you begin initial
installation.
11

4 Installation
Rating plate content:
Type designation
Part number
Weight
Year of manufacture
Width
Quick coupler
Serial number
4.2. Mechanical
If the product is installed on a machine hitch, tiltrotator or rotator, use
the user manual for connecting tools.
DANGER
Do not exceed tipping load limits. The weight of the
product and the increased reach may impair stability.
Risk of personal injury and damage to property.
WARNING
If you have any doubts concerning the safety aspects
of your knowledge, the equipment or work, contact
a dealer or engcon Nordic AB. Incorrect installation
affect safety.
4.3. Electrical and hydraulics
Installing hydraulic hoses
1. Make sure the tool is level and resting stably.
2. Connect the base machine’s machine hitch/tiltrotator to the tool.
3. Stop the engine and depressurize the base machine's hydraulic outlet by operating the
tool's functions.
WARNING
The hydraulic system must be de-pressurized before
work on the system is begun. Risk of personal injury
and damage to property.
12

4 Installation
4. Connect the hydraulic hoses to the base machine's hydraulic outlets. Make sure the
correct hydraulic outlets are used.
4.4. On completion
1. Affix the warning decals supplied in a conspicuous
place in the operator's cab, without obscuring operator
visibility.
WARNING
Replace damaged or
illegible signs and
decals before using
the machine. Risk of
personal injury and
damage to property.
2. Carry out function checks:
Figure 4.
- Run the tool functions a few times to remove any air
from the system. Important for preventing uncontrolled
movement.
- Make sure the tool operates when the hydraulics are
running.
- Check that the hoses are not subjected to pinching,
cutting or stretching.
13

5 Operation
5. Operation
5.1. Before and during use
Check your base machine manufacturer's recommendations for calculating tipping loads,
and be sure to include the increased weight and reach the product entails.
DANGER
Do not exceed tipping load limits. The weight of the
product and the increased reach may impair stability.
Risk of personal injury and damage to property.
Before using your product, remove the yellow protective covers from the EC-Oil block.
WARNING
When using pallet forks together with the tiltrotator,
exercise caution and maneuver carefully. The load can
easily fall off during rapid rotation or tilting.
WARNING
Beware of moving parts. A lack of awareness may lead
to crush injuries. Risk of personal injury.
IMPORTANT
Check the base machine's specified max capacity. Any use
of the product in excess of base machine max capacity may
damage the machine.
5.1.1. Before use
When using the pallet fork, large variations in the center of gravity may occur depending
on the type of load being raised.
- Check pallet fork lifting capacity before operation to ensure a good safety margin in
relation to the goods being lifted.
- Check that each of the blade locking mechanisms has engaged with the fork carriage.
14

5 Operation
WARNING
Do not overload the pallet fork blades. The maximum
load is shown on the pallet fork rating plate. The
weight applies per blade pair as measured 19.7 inches
from their heels. Risk of personal injury and damage
to property.
WARNING
The pallet fork tips may not be extended beyond the
range specified in the machine's load chart.
5.2. Excavator/Backhoe loader
When using the pallet fork on an excavator or backhoe loader, the hydraulic cylinders on
the base machine arm system must be equipped with valves that prevent the load from
dropping in the event of a hose failure.
5.3. Tiltrotator
If the pallet fork will be used together with a tiltrotator or similar equipment intended to tilt
or rotate tools, all of the tiltrotator's hydraulic cylinders must be equipped with hose break
valves. Contact your supplier if in doubt.
When connecting the pallet fork to a base machine fitted
with a tiltrotator, position the pallet fork with the blades
facing the machine in order to avoid overloading the lock
pins on the machine hitch.
WARNING
The excavator arm system cylinders must be fitted
with valves to prevent the load from dropping in the
event of a hose failure. Risk of personal injury and
damage to property.
WARNING
When using pallet forks together with the tiltrotator,
exercise caution and maneuver carefully. The load can
easily fall off during rapid rotation or tilting.
15

5 Operation
5.4. Attachment
DANGER
Do not exceed tipping load limits. The weight of the
product and the increased reach may impair stability.
Risk of personal injury and damage to property.
WARNING
Check that each of the blade locking mechanisms has
engaged with the fork carriage before using the pallet
fork. Risk of personal injury and/or property damage.
1. Make sure the hydraulic hoses are not pinched when connecting the fork carriage to the
quick coupler/machine hitch.
2. Connect the pallet fork to the quick coupler/machine hitch.
3. Check that the quick coupler/machine hitch locks the pallet fork securely.
4. Switch off the base machine’s engine.
WARNING
Make sure the base machine is switched off and
hydraulic connections are depressurized when
connecting or disconnecting electrical connections
(some models). Risk of personal injury.
5. Connect the hydraulic hoses to the base machine’s hydraulic system. Check that all
quick connect fittings are correctly connected.
6. Start the base machine’s engine.
7. Check that both blades are able to move easily to their respective end positions by
running them to max closed and max open.
5.4.1. After attachment
1. Check that the quick coupler/machine hitch is locked.
2. Make sure the pallet fork is securely attached to the quick coupler/machine hitch by
carefully pressing the pallet fork onto the ground.
WARNING
Once the pallet fork is connected to the base machine,
determine the direction of blade movement when they
are operated using the machine's hydraulic system.
Risk of personal injury and damage to property.
3. Check the direction of pallet fork movement when it is operated using the base
machine's hydraulic system.
16

5 Operation
5.5. Handling loads
The penetration force exerted by the blades is very large. Select a suitable blade length so
they do not protrude beyond the load. The next pallet or load in line can be damaged.
WARNING
Make sure no one is within the base machine's hazard
area during operation and/or working with the tool.
Risk of personal injury.
WARNING
Make sure no one is present under a raised tool. Risk
of personal injury.
WARNING
Bear in mind that the base machine's tipping
characteristics can be changed when using a pallet
fork. Always position the load with the center of
gravity as close as possible to the fork carriage. Risk
of personal injury or property damage.
WARNING
Take care when handling long objects. Take dynamic
load and the extended risk area into account. Risk of
personal injury and damage to property.
WARNING
Raise the load with the least possible tilt. Risk of
personal injury and damage to property.
WARNING
Leave room for rotating, tilting and sideways-moving
tools. Hazard zone 10 feet.
- Never overload the tool or machine – danger of death.
- Always handle the load such that it is as close to the shanks as possible.
- Deviations from full parallel operation can occur (see specifications) and this may affect
use.
- Begin lifting a short distance from the delivery point as the forks describe a semicircular
motion when lifting.
17

5 Operation
- Raise the load with as little tilt as possible on the pallet fork.
5.6. Driving
WARNING
Always keep the load as low as possible when driving.
Risk of personal injury and damage to property.
WARNING
Exercise caution in traffic when the pallet fork is
attached to the machine, especially at intersections
as the blades extend a long way in front of the base
machine. Risk of personal injury and damage to
property.
WARNING
When using pallet forks together with the tiltrotator,
exercise caution and maneuver carefully. The load can
easily fall off during rapid rotation or tilting.
- Keep the blades low and angled upwards during unladen transits.
- Adapt speed to suit surface conditions.
- Keep the load low and just above the surface (12-16 inches) for best stability and
visibility.
- Do not drive the base machine with a raised load other than when stacking and
unloading.
- Keep the forks horizontal when stacking materials.
5.7. Detaching
WARNING
Make sure the base machine is switched off and
hydraulic connections are depressurized when
connecting or disconnecting electrical connections
(some models). Risk of personal injury.
1. Stop the engine and disconnect the hydraulic hoses.
2. Start the engine and disconnect the quick hitch lock.
3. Disconnect the pallet fork from the base machine.
4. The procedure is complete.
18

6 Maintenance
6. Maintenance
6.1. General
Intervals for greasing and inspections to be performed by the user:
- Daily, carried out on all configurations before the machine is put into use for the working
day.
- Every 500 hours.
- Regular lubrication.
DANGER
Check the attachment points regularly and be alert for
the formation of cracks. Risk of personal injury and
damage to property.
WARNING
Make sure that service and maintenance is carried out
according to the manufacturer's recommendations.
Inadequate maintenance may cause defects on the
base machine and its equipment.
WARNING
When changing hoses, only hoses with press
couplings may be used. Screw connections may
not be used. Risk of personal injury and damage to
property.
IMPORTANT
Review the personal and environmental risks of hydraulic oil
and grease by reading the safety data sheets for the hydraulic
oil and grease in use. Risk of personal injury and damage to
surroundings.
IMPORTANT
Be sure to keep your product clean. Inadequate cleaning can
cause damage to your equipment.
19

6 Maintenance
6.2. Daily inspections
WARNING
Avoid contact with hydraulic oil. Risk of burns.
WARNING
Never use your hands to search for leaks in the
hydraulic system. Use the necessary protective
equipment. Pressurized hydraulic oil can penetrate the
skin. Risk of personal injury.
WARNING
Beware of moving parts. A lack of awareness may lead
to crush injuries. Risk of personal injury.
WARNING
The hydraulic system must be de-pressurized before
work on the system is begun. Risk of personal injury
and damage to property.
WARNING
Replace the forks if fork heel wear exceeds 10% of the
original thickness or if the angle of the heel is greater
than 93 degrees. Risk of personal injury and damage
to property.
WARNING
When replacing blades, check that the new blades
have the same max load as the fork carriage. Blades
with a different max load than the fork carriage may
not be used. Fork carriage max load is stated on the
rating plate. Risk of personal injury and damage to
property.
- Check that there are no cracks or damage. The fork heels are particularly vulnerable.
- that warning decals are in position and legible
20