Bobcat Hydraulic Pallet Fork Service Repair Manual Instant Download

1
Babcat.
Service Manual Hydraulic Pallet Fork
(42 Hyd Pallet Fork) S/N 230900101 Above (48
Hyd Pallet Fork) S/N 230800101 Above
Dealer Copy -- Not for Resale
Primed in U.S.A.
_at_ Bobcat Company 2011
60tXf880 (1t-11)
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MAINTENANCE SAFETY Instructions are necessary
before operating or servicing machine. Read and
understand the Operation Maintenance Manual,
Operator's Handbook and signs (decals) on
machine. Follow warnings and instructions irt the
manuals when making repairs, adjustments or
servicing. Check for correct function after
adjustments, repairs or service. Untrained
operators and failure to follow instructions can
cause injury or death. W-20D30807
-
Safety Alert Symbol This symbol with a warning
statement, means Warning, be alert! Your safety
is involved!" Carefully read the message that
follows.
CORRECT P-90216
Dealer Copy -- Not for Resale
Never service attachments / implements
without instructions. See Operation Maintenance
Manual and Attachment / Implement Service
Manual. Cleaning and maintenance are required
daily. Never service or adjust attachment /
implement with the engine running unless
instructed to do so in manual. Always lower the
attachment / implement to the ground before
lubricating or servicing. Avoid contact with
leaking hydraulic fluid or diesel fuel under
pressure. It can penetrate skin or eyes. Stop,
cool and clean engine of flammable materials
before checking fluids. Keep body, loose objects
and clothing away from moving parts, electrical
contacts, hot parts and exhaust. Safety glasses
are needed for eye protection from electrical
arcs, battery acid, compressed springs,
fluids under pressure and flying debris or when
tools are used. Use eye protection approved for
type of welding.
MSW30009
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Hydraulic Pallet Fork Service Manual
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CONTENTS SAFETY AND MAINTENANCE
.............................................10-01
HYDRAULIC SYSTEM ...............................
.....................20-01 SPECIFICATIONS
..................................................
.. SPEC-01 ALPHABETICAL INDEX ...................
.............................INDEX-01
Resale
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Hydraulic Pallet Fork Service Manual
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FOREWORD SERIAL NUMBER LOCATION
................................................
1-7 Attachment Serial Number .....................
........................... 1-7 DELIVERY REPORT
..................................................
..... 1-7 ATTACHMENT IDENTIFICATION
..............................................1-8
Resale
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Dealer Copy
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Hydraulic Pallet Fork Service Manual
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SERIAL NUMBER LOCATION
DELIVERY REPORT
Attachment Serial Number
Figure 2
Figure 1
P-96335
The delivery report Figure 2 must be completed
by the dealer and signed by the owner or operator
when the Bobcat hydraulic pallet fork is
delivered. An explanation of the form must be
given to the owner.
Always use the serial number of the Bobcat
hydraulic pallet fork when requesting service
information or when ordering parts. Early or
later models (identification made by serial
number) may use different parts, or it may be
necessary to use a different procedure in doing a
specific service operation Figure 1.
Not
Dealer Copy
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Hydraulic Pallet Fork Service Manual
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ATTACHMENT IDENTIFICATION
SLIDE ROD
HOSE GUIDE
Dealer Copy -- Not for Resale
FORKS
P105112
Hydraulic Pallet Fork Service Manual
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SAFETY AND MAINTENANCE TROUBLESHOOTING
..................................................
10-10-1 Chart ...................................
.......................... 10-10-1 DAILY
INSPECTION .......................................
............. 10-20-1 Attachment Mounting Frame
...........................................
10-20-1 Bob-Tach .................................
......................... 10-20-1 INSPECTION
..................................................
....... 10-30-1 Fork Inspection, Repair And
Testing Standards ............................
10-30-1 Step Inspection ..........................
........................... 10-30-2 REMOVAL AND
INSTALLATION ....................................
...... 10-40-1 Forks .............................
................................
10-40-1 Replaceable Step .........................
.......................... 10-40-1 ATTACHMENT
STORAGE AND RETURN TO SERVICE ....................
... 10-50-1 Storage ..............................
............................. 10-50-1 Return To
Service ..........................................
......... 10-50-1
Resale
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Dealer Copy
10-01
Hydraulic Pallet Fork Service Manual
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TROUBLESHOOTING Chart
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation Maintenance Manual, Operator's
Handbook and signs (decals) on machine. Follow
warnings and instructions irt the manuals when
making repairs, adjustments or servicing. Check
for correct function after adjustments, repairs
or service. Untrained operators arid failure to
follow instructions can cause injury or
death. 2gq3 ggg If the attachment is not working
correctly, check the hydraulic system of the
machine thoroughly before making any repairs on
the attachment. Attachment problems can be
affected by a hydraulic system that is not
operating to specifications. Connect a flow meter
to the machine to check the hydraulic pump
output, relief valve setting and tube lines to
check flow and pressure. (See the machine's
Service Manual for the correct procedure to
connect the flow meter.) Use the following
troubleshooting chart to locate and correct
problems which most often occur with the
attachment.
PROBLEM CAUSE CAUSE CAUSE CAUSE CAUSE CORRECTION
Hydraulic Pallet Fork does not engage correctly on the Bob-Tach T". Bob-Tach retracted. wedges are not fully Retract Bob-Tach wedges.
Hydraulic Pallet Fork does not engage correctly on the Bob-Tach T". Debris lodged between the Bob-Tach and the hydraulic pallet fork. Debris lodged between the Bob-Tach and the hydraulic pallet fork. Debris lodged between the Bob-Tach and the hydraulic pallet fork. Debris lodged between the Bob-Tach and the hydraulic pallet fork. Debris lodged between the Bob-Tach and the hydraulic pallet fork. Remove debris from between Bob- Tach and hydraulic pallet fork.
Forks will not move. Front auxiliary hydraulics not engaged. Front auxiliary hydraulics not engaged. Front auxiliary hydraulics not engaged. Front auxiliary hydraulics not engaged. Front auxiliary hydraulics not engaged. Engage loader front auxiliary hydraulics.
Forks will not move. No hydraulic fluid. No hydraulic fluid. No hydraulic fluid. No hydraulic fluid. No hydraulic fluid. Check quick coupler connections. Check for damaged hose ends and fittings.
Not for Resale
Dealer Copy
10-10-1
Hydraulic Pallet Fork Service Manual
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DAILY INSPECTION
Figure 10-20-2
Attachment Mounting Frame Figure 10-20-1
P-41502A
Push down on the Bob-Tach levers until they are
fully engaged in the locked position Figure
10-20-2 (wedges fully extended through the
attachment mounting frame holes).
P105160
Inspect the Bob-Tach wedge mounts (Item 1),
mounting flange (Item 2) Figure 10-20-1 and all
welds on the attachment for wear and damage
each time the attachment is removed from the
machine.
The levers and wedges must move freely Figure
10-20- 2-
Dealer Copy -- Not for Resale
Figure 10-20-3
Frequently inspect the hydraulic pallet fork to
ensure that all components are secure and that
all bolts and nuts are thoroughly tightened.
Bob-Tach wedge must contact the lower
edge of the attachment mounting frame
hole. P-79780
Bob-Tach
Hand Lever Bob-Tach
,/ WARNING
AVOID INJURY OR DEATH The Bob-Tach wedges must
extend through the holes in the attachment
mounting frame. Levers must be fully down and
locked. Failure to secure wedges can allow
attachment to come off. W-2715-0208
The wedges must extend through the holes in the
attachment mounting frame, securely fastening
the attachment to the Bob-Tach Figure 10-20-3.
NOTE If the wedge does not contact the lower
edge of the hole, the attachment will be loose
and can come off the Bob-Tach. Inspect the
mounting frame on the attachment. (See the
machine's Operation and Maintenance Manual
for inspecting the Bob-Tach). Replace any parts
that are damaged, bent or missing. Keep all
fasteners tight. Look for cracked welds. Contact
your Bobcat dealer for repair or replacement
parts. Lubricate the wedges. (See the machine's
Operation Maintenance Manual for the correct
procedure.)
10-20-1
Hydraulic Pallet Fork Service Manual
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DAILY INSPECTION (CONT'D)
Figure 10-20-6
Bob-Tach (Cont'd) Power Bob-Tach
AVOID INJURY OR DEATH The Bob-Tach wedges must
extend through the holes in the attachment
mounting frame. Levers must be fully down and
locked. Failure to secure wedges can allow
attachment to come off. W-27t5-0208
P-41S00A
Push (Item 1) Figure 10-20-4 or Figure
10-20-5 and hold the BOB-TACH WEDGES DOWN
switch until the levers are fully engaged in the
locked position Figure 10-20-6 (wedges fully
extended through the attachment mounting frame
holes).
Figure 10-20-4
Loader Switch
Figure 10-20-7
Dealer Copy -- Not for Resale
Bob-Tach wedge must contact the lower edge of the
attachment mounting
B-1S663A
Figure 10-20-5
frame hole. -94 g
P 7 2
Work Machine Switch
The wedges must extend through the holes in the
attachment mounting frame, securely fastening
the attachment to the Bob-Tach Figure
10-20-7. NOTE If the wedge does not contact
the lower edge of the hole, the attachment will
be loose and can come off the Bob-Tach. Inspect
the mounting frame on the attachment. (See the
machine's Operation Maintenance Manual for
P-88124
inspecting the Bob-Tach). Replace any parts that
are
damaged, bent or missing. Keep all fasteners
tight. Look for cracked welds. Contact your
Bobcat dealer for repair or replacement
parts. Lubricate the wedges. (See the machine's
Operation Maintenance Manual for the correct
procedure.)
10-20-2
Hydraulic Pallet Fork Service Manual
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INSPECTION
D. Difference in Height of Fork Tips. The
difference in height of one set of forks when
mounted on the fork carrier shall be checked. If
the difference in tip heights exceeds 3 of the
length of the blade, the set of forks shall not
be returned to service until repaired in
accordance with para. 6.2.8.2.
Fork Inspection, Repair And Testing Standards
NOTE The Fork Inspection, Repair And Testing
Standards is reprinted from the Safety
Standard for Low Lift and High Lift Trucks
ANSI/ITSDF B56.1 1-2009.
E. Positioning Lock (When Originally Provided).
It shall be confirmed that the positioning lock
is in good repair and correct working order. If
any fault is found, the fork shall be withdrawn
from service until satisfactory repairs have been
effected.
6.2.8 Inspection and Repair of Forks in Service
on Fork Lift Trucks
A. Forks in use shall be inspected at intervals
of not more than 12 months (for single shift
operations) or whenever any defect or permanent
deformation is detected. Severe applications will
require more frequent inspection.
F. Wear
1. Fork 6/ade and Shank. The fork blade and shank
shall be thoroughly checked for wear,
special attention being paid to the vicinity of
the heel. If the thickness is reduced to 90 of
the original thickness, the fork shall not be
returned to service.
B. Individual Load Rating of Forks. When forks
are used in pairs (the normal arrangement), the
rated capacity of each fork shall be at least
half of the manufacturer's rated capacity of the
truck, and at the rated load center distance
shown on the lift truck nameplate.
2. Fork Hooks (When Originally Provided). The
support face of the top hook and the retaining
faces of both hooks shall be checked for wear,
crushing, and other local deformations. If these
are apparent to such an extent that the clearance
between the fork and the fork carrier becomes
excessive, the fork shall not be returned to
service until repaired in accordance with O
6.2.8.1 Inspection. Fork inspection shall be
carried out carefully by trained personnel with
the aim of detecting any damage, failure,
deformation, etc., which might impair safe use.
Any fork that shows such a defect shall be
withdrawn from service, and shall not be returned
to service unless it has been satisfactorily
repaired in accordance with para. 6.2.8.2.
para. 6.2.8.2.
O
6.2.8.2 Repair and Testing
A. Su/face Cracks. The fork shall be
thoroughly examined visually for cracks and
if considered necessary, subjected to a
nondestructive crack detection process, special
attention being paid to the heel and welds
attaching all mounting components to the fork
blank. This inspection for cracks must also
include any special mounting mechanisms of the
fork blank to the fork carrier including
bolt-type mountings and forged upper mounting
arrangements for hook or shaft-type carriages.
The forks shall not be returned to service if
surface cracks are detected.
A. Repair. Only the manufacturer of the fork or
an expert O of equal competence shall decide if a
fork may be repaired for continued use, and the
repairs shall only be carried out by such
parties. It is not recommended that surface
cracks or wear be repaired by welding. When
repairs necessitating resetting are required,
the fork shall subsequently be subjected to an
appropriate heat treatment, as necessary.
B. Straightness of Blade and Shank. The
straightness of the upper face of the blade and
the front face of the shank shall be checked. If
the deviation from straightness exceeds 0.5 of
the length of the blade and / or the height of
the shank, respectively, the fork shall not be
returned to service until it has been
repaired in accordance with para. 6.2.8.2. C.
Fork Angle (Upper Face of Blade to Load Face of
the Shank). Any fork that has a deviation of
greater than 3 from the original specification
shall not be returned to service. The rejected
fork shall be reset and tested in accordance with
para. 6.2.8.2.
10-30-1
Hydraulic Pallet Fork Service Manual
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REMOVAL AND INSTALLATION
Figure 10-40-3
Forks Remove the hydraulic pallet fork from the
machine. Figure 10-40-1
P105112 Slide the slide rod (Item 1) Figure
10-40-3 out. If you cannot slide the rod out,
remove the other slide rod cover and drive the
slide rod out. P-96335
Remove the cotter pins and cylinder pins (Item 1)
Figure 10-40-1 connecting the forks to the rod
ends of the hydraulic cylinders.
AVOID INJURY OR DEATH Wear safety glasses to
prevent eye injury when any of the following
conditions exist
Figure 10-40-2
O

• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.

W-2019-0907 O
Replaceable Step Figure 10-40-4
P-14127 Remove the two bolts (Item 1) from one
of the slide rod covers (Item 2) Figure
10-40-2. /nsta/lation Tighten the bolts to 88
- 95 N m (65 - 70 ft- lb) torque.
Remove the two bolts (Item 1) Figure 10-40-4
attaching the step to the main frame. Installatio
n. Tighten the bolts to 34 - 38 Nm (25 - 28 ft-
lb) torque.
10-40-1
Hydraulic Pallet Fork Service Manual
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