T53 SLAB BUNDLE EXTRACTOR ATTACHMENT

Transcription

1 T53 SLAB BUNDLE EXTRACTOR ATTACHMENT APPLICATION AND OPERATING GUIDE Distributed By: UNIT LOAD HANDLING SYSTEMS, INC SO. MISSION CIRCLE, FRIENDSWOOD, TX PH: FX: EM: Manufactured By: TOTALL ATTACHMENTS, INC SPEERS ROAD, OAKVILLE, ONT L6L2X5 PH: FX: EM:

2 Marble and Granite Bundle Extractor Clamp Forklift Specifications and Workplace Set-up The Unit Load Handling / Totall Attachments Model T53 Extractor Clamp requires the following minimum forklift/ workplace set-up configuration in order to work effectively inside containers: FORKLIFT CAPACITY: The truck should be ideally an 8000 LB to 15,500 LB capacity, cushion tired in either internal combustion or electric power. CARRIAGE CLASS: The T53 is made to fit either ITA Class III or IV. All lift trucks, world wide, use the same dimensions for the carriages within a certain capacity range. These are called in different countries by various names such as ITA, ISO, FEM, DIN dimensions. In the USA we use the term ITA (Industrial Truck Association) to define the Class. Trucks from 6000 LB capacity to 9000 LB capacity all use the ITA Class III. SOME forklifts are available on request with ITA Class III carriages on the 10,000 LB models. Trucks 10,000 to 15,500 LB capacity use the ITA Class IV carriage. MAST/TRUCK OVERALL LOWERED HEIGHT: The clamp must enter into the container to operate The Highest point of the truck, mast and overhead guard, should not exceed 88 inches. HYDRAULIC SET-UP: The truck must have at least a double auxiliary valve and hose group to operate the clamp and lateral traverse sideshifter of the T53. Some existing trucks have a sideshifter installed. This can be one of the functions needed if the hoses are rerouted to allow attaching the T53 hoses using quick couple fittings. Another function (valve and hose group) must be added. NOTE: If the existing sideshifter hydraulic supply is used, the control valve on the truck must be readjusted to increase the flow rate and the PSI of this circuit. Sideshifters are normally restricted in flow for speed control and pressure for efficiency. When the T53 is removed from the forklift and the forks reinstalled for normal use, the sideshifter can be connected by the quick couple hoses. Unit Load Handling can supply a quick change sideshifter to make this job simpler. DRAWBAR PULL RATING: Forklifts should be able to produce approximately 7000 lb drawbar pull to allow efficient extraction and bundle handling. DOCK HEIGHT: Try to avoid extreme differences in height between the dock floor and the container. A difference more than 8 inches may require additional forward mast tilt in the truck. Longer dock levelers/plates may lessen this angle. Distributed UNIT LOAD HANDLING SYSTEMS, INC SO. MISSION CIRCLE, FRIENDSWOOD, TX Manufactured TOTALL ATTACHMENTS, INC SPEERS ROAD, OAKVILLE, ONT

3 Distributed UNIT LOAD HANDLING SYSTEMS, INC SO. MISSION CIRCLE, FRIENDSWOOD, TX Manufactured TOTALL ATTACHMENTS, INC SPEERS ROAD, OAKVILLE, ONT

4 LIFT TRUCK CARRIAGE SIZES ITA /FEM Carriage dimensions FRONT VIEW OF TRUCK CARRIAGE LESS FORKS A dim. ITA /FEM Carriage dimensions: DIMENSION A : ITA I: ITA II: ITA III: ITA IV: 13 INCHES 16 INCHES 20 INCHES 25 INCHES

5 TOTALL SYSTEM T53 EXTRACTOR CLAMP Used In Unloading Closed Top Containers: Use bolt cutters to cut the tamper-evident lock and secure the doors open with safety straps. Chock chassis wheels. Ensure the dockplate is secured in place. Block up the container using load jacks at four corners. Forklifts inside the container can cause it to sway and tilt. This can cause bundles to slip and fall. The load jacks should be installed to prevent tilt and sway. Remove all bracing blocks and nails from the container floor. This is done before removing any of the top bracing. The removal of the bracing is done in a specific sequence to keep warehousemen clear of bundles that may shift or that are unstable. Starting from the right of the rear row of bundles in the container, remove the bracing from the first bundle. For safety, the warehouseman must remove one side at a time, one bundle at a time, and from the furthest brace to the closest brace. This will result in only one bundle being freed, and the warehouseman will be clear of any shifting weight. Then, remove bracing at the rear of the container of the first bundle only, while making sure that the warehouseman is clear from shifting material. A power saw or Sawz-All on a long handled extension is ideal for this operation. CONTINUED... Distributed UNIT LOAD HANDLING SYSTEMS, INC SO. MISSION CIRCLE, FRIENDSWOOD, TX Manufactured TOTALL ATTACHMENTS, INC SPEERS ROAD, OAKVILLE, ONT

6 TOTALL SYSTEM T53 EXTRACTOR CLAMP Used In Unloading Closed Top Containers: CONTINUED Once the bundle is free, removal can be done with a specialized forklift attachment, called the Totall Clamp System, designed to extract stone slab bundles. When using the Totall Clamp System, the forklift lifts the bundle slightly and drags it out of the rear of the container. At this point, a second forklift and boom can be used to cable or strap the bundle while the bundle is still secured from shifting by the first forklift. Once cables are taut, the attachment can be removed. This procedure is continued for the second bundle: remove the front brace, then the rear. The procedure changes for the third and fourth bundles. After cutting the bracing in the front of the third bundle and prior to cutting the rear bracing, the fourth bundle must be secured to the side of the container with a strap or chain. This is very important. If it is not secured to the container wall when the last bracing is cut, this fourth bundle will be loose and unstable when the third bundle is removed. Once the fourth bundle is secured by the Totall Clamp System, the chain can be safely removed. The removal of the bracing will be the same throughout the remainder of the container. Distrib- UNIT LOAD HANDLING SYSTEMS, INC SO. MISSION CIRCLE, FRIENDSWOOD, TX Manufac- TOTALL ATTACHMENTS, INC SPEERS ROAD, OAKVILLE, ONT L6L2X5

7 EXTRACTION PROCEDURE Using The T53 Totall Extractor Clamp System When the T53 Totall Clamp has entered as far as the upright crossmember or stone allows, a slight forward tilt is applied to the clamp. Lift is applied until the bundle is 4 to 6 inches off the floor under the posts. IMPORTANT: This angle and relationship of alignment between the clamp and stone MUST be retained all though the extraction process. In this photo the forklift has begun to descend tinclined dockplate. The operator has raised the lift cylinder to compensate as the forklift gets lower. The truck not only gets lower, it changes angles to the stone. The operator compensates using his forward tilt to keep the stone aligned as it was in the container. As the bundle slides down the dsockplate, the operator lowers the mast accordingly to keep the stone aligned to the clamp. If this is not done the stone will twist up and down during movement causing the posts to weaken or crack. Note that the 4 to 6 inches of elevation have been maintained all during the extraction. We see that the angle of the clamp to the stone has retained its slight forward tilt from the start and the stone has not tried to move within the arms. Distributed UNIT LOAD HANDLING SYSTEMS, INC SO. MISSION CIRCLE, FRIENDSWOOD, TX Manufactured TOTALL ATTACHMENTS, INC SPEERS ROAD, OAKVILLE, ONT

8 EXTRACTION PROCEDURE Using The T53 Totall Extractor Clamp System DO NOT DO THIS To understand the importance of extracting the stone on a level axis, that is, an axis parallel to the ground, look at this picture. It shows what happens when the operator backs down the dock plate ramp without adjusting the lift upward and the tilt forward. The stone bundle has followed the truck downward. The stone is trying to push into the dockplate, to go through the Earth. We can see the skid board bending and the posts ready to crack. In this situation it is impossible to pull the stone out and over the dock plate. This is dangerous to personnel and stone. The posts were weakened enough that chain had to be used to keep the bundle intact. Distrib- UNIT LOAD HANDLING SYSTEMS, INC SO. MISSION CIRCLE, FRIENDSWOOD, TX Manufac- TOTALL ATTACHMENTS, INC SPEERS ROAD, OAKVILLE, ONT

9 Slight tilt forward. Lift up with the fork so the bundle aligns to the clamp. 1 Make contact with the fork here. APPROACHING AND SECURING THE BUNDLE: Approach the bundle with slight forward tilt in the angle of the clamp in relation to the bundle. Drive the fork blade under the end of the bundle as far as possible. Leave 2-3" clearance between bundle and clamp face. Lift the bundle so the weight is on the fork. As the bundle lifts in contact with the fork blade it should align to the angle of the clamp. When the bundle is supported on the fork and is roughly parallel to the vertical clamp face, close the arms and clamp the uprights. Check Point: After clamping the arms will be approximately parallel with the top edge of the stone.

10 2 LIFTING AND MOVING THE BUNDLE: Lift up until the upright clears the floor by 4-6". As you lift, be sure to maintain the tilt angle so the stone is parallel to the clamp. Extract the bundle by backing the forklift straight back. Do not try to steer off line. As the stone moves backward, the far upright and the skid board are sliding on the floor. The angle created at lift is maintained. Be sure the wooden ties on the floor and any nails are removed before extracting. Check Point: As the stone moves, be sure the arms do not twist downward on the uprights. This will stress and crack the wood.

11 3 VIRTUAL LEVEL EXTRACTION The stone is moving horizontally as the truck begins extraction. If the warehouse floor and the container are on the same level, the dotted linbe is the level of traqvel for the truck. But, if the dock plate is angled downward severely, the truck, clamp and mast will tip away from the stone, prying the clamp arms off the uprights. Check Point: As the stone moves, be sure the arms do not twist downward on the uprights as the truck traverses the dock plate. This will stress and crack the wood.

12 4 PULLING THROUGH THE FLOOR As the fork lift truck descends the dock plate, it travels downward from the bundle. At first, the bundle seems to be OK, but as the truck gets farther down the ramp the uprights contact the floor. As the truck keeps moving down, the bundle wants to penetrate the floor. Continued extraction will cause damage to the wood and/or the stone.

13 5 Contact either place will cause damage or upright failure. FAILING TO ADJUST FOR LEVEL If the level and tilt is nopt adjusted as the truck declines the ramp, the clamp will hit the dockplate, the uprights will press down on the floor and the skid boards under the bundle can bow and break. The clamp will follow the forklift angles and may rip the uprights then snap loose. To prevent this, you must adjust the lift height to compensate for the forklift going lower as it backs out. You must also adjust the tilt of the mast forward to equal the angle of the dockplate. Check Point: Watch for and prevent any relative movement between the clamp and the edge of the stone. Keep the upright's base at 4-6" elevation.

14 6 ADJUSTING FOR LEVEL: Compensate for the fork lift truck descending. Tilt the mast forward as the truck tilts backward. Lift the mast so the stone stays at the same 4-6" height above the floor as the truck backs down the ramp.

15 7 LEVEL EXTRACTION The operator makes two adjustments constantly as the bundle moves out. Tilt is used to alter the mast angle as the truck enters and leaves the dockp plate while backing up. Tilt couteracts the tipped back angle of the truck on the dockplate. It keeps the clamp arms in stable, constant position on the uprights. However, Lift is performed constantly as soon as the truck steer wheels enter the dockplate. As the truck backs down the ramp, it may take as much as 12 inches more lift to keep the stone travelling level to the floor. The lift distance is dependant on the warehouse floor compared to the container floor. Lift and tilt adjustments prevent twisting the arms on the uprights and prevent trying to pull the stone through the container and the dockplate.