PIGGY BACK® Delivery System - Princeton Delivery Systems

PIGGY BACK® Delivery System - Princeton Delivery Systems
PIGGY BACK® Delivery System
EASY HITCH™ Truck/Trailer
3-Position Mounting Installation
Instruction Manual
PIGGY BACK® Delivery System
EASY HITCH™ Truck/Trailer
3-Position Mounting Installation
Instruction Manual
Manual Part No.: 625-253
Rev. 12/2004
Notice: The information in this manual was in effect at the time of printing. Princeton Delivery
Systems reserves the right to make improvements and changes in specifications or design, without
notice and without incurring obligation. Please check with your Princeton dealer for possible updates
or revisions.
955 West Walnut Street
Canal Winchester, OH 43110
(614) 834-5000
FAX: (614) 834-5001
IMPORTANT INFORMATION
The attached information provides suggested methods of mounting a Princeton PIGGY BACK® Delivery
System to a truck or trailer.
The truck manufacturer, truck body manufacturer, and/or the trailer manufacturer should be contacted for
information concerning load requirements and safe installation on their products.
The mounting methods described herein supersede any previous information.
This mounting assembly is covered by one or more of the following patents: 5,575,604 5,813,820 6,024,535.
While installing the Princeton PIGGY BACK® Delivery System mounting, the truck or trailer brakes must be
applied and wheels must be chocked so that no movement occurs.
The complete mounting system must be installed to provide proper mounting and to retain full PIGGY BACK®
Delivery System warranty.
Contact your State Highway Patrol for information concerning local load limits, width limits, and other limitations.
All welding must be done by certified welders with qualification in accordance with AWS D1.1.
Disconnect battery cables on the PIGGY BACK® Material Handler and the truck/trailer before welding or battery explosion may occur.
Contact Princeton for information concerning any special applications that are outside the scope of this procedure.
Contact Princeton if you have any questions about the mounting or operation of the PIGGY BACK® Delivery
System.
LIMITED WARRANTY
PRINCETON DELIVERY SYSTEMS WARRANTS THAT FOR INITIAL USE THIS VEHICLE IS FREE FROM
DEFECTS IN MATERIAL OR WORKMANSHIP. IF THIS VEHICLE IS DEFECTIVE UPON INITIAL USE,
CONTACT YOUR AUTHORIZED PRINCETON DEALER FROM WHOM IT WAS PURCHASED AND THE
VEHICLE WILL BE REPAIRED OF EXCHANGED FOR A NEW ONE. THIS WARRANTY EXCLUDES
DEFECTS OR DAMAGE DUE TO MISUSE OR NEGLECT.
THIS LIMITED WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER
RIGHTS THAT VARY FROM STATE TO STATE. THE FOREGOING WARRANTY IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES
OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT SHALL
PRINCETON DELIVERY SYSTEMS BE LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL OR
CONSEQUENTIAL DAMAGES WHETHER CONTRACT, TORT OR NEGLIGENCE. AS WITH ALL HEAVY
MACHINERY, THE USE OF THIS VEHICLE IS POTENTIALLY DANGEROUS IF THE OPERATOR DOES
NOT EXERCISE PROPER OPERATOR PROCEDURES PROVIDED FOR YOU IN THE OPERATOR
MANUAL AND HAVE READ AND BEEN INSTRUCTED ON THE PROPER LOADING AND UNLOADING
PROCEDURE FOR THE PRINCETON PIGGY BACK®.
Contents
1
General Information
5
2
Installation Kits
7
3
Major Component Photos
8
4
Fork Supports
9
5
Main Installation
10
6
Safety Chains
13
7
Tire Pad Installation
14
8
Truck/Trailer 7-Pin Wiring
16
9
Safety Signs
18
10
Detail Drawing
19
11
Mount Installation Check
20
ADDENDUM
A
Dump Bed
21
1
General Information
These illustrations describe the factory-approved methods of mounting a Princeton
PIGGY BACK® Delivery System to an owner's truck or trailer.
This section covers the general setup information on the PIGGY BACK® and truck or trailer.
NOTE: This information is necessarily general and is based on similar applications. Contact
Princeton and fill out a Mounting Application Form to assure your specific truck or trailer
application meets the requirements for installation of a Princeton PIGGY BACK® Delivery
System.
Figure 1
Dimensions
Axle Location
Axles as far to rear as possible while leaving clearance for the PIGGY
BACK® front tires. A minimum dimension of 27" for D45 and PB50 (33” for
PB65, Z-Series and E-Series units) is recommended from the rear of the
tire to the rear of the bed, with a maximum dimension of 48".
Height
The PIGGY BACK® be installed as high as possible to avoid contact with
the ground when driving the onto steep inclines, ramps, etc. The
minimum distance from the ground to the bottom of the truck or
trailer crossmember is 48”. Minimum recommended distance between the
front tires and the ground is 11" and between the rear tire and the ground
is 18".
Structural
Bed side and rear members-minimum C6 x 10.5 pounds per foot.
Bed cross members-minimum C4 x 7.7 pounds per foot, 10-12"
center to center.
Dimensions (cont.)
ICC Bumper
On trailers manufactured after 1-26-98, the ICC bumper may need to be
replaced with a certified bumper, similar to Sun Underride PN 103-114.
Electrical
On most trucks or trailers, tail light buckets will need to be relocated.
Tail, clearance and identification lights should be mounted as high as
possible to allow the PIGGY BACK® to be raised as close to the bed
bottom as possible to meet minimum ground clearance requirements.
Lights should be no wider than 54” (outside edge to outside edge).
Always check to insure proper light operation before and after tail light
relocation.
License Plate
The license plate bracket and light must be mounted such that they are
clearly visible when the unit is and is not on the truck.
Suspension
Air-ride suspension system is recommended.
Overhang
All overhang dimensions are with the rear wheel of the PIGGY BACK®
turned sideways.
Truck/Trailer Bed and Chassis Specifications
Standard Dimensions For Straight Truck
Chassis Data
Bed Data
A
B
C
D
E
F
G
H
I
92’ min.-102” max.
5” min.
16” min.-22” max.
53” max.
3” min.
2” min.
4” min.-6” max.
2.25” min.
6” min.-8” max.
Clearance Data
J
K
L
M
N
R
S
20’ min.
10” min.
34” min.
3/8” min.
3” min.
48” min.
_27” min. (D45 & PB50)_____ ____
33” min. - 48” max. (PB65, Z & E Series)
T
FLUSH AT REAR
THE INFORMATION CONTAINED HEREIN IS PROPRIETARY TO PRINCETON DELIVERY SYSTEMS OR ONE OF ITS CUSTOMERS AND SHALL NOT BE
USED, DUPLICATED OR FURTHER DISSEMINATED FOR ANY PURPOSE OTHER THAN THAT FOR WHICH IT IS FURNISHED WITHOUT THE WRITTEN
CONSENT OF PRINCETON DELIVERY SYSTEMS.
Dimensions (cont.)
Standard Dimensions For Trailer
Bed Data
A 92’ min.-102” max.
B 6” min.-8” max.
C 16” min.-22” max.
D 53” max.
E 3” min.
F 2” min.
Chassis Data
G 4” min.-6” max.
H
I
J
K 10” min.
L 38” min.-44” max.
Clearance Data
M 3/8” min.
N 4” min.
R 48” min.
S 27” min.(D45 & PB50) ____
_33” min.-48” max. (PB65, &
__E-Series)
T FLUSH AT REAR
THE INFORMATION CONTAINED HEREIN IS PROPRIETARY TO PRINCETON DELIVERY SYSTEMS OR ONE OF ITS CUSTOMERS AND SHALL NOT BE USED,
DUPLICATED OR FURTHER DISSEMINATED FOR ANY PURPOSE OTHER THAN THAT FOR WHICH IT IS FURNISHED WITHOUT THE WRITTEN CONSENT OF
PRINCETON DELIVERY SYSTEMS.
2
Installation Kit
A complete mounting kit as described below is available from Princeton
Delivery Systems.
P90.1070 Easy Hitch, 3 Position, Mounting Kit
Parts List
Item
Description
Quantity
P80.07B
Kit, 7 Pin Trailer Receptacle
P90.321A
Tubing, Mount Kit
P10.376C
Chain Loop
P90.291B
Chain Assembly
P90.1073
Kit, Front Tire Pad Mtg.
P90.1067C
Weldment, Hanger Plate
P90.292A
Gusset, Hanger Plate
P90.269B
Gusset
P90.1069B
Bed Strengthener
P90.303B
Shaft, Hook Mtg.
118-115
Snap Ring, 2" Dia.
402-108
Hitch Pin
604-190
Decal, Patent in Process
604-127
Decal, PIGGY BACK® Transport
604-143
Safety Sign Warning
604-152
Safety Sign, Warning Mounting
604-125
Safety Sign, Pinch Point
Optional items that can be purchased
103-114
Sun Underride Protection Asm.
P10.970B
Hook Right (Weld To Older, D5000 & Dump Units)
P10.969B
Hook Left (Weld To Older, D5000 & Dump Units)
1
2
2
2
1
2
6
8
2
2
4
2
3
1
1
1
4
1
1
1
3
Major Component Photos
Safety Chain P/N P90.291B (2)
Retaining Ring P/N 118-115 (4)
Weldment, Hanger Plate P/N P90.1067C (2)
Tire Pad Kit P/N P90.1073 (1)
Hitch Pin P/N 402-108 (2)
Shaft P/N P90.303B (2)
Chain Loop P/N P90.376C (2)
Gusset P/N P90.269B (8)
Wire Harness P/N P80.07B (1)
Bed Strengthener P/N P90.1069B (2)
4
Fork Supports
EASY HITCH™
Material Required
Only one method of fork supports is approved with the Easy
Hitch™ mounting system. The Transverse Mount uses two 2” x 4”
rectangular tubes parallel to the truck axle. This method can be
used on PIGGY BACK® Delivery Systems with block forks or
pallet forks.
Description
Quantity
2
Installation
Part No.
Steel Rectangular Tubing
2” x 4” x 1/4” wall x 48” long
ASTM A-500, Gr. B
P90.321A
The 48” tubing can be cut down to fit between the truck rails.
However, it must be long enough to support all of the forks.
If the forks on the PIGGY BACK® Delivery Systems are 36” or
longer, space the tubes at a 30” centerline with the bottom of the
front tube level with the top of the rear tube. The distance between
the bottom of the rear truck or trailer sill and the top of the rear
transverse tube should be 3” min. Make sure both tubes are
square and weld the tubing to the frame rails.
B
NOTE:
The bottom of (front transverse tube) must be in the same
plane or lower than the top of (rear transverse tube). IF the
bottom of B is higher than the top of A, the PIGGY BACK®
will not have enough tilt to angle the front tires away from the
tire pads when mounting and the PIGGY BACK's mounting
hooks will NOT reach the mounting pins.
A
IF the PIGGY BACK's hooks will not reach the mounting
pins, check the Tire Pad’s location.
B
A
Figure 2
5
Main Installation
Hanger Plate
Installation Procedure
Cut notches in c-channel at rear of bed as shown in Figure 3.
Clean weld area.
Figure 3
Measure centerlines of the truck or trailer bed crossmembers.
Install P90.292A (1/2 “ x 3” x 3”) Plates in the P90.1067C Hanger
Plate Weldments at each crossmember dimensional centerline as
shown in Figure 4 and Figure 5. Tack weld in place.
Figure 4
Figure 5
5
Main Installation (Cont.)
Hanger Plate
Installation Procedure
Install Hanger Plate Assemblies (P90.1067C with P90.292A
Gussets) at 67” centerlines as shown in Figure 6 and Figure
7. Square the assemblies and clamp them in place.
Figure 6
Figure 7
Install the gussets connecting the Hanger Plate Assemblies and
the main c-channel as shown in Figure 8, and tack weld into place.
If gussets are too long, trim to fit. Do not move Cradle Plate
Assemblies.
Check to insure the Hanger Plate Assemblies are still square and
at 67” centerline.
Figure 8
5
Main Installation (Cont.)
Hanger Plate
Installation Procedure
Weld Hanger Plate Assembly to the rear c-channel as shown.
Figure 9
Prepare the Bed Strengtheners for installation as shown in Figure
10 (right shown, left opposite). Chamfer the notch to allow the Bed
Strengtheners to fit over the Cradle Plate Assemblies. Also,
chamfer the strengtheners to allow them to be welded together.
Figure 10
Locate Bed Strengthener, clean notches, and tack weld into place.
Figure 11
Complete finish welding as shown in Figure 9 and Figure 11.
Install Shafts with Snap Rings in each Hanger Plate Assembly.
Install Hitch Pins.
6
Safety Chains
The safety chains are designed to provide a compact, easy to use
method of securing the PIGGY BACK® Delivery System.
Material Required
Description
Quantity
2
2
1
Chain Assembly
Chain Loop
P90.291B
P10.376C
One P90.291B consists of the following:
Chain 1/2" high test Gr. 43
606-108
working load rating 9,200 lb.
1
5/8" shackle w/ bolt and nut
working load rating 10,000 lb.
606-106
1
7/16" clevis slip hook w/ latch
working load rating 7,200 lb.
606-107
NOTE:
Installation Procedure
Part No.
Standard chains may NOT be substituted.
Position the chain loops on the truck/trailer as shown in Figure 12.
Weld the chain loops securely to the truck/trailer.
Ensure that the Swing Latch Hook reaches the Mounting Bolt
when the PIGGY BACK® Delivery System is mounted.
Chain Loop
Truck/Trailer
Chain
PIGGY BACK®
Coupler
Swing Latch Hook
Figure 12
7
Front Tire Pads
Material Required
Front Tire Pads as shown in Figure 14 reduce the loading on the mast
structure and bearings. The pads should be installed so that they contact
evenly and on the centerline of the tires.
Part No. P90.1073 Kit contains the following:
Quantity
2
1
1
8
8
6
For Standard Models
Description
Upper Base Plate
Tire Pad Weldment, Left
Tire Pad Weldment, Right
Bolt, 3/4”-10 x 2” Long, Grade 8
Lockwasher, 3/4”
Gusset Plate
Part No.
P90.1107B
P90.971C
P90.976C
8301210160
8111200000
P90.1074B
The horizontal distance from the center of the Cradle Plate Shaft to the
Tire Pad is 26 1/4" thru 33 1/2” (See Fig. 14). The vertical distance from
the center of the Cradle Plate Shaft to the Ground should be 48 5/8”
minimum.
IMPORTANT NOTE:
If the PIGGY BACK® has front tires other than 31" diameter, fork positioner attachment, or was produced for Home Depot, these dimensions may not be correct. Contact Princeton for information on
these applications.
Welding Base Plates P90.1107B
Figure 13
7
Front Tire Pads (Cont.)
Installation
Install the Upper Base Plates (P90.1107B) by inserting the one inch tabs into the
Hanger Plate Weldment slots. Clamp and tack weld the Base Plates in position. Weld
inside of upper Base Plates to Crossmembers. To support the front edge of Base Plate
P90.1107B, use a Gusset Plate (P90.1074B). Weld one Gusset Plate to the end of the
Hanger plate as shown in Figure 13 to provide a surface to continue the weld on the
edge of the Base Plate. Also tack weld a Gusset Plate (P90.1074B) between the
Hanger Plate and the truck bed side member. Clamp and tack weld a Base Plate to
rear edge of base plate as shown in Figure 13. When setting Gusset Plates front and
rear, set the plates at an angle to Base Plate for increased strength. If material was
removed from the frame to weld the Upper Base Plate in place, replace material to
retain the beds structural integrity.
Install Tire Pad Weldments with 3/4”-10 x 2” Lg. Grade 8 Bolts and lockwashers. Refer
to Figure 14 for proper location of Tire Pad Weldments. If a PIGGY BACK® is available,
check tire pad placement by mounting the unit. Remove Tire Pads and finish welding
Base Plates.
NOTE:
The distance from the centerline of the mounting pin to face
of tire pad is critical! IF the dimension is greater than the
distances listed, the lifts will "sag" when the pressure is
released from the tilt. IF the lift's hooks will not reach the
mounting pins, check the transverse tubes.
Figure 14
8
Truck/Trailer 7-Pin Wiring Kit
Material Required Quantity
1
Installation
Description
Truck/Trailer Receptacle Kit
Part No.
P80.07B
To determine the location of the receptacle, mount the PIGGY BACK® to the
truck/trailer. Since the PIGGY BACK® receptacle is located in its left side, locate
receptacle to the left side of the truck/trailer. The coil plug provided with the PIGGY
BACK® is approximately 12 feet long at full extension for mounting location flexibility.
With the unit mounted, insert the coil plug into the receptacle on the left side.
Stretch the cable to the truck/trailer to determine a convenient and protected
location for the truck/trailer receptacle.
With the receptacle location determined, lay out the mounting holes.
Drill or torch out a 2" diameter through hole for the receptacle body.
Feed the receptacle harness through the hole and mark the location of the mounting
holes. Drill 2 holes, 3/16" diameter for self-tapping mounting screws. Secure the
receptacle to the truck/trailer with the screws.
Wiring - Trailer
With the seven tap-in connectors provided, splice into the trailer wiring. In the package,
there will be six blue and one yellow wire taps. The yellow tap is for the white wire or
ground.
All wiring is required to be color coded to S.A.E. Standards. Use Table 1 to locate
the proper wire for trailers that have separate turn lamps & stop lamps.
If you have taken the unit off the trailer, reload to check electrical installation. Install
coil plug from your trailer to the receptacle on the left side of the forklift. The plug can
go in only one way to ensure proper alignment of wires.
Wiring - Truck
With the seven tap-in connectors provided, splice into the truck wiring. In the package,
there will be six blue and one yellow wire taps. The yellow tap is for the white wire or
the ground.
All wiring is required to be color coded to S.A.E. Standards. Use Table 2 in to locate
the proper wire for trucks which have combined turn lamps & stop lamps.
To use both lights on each side of the PIGGY BACK®, cut the red wires to the out
side lamps and at the connector. On the left pair, install a jumper wire to connect to the
yellow wire on the inside lamp to the red wire on the outside lamp. On the right pair,
install a jumper wire to connect to the green wire on the inside lamp to the red wire on
the outside lamp.
8
Truck/Trailer 7-Pin Wiring Kit (cont.)
If you have taken the unit off the truck/trailer, reload to check electrical installation.
Install coil plug from your truck/trailer to the receptacle on the left side of the forklift.
The plug can go in only one way to insure proper alignment of the wires (Figure 15).
Table 1 - Wiring Circuits - Trailer with Separate Stop and Turn Lamps
Conductor Wire Color
Lamp and Signal Circuits
Wht
White
Ground return to towing vehicle
Blk
Black
Clearance, side marker, and identification lamps
Yel
Yellow
Left-hand turn signal and hazard signal
Red
Red
Stop lamps and anti wheel lock devices
Grn
Green
Right-hand turn signal and hazard signal
Brn
Brown
Tail and license plate lamps
Blu
Blue
Back-up lamps
Table 2 - Wiring Circuits - Truck with Single Stop and Turn Lamps
Lamp and Signal Circuits
Conductor Wire Color
Wht
White
Ground return to towing vehicle
Blk
Black
Clearance, side marker, and identification lamps
Yel
Yellow
Left-hand turn signal, hazard signal, and stop lamp.
Red
Not Used.
Grn
Green
Right-hand turn signal, hazard signal, and stop lamp.
Brn
Brown
Tail and license plate lamps
Blu
Blue
Back-up lamps
Figure 15
9
Safety Signs
Install safety sign 604-127 (shown below) on the truck dashboard or other
prominent area.
Install safety signs 604-143 and 604-152 (shown below) at the rear of the
truck/trailer.
Install safety signs 604-125 (shown below) on the Cradle Plates & Tire Pads of
the truck/trailer.
10
Detail Drawing
P90.1107B
P90.1107B
Component Identification (Contact Princeton if additional drawings are needed.)
11
Mount Installation
Check
Mount the unit per 625-244 and check all points of installation including fit
and function.
Make sure 7-pin connector mates and safety chains are the right lengths.
The PIGGY BACK® Delivery System may be equiped with an Automatic
Tilt Release. Check for proper operation at this time. Leave the PIGGY
BACK® away from the Tire Pads. Depress the brake pedal on the truck or
activate hazard lights on the trailer and look for PIGGY BACK®
movement.
Installation is now complete.
Figure 16
ADDENDUM A DUMP BED
P90.1151
Easy Hitch, 3 Position, Dump Bed, Mounting Kit
Parts List
Item
Description
P80.07B
P90.321A
P10.376C
P90.291B
P90.1073
P90.424C
P90.292A
P90.269B
P90.1069B
Kit, 7 Pin Trailer Receptacle
Tubing, Mount Kit
Chain Loop
Chain Assembly
Kit, Front Tire Pad Mtg.
Weldment, Hanger Plate
Gusset, Hanger Plate
Gusset
Bed Strengthener
Qty
1
2
2
2
1
2
6
8
2
Item
Description
P90.303B
118-115
402-108
604-190
604-127
604-143
604-152
604-125
Shaft, Hook Mtg.
Snap Ring, 2" Dia.
Hitch Pin
Decal, Patent in Process
Decal, PIGGY BACK® Transport
Safety Sign Warning
Safety Sign, Warning Mounting
Safety Sign, Pinch Point
Qty
2
4
2
3
1
1
1
4
IMPORTANT NOTES:
1. If the PIGGY BACK® has non-standard mast height, front tires other than 31" diameter, fork positioner attachment, or
was for Home Depot, these dimensions will not be correct. Contact Princeton Delivery Systems for information on these
applications.
2. Bed of vehicle is required to be tied down when Piggy Backing the fork lift. If the vehicle does not come with bed tie
downs, tie downs may be purchased from Princeton Delivery Systems, PN 629-109. Two required per vehicle.
3. If bed frame rail is a C-Channel, the frame will require stiffening from end of bed past hinge point by at least two feet.
4. A ramp may be required at the leading edge of the 6x6 angle bed stiffener to facilitate dumping without catching load on
front lip.
ADDENDUM A DUMP BED (Cont.)
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