Princeton PIGGYBACK EZ HITCH Installation Instructions Manual

Truck/trailer mounting

Hide thumbs

Table Of Contents

Table of Contents

Quick Links

Princeton PIGGYBACK

EZ HITCH™ Truck/Trailer

Mounting Installation

Instruction Manual

Rev. 8/2016

Table of Contents

Need help?

Do you have a question about the PIGGYBACK EZ HITCH and is the answer not in the manual?

Questions and answers

Summary of Contents for Princeton PIGGYBACK EZ HITCH

Page 1 Princeton PIGGYBACK ® EZ HITCH™ Truck/Trailer Mounting Installation Instruction Manual Rev. 8/2016...
Page 2 Instruction Manual Manual Part No: 625-268 Rev. 8/2016 Notice: The information in this manual was in effect at the time of printing. Princeton PIGGYBACK ® 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.
Page 3 Contact your local State Highway Patrol for information concerning local load limits, width limits, and other limitations. The Princeton EZ Hitch Mounting System incorporates three safety features for proper trans- port of a PIGGYBACK forklift. The frame hooks, safety chains and hitch pins. All three of ®...
Page 4 ® 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.
Page 5: Table Of Contents
Contents General Truck/Trailer Requirements Installation Kits Major Component Photos Fork Supports Main Installation Tire Pad Installation Safety Chains Truck/Trailer 7-Pin Wiring Safety Signs Dump Bed Style EZ Hitch™ Underride M22416 Special Mounting Mount Installation Check Truck/Trailer Weighing Procdures Truck/Trailer Analysis Sheets...
Page 6: General Truck/Trailer Requirements
® 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 transport vehicle application meets the requirements for installation of a Princeton PIGGYBACK ®...
Page 7 Dimensions (cont.) Frame Structure 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. Rear Sill Truck/trailer rear sills must be of adequate strength for supporting the mounted PIGGYBACK forklift.
Page 8 Dimensions (cont.) Truck/Trailer Bed and Chassis Specifications Chassis Data Clearance Data 92’ min.-102” max. 20’ min. 5” min. 10” min. 16” min.-22” max. 34” min. 53” max. 3/8” min. 3” min. 3” min. 2” min. 48” min. 4” min.-6” max. S _____ ____33”...
Page 9: Installation Kits
Installation Kit ™ A complete EZ Hitch mounting kit as described below is available from Princeton PIGGYBACK ® P90.2360 EZ Hitch Mounting Kit w/Adjustable Tire Pads Parts List Item Description Quantity P10.376C Chain Loop P80.07B 7-Pin Harness P90.269B Main Gusset P90.292A...
Page 10: Major Component Photos
Major Component Photos Shaft P/N P90.303B (2x) Retaining Ring, P/N 118-115 (4x) Hitch Pin w/Clip, P/N 402-105 (2x) Bed Strengthener P/N P90.1069B (2x) Hanger Wldmt. P/N P90.1067C (2x) Base Plate Wldmt. P/N P90.2352 (2x) Adj. Tire Pad Kit P/N M25716 (1x) Transverse Tube P/N P90.321A (2x) Main Gusset P/N P90.269B (8x) (LHS &...
Page 11: Fork Supports
Transverse Tube Install The 48” long tubing can be cut down to fit between the truck/trailer main rails, however, it must be long enough to support all of the forks. If the forks on the Princeton PIGGYBACK are 36” or ®...
Page 12: Main Installation
Main Installation Transverse Tube Install (Cont.) In special instances, where there is a conveyor or boom mechanism, that extends beyond the rear sill of a transport vehicle, a ‘low fork tine setup’ may be necessary. The minimum distance of the rear transverse tube, from the top surface to level ground should be set between 18”...
Page 13 Main Installation (Cont.) Hanger Plate Install 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.
Page 14 Main Installation (Cont.) Hanger Plate Install (Cont.) Weld Hanger Plate Assembly to the rear c-channel as shown. 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.
Page 15 Tire Pads Tire Pads reduce the loading on the mast structure and bearings. There are two types of tire pad designs. The first design is the older 3-position vertical tire pads, which require removing 4x bolts to adjust position (These tire pads are and used in conjunction with P90.1107B Base Plate Weldments only).
Page 16 Tire Pads (Cont.) Installation of Tire Pads The Adjustable Curved Tire Pads are designed to install in the former base plate, P90.1107B (3-Position Vertical Tire Pad system) and the current P90.2352. The Tire Pads are adjustable in 1” increments, by removal of just one bolt and lynch pin. Mount each Tire Pad (LHS &...
Page 17 Tire Pads (Cont.) Tire Pad Position Nomenclature The Adjustable Curved Tire Pads can be positioned in 1” increments by utilizing two pin bosses in the Tire Pad and horizontal holes in the Track Weldment. The two pin bosses are noted from operator’s view and labeled ‘Rear’ and ‘Front’ as shown in Figure 13.
Page 18: Safety Chains
™ no longer included in the EZ Hitch mounting kits (Must be purchased separately, through Princeton Parts Dept.). Safety Chain, prior and incl. up to 2013 (P/N P90.291B) 1.) 5/8” Shackle, P/N 606-117. 2.) Slip Hook, P/N 606-107 or 606-115.
Page 19 Safety Chains (Cont.) Safety Chain Selection To select the proper Safety Chain for your PIGGYBACK forklift, you ® must first identify, the frame mounting point style (clevis or pin style) as shown below. The clevis style mounting point is designed to accept the 3/8”...
Page 20 Truck/Trailer 7-Pin Wiring Kit Material Required Quantity Description Part No. 7-Pin Receptacle Kit P80.07B Installation For placement of the 7-pin receptacle, mount the PIGGYBACK to the transport ® vehicle. The PIGGYBACK receptacle is located on the left side, so locate the ®...
Page 21: Truck/Trailer 7-Pin Wiring
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 as shown in Figure 15 below.
Page 22: Safety Signs
Safety Signs Install safety sign 604-127 (shown below) on the truck dashboard or other prominent area inside the cab. Install safety signs 604-143 and 604-152 (shown below) at the rear of the transport vehicle (Rear Sill). Install safety signs 604-125 (shown below) on the Cradle Plates & Tire Pads of the transport vehicle.
Page 23: Dump Bed Style Ez Hitch
Dump Bed Style EZ Hitch ™ Some transport vehicles have a bed that elevates at an angle hydraulically to unload cargo. This type of bed is called a Dump Bed and requires a different style of ™ Hanger Plate Weldment. There is a Dump Bed EZ Hitch mounting kit available, P/N P90.2362.
Page 24 Dump Bed Style EZ Hitch™ (Cont.) P90.2362 EZ Hitch Dump Bed Mounting Kit w/Adjustable Tire Pads Parts List Item Description Quantity P10.376C Chain Loop P80.07B 7-Pin Harness P90.269B Main Gusset P90.292A 3x3 Gusset P90.303B Shaft Pin P90.321A Transverse Tubing P90.424D Dump Bed Hanger Plate Weldment P90.1069B Bed Strengthener...
Page 25: Underride M22416
Princeton Piggyback, a product of Hiab US, offers a certified replacement bumper kit, M24416. This is a direct replacement for the previous supplied 628-258.
Page 26 Underride M22416 (Cont.) Underride Installation 1.) With the trailer unloaded, on a flat level surface, tires and air suspension properly inflated, note the location of the existing underride bumper (distance from bottom surface to ground and offset from rear sill). See figure 17 on next page. 2.) Completely remove existing underride bumper from rear of trailer.
Page 27 Underride M22416 (Cont.) Underride Installation 5.) If necessary, using the existing underride bumper location dimension, cut both Rear Upright Tubes (M23193-3), so the bottom surface of the new underride bumper (main tube) is at the former location, but no higher than noted below in figure 19. Keep in mind, the higher the bumper the bet- ter the chance of interference with trailer/mounting components, when it’s in the stowed position.
Page 28 Underride M22416 (Cont.) Underride Installation 6.) Cut the Front Upright Tubes (M22463), so that their overall length is 1-1/4” shorter than the Rear Upright Tubes. 7.) Prep. Front & Rear Upright Tube (M23193-3 & M22463) ends by grinding a minimum 1/8” to 3/16”...
Page 29 Underride M22416 (Cont.) Underride Installation Figure 21 13.) After ensuring the Foldable Underride Bumper doesn’t interfere with any mounting or trailer components in the stowed position, weld kit components, per ANSI/AWS D1.1. See figure 22 below. 14.) Re-install/relocate any items removed from steps 2. 15.) Paint newly installed underride bumper components to match customer specification.
Page 30: Special Mounting
Special Mounting Box Truck/Trailer, Softside or Curtainside Special consideration must be given to transport vehicles that have enclosures built around the beds of truck or trailers. These types of enclosures are called ‘Box Truck/Trailers’, ‘Soft Sides’ or ‘Curtainsides’. Items such as the rear door, lock rods and rear door hardware, can cause interfer- ence with the PIGGYBACK , during the mounting process.
Page 31 Special Mounting (Cont.) Box Truck/Trailer, Softside or Curtainside Picture to the left shows a ‘Box Trailer’ with rear sill build-out and ‘Dump Bed’ style Hanger Plate Weldments, P90.424D. Composite Trailer Another special consideration, that needs to be addressed is a Composite Trailer. Composite Trailers have an aluminum bed, but steel frame work.
Page 32 Special Mounting (Cont.) Composite Trailer Special Instructions Underride Protection, P/N M24416...
Page 33 Special Mounting (Cont.) Composite Trailer Special Instructions Replace the last 48” to 52” with steel members...
Page 34: Mount Installation Check
Mount Installation Check 1.) Check that the front tire pressures are correct, per the rating on the tire sidewall. 2.) Position both tire pads, per the particular forklift model. Check that the Pin Bolt Nuts are tight and that the Lynch Pins are in their locked position. 3.) Check that the 4x mounting bolts on both Track Weldments are torqued properly.
Page 35: Truck/Trailer Weighing Procdures
® prediction of the weight distribution resulting from the installation of the Princeton forklift. One of the most important pieces of information required for the completion of an accurate weight distribution is the curb weight of the empty truck. Be sure to record the condition of the truck when taking weight measurements –...
Page 36 Truck/Trailer Weighing Procedures (Cont.) Trailer Curb Weights 1. With the empty trailer connected to the tractor, drive the tractor onto the scale, as shown below. Measure the weight on the axles, and record all three weights. 2. With the trailer removed from the tractor, drive onto the scale as shown below. Measure the weight on the axles, and record both weights.
Page 37 Princeton Delivery Systems 0 Dove Parkway Canal Winchester, Ohio 43110 1-800-331-5851 www.piggy-back.com TRUCK MOUNTING APPLICATION ANALYSIS Fax Forms to: 614-834-50 Step 1. Input Customer and General Analysis Information. Customer: Analysis Date: Street Address: Phone: City, State & Zip: Fax: Contact:...
Page 38 Princeton Delivery Systems 0 Dove Parkway Canal Winchester, Ohio 43110 1-800-331-5851 www.piggy-back.com TRUCK MOUNTING APPLICATION ANALYSIS (CONTINUED) Customer and General Analysis Information Customer: Date: Street Address: Phone: City, State & Zip: Fax: Contact: Email: Truck Make: Truck Model: Step 8. Input truck geometry information:...
Page 39 All Steel Composite Steel & Aluminum All Aluminum Other If Other Specify: If bed construction is composite or all aluminum check with Princeton for special instuctions. Step 5. Select Piggyback Model: Other Step 6. Select Mast Height Option: D45, PB40, PB45, PB50, PB55, PBX, PBL (Class II Mast) PB65, PB70, PB80 (Class III Mast) 86"...
Page 40 Distance landing gear to rear axle(s) center (KL): Note: if H is less than 48 inches must use Princeton Top Mount or High Mount. If S is less than 36" contact Princeton for options. Step 9. Input Trailer Weight Information: (Specify weight on kingpin or landing gear.