KAUP 3,5T 456BZ, Operating Manual

Page 1: ... Positioner 3 5T 4 5T 456BZ 3 5T 4 5T 456BZA 3 5T 4 5T 496BZ 3 5T 4 5T T496BZA T456BZ T496BZ Rotating Fork Positioner without sideshift Rotating Fork Positioner with sideshift T456BZA T496BZA Rotating Fork Positioner without sideshift with bolt on forks Rotating Fork Positioner with sideshift with bolt on forks ...

Page 2: ...y aspects 6 3 Design 7 3 1 Clamping body and flange 7 3 2 Rotator with mounting 8 3 3 Proper use of the equipment 8 3 4 Improper use 9 3 5 Hydraulic oil flow required 9 4 Installation and checking out 10 4 1 Installation 10 4 1 1 Model T456xx without sideshiftBZ 10 4 1 2 Model T496xx with sideshift 11 4 2 Checking out 12 4 2 1 Bleeding the hydraulic system 12 4 2 2 Adjustment after putting into se...

Page 3: ... not part of the Operating Manual 26 12 EC Declaration of Conformity Summary 26 Our service department in Aschaffenburg will be happy to answer your technical questions and to provide additional support Technical Support 0049 0 6021 865 395 0049 0 6021 865 284 0049 0 6021 865 352 Orders for spare parts Domestic 0049 0 6021 865205 0049 0 6021 865251 Orders for spare parts Export 0049 0 6021 865344 ...

Page 4: ... following symbols are used in this operating manual to highlight details of special importance Identifies details relating to do s and don ts for the purpose of avoiding injury and property damage Specific details relating to the efficient use of the attachment and other advice Lists are denoted by a shadowed box Steps to be performed by the operator are denoted by a black dot 1 In illustrations ...

Page 5: ...onents Inappropriate installation maintenance inspection and servicing Assignment of unqualified or non authorised personnel Claims raised by third parties 1 7 Limits of applicable use KAUP attachments are intended for use under the following climatic conditions Average ambient temperature for continuous operation 25 C Allowable maximum ambient temperature short term up to 1h 40 C Allowable minimu...

Page 6: ...a safe distance away from moving reciprocating or rotating parts of the attachment to avoid danger of crushing pinching or entanglement Notify the responsible department person immediately of changes and faults in operation of the attachment that affect safety The attachment shall be shut down Use aids to vision e g mirrors camera etc where goods being transported obstruct vision Only allow work o...

Page 7: ... Operating Manual 7 3 Design 3 1 Clamping body and flange An fork positioner consists of two carriages 1 on which sliders 2 are mounted The slides 1 are moved with cylinders in the clamp body 3 which are welded to the flange 4 ...

Page 8: ...ewed on top hooks 5 and screwed on bottom hooks 6 The optional sideshift 7 is fitted with supporting rollers 8 and screwed onto the basic plate 2 3 3 Proper use of the equipment Rotating fork positioner are intended for rotating loads such as crates containers etc that have been picked up with fork arms Proper use of the machine and or equipment includes the following Observance of the operating m...

Page 9: ...pment on the attachment such that the original mode of usage is changed e g fork extensions must be authorised by the manufacturer 3 5 Hydraulic oil flow required When the hydraulic oil flow is insufficient the speed of rotation of the rotary units at the attachments will be reduced When the hydraulic oil flow is too high the hydraulic oil temperature will raise which will reduce efficiency and in...

Page 10: ...ioning should be performed by qualified and authorised personnel only Pay attention to a sufficient load carrying capacity of the lifting means The following are examples of preferred lifting means Capacity 250 kg M16 1200 kg M16 2000 kg M16 Part no 9710160008 0360010201 0360010301 4 1 1 Model T456xx without sideshiftBZ ...

Page 11: ...tions indicated 1 Demount the lower hooks 2 Mount the attachment on the fork carriage of the lift truck 3 Check that the attachment is correctly seated in the centre lock 4 Mount the lower hooks 2 tightening the screws 5 with a torque of 190 Nm Replace the plug screw 6 in the gear box with the vent screw supplied ...

Page 12: ...nd before initial operation check the functions and the identification of the attached equipment with the movement directions of the operating elements operating lever joystick etc 4 2 1 Bleeding the hydraulic system Start the lift truck Move the sideshifter repeatedly in both directions to maximum extent Rotate the rotator left and right several times Repeatedly cycle the fork positioner from the...

Page 13: ...sport any load exceeding that specified on the residual load plate for the particular combination of lift truck and attachment Note the load bearing capacity of the attachment as stated on the rating plate This figure always represents the load carried by two or more fork arms The nominal capacity of the forks must exceed the load 5 2 Load handling Set the forks as wide apart as possible for the l...

Page 14: ...ficient distance of the load to the floor the ceiling to shelves etc If higher torque than specified is generated by the load the rotation device rotates uncontrolled or not at all This can lead to damage to the load and the attachment Note the torque given on the type plate of the attachment The torque given on the type plate refers to the pressure difference of 125 bar at the hydraulic motor Onl...

Page 15: ...they can result in a risk of accident The EC Declaration of Conformity by the manufacturer becomes invalid and you assume full responsibility in the case of accident Use only original spare parts from the manufacturer The hydraulic system is under pressure During work on hydraulic components oil spurting out can cause injuries Unload the system in accordance with the operating instructions of the ...

Page 16: ...nufacturer 6 3 Schedule for routine maintenance and lubricants Lubricants approved and recommended by KAUP Greases Note Lithium soap grease NLGI Class 2 e g Avialith 2 Designation DIN51825 K 2 K 30 Complex soap grease NLGI Class 2 e g Turmogrease Gel M 5 Foundry quality Teflon spray e g Wieds or Rivolta Only for plastic sections Hydraulic oil Series gear box 80 e g Avia Gear RSX 680 DIN 51517 Fill...

Page 17: ...kage and damage After 50h every 500h thereafter Check screws 1 on the clamp body 2 flange 3 4 on the flange 3 slewing ring 5 6 on the forks 7a sliding carriages 7 Model T4xxBZA Replace loose or damaged screws Torque the screws as specified in Chapter 6 1 General Weekly Grease Sliding pieces in brass 8 by way of the greasing nipples 9 ...

Page 18: ...lways check the clearance between the cylinder mount and nut 12 of the cylinder 11 Cylinders are installed with axial clearance of 1 5 to 2 mm Yearly Inspect the heel of the fork 13 for wear and cracks Remove forks from service when wear exceeds 10 of the thickness of the fork Bent forks are not safe to operate and their continued use should be prevented Straightening of forks may only be performe...

Page 19: ...Operating Manual Original Operating Manual 19 6 3 2 Rotator ...

Page 20: ...Operating Manual 20 Original Operating Manual 6 3 3 Rotator mounting without sideshift 6 3 4 Rotator mounting with sideshift ...

Page 21: ...ce loose or damaged screws Torque the screws as specified in Chapter 6 1 General Weekly Grease Sliding pieces 21 by way of the greasing nipples 20 Supporting rollers 26 on the lower hooks 27 as necessary Every 200h Check wear on sliding pieces 21 supporting rollers 26 Prevent entry of dirt water or moisture into the slewing ring Grease Slewing ring 3 by way of the greasing nipples 14 Gearing of th...

Page 22: ...pieces 21 Using suitable lifting tackle lift the Fork Positioner back onto the fork carriage of the forklift truck and re assemble the hooks 25 and screws 24 Replace defective supporting rollers 26 in the hooks 25 by dis assembling the screws 24 Using suitable lifting tackle tilt the complete Rotating Fork Positioner forwards and away from the fork carriage of the forklift truck and secure this po...

Page 23: ...by qualified and authorised personnel Fault Possible cause Correction Clamp Opening and closing No synchronism WE throttles on the cylinder unequally adjusted Adjust the WE throttles on the cylinder Movement too slow Insufficient fluid flow from truck s hydraulics Increase flow rate of truck s hydraulics Load not holding Pressure too low Increase the pressure from the lift truck Pressure too low o...

Page 24: ...e valve is too small Re bore the throttle valve or replace it with a larger one Jerky shifting action Supporting roller defective Replace supporting roller Sliders not properly lubricated Lubricate sliders Supporting roller does not rotate Supporting roller defective Replace supporting roller Housing scrapes on the conduit Slider is worn Replace sliders No cusion for backward position Cusion for b...

Page 25: ...ed Check weight and torque required Slides move downwards Load not clamped Clamp load Clearance Clearance too large Bevel gear defective Replace bevel gear RJ defective Replace RJ Flange tip forwards Bolts loose Tighten bolts or replace if necessary Oil leakage On motor Hydraulic motor leaks Change hydraulic motor Bolt loose Tighten bolt Shaft seal defective Renew shaft seal On gear box Filling le...

Page 26: ...allets These must not be damaged The attachment must be secured against slipping or tipping over on the support 10 Decommissioning and storage If the attachment is to be stored for an extended period all hydraulic connectors must be sealed against contamination and damage Store the attachment in a clean dry environment 11 Spare parts list not part of the Operating Manual 12 EC Declaration of Confo...