KAUP 3T456ZA, Operating Manual

Page 1: ...ting Fork Positioner 3T456ZA 3T496Z 3T496ZA 4T456Z 4T456ZA 4T496Z 4T496ZA T456Z T496Z Rotating Fork Positioner without sideshift Rotating Fork Positioner with sideshift T456ZA T496ZA Rotating Fork Positioner without sideshift with bolt on forks Rotating Fork Positioner with sideshift with bolt on forks ...

Page 2: ...ects 5 1 7 Limits of applicable use 5 2 Safety aspects 6 3 Design 7 3 1 Slide and flange 7 3 2 Rotator with mounting 7 3 3 Proper use of the equipment 8 3 4 Improper use 8 3 5 Hydraulic oil flow required 9 4 Installation and checking out 9 4 1 Installation 9 4 2 Checking out 11 4 2 1 Bleeding the hydraulic system 11 4 2 2 Adjustment after putting into service 11 5 Operation 12 5 1 General 12 5 2 L...

Page 3: ... of the Operating Manual 24 12 EC Declaration of Conformity Summary 24 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 0049 0 60...

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: ...anual 7 3 Design 3 1 Slide and flange An fork positioner consists of two carriages 1 on which sliders 2 are mounted The slides 1 are moved with cylinders 5 in the guide profiles 3 which are welded to the flange 4 3 2 Rotator with mounting ...

Page 8: ...ositioner 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 manual at all times Observance of the technical data on the identification plate on the attachment Adherence to the specified inspection and maintenance instructions 3 4 Improper use Exceeding t...

Page 9: ...crease wear Please refer to the following Specifications ISO Class Model family Oil flow 2328 l min 2 1T 2 5T 20 5 3 2 5T 4 8T 40 10 4 4 5T 5T 50 20 6T 8T 60 15 4 Installation and checking out 4 1 Installation Installation and commissioning should be performed by qualified and authorised personnel only Pay attention to a sufficient load carrying capacity of the lifting means The following are exam...

Page 10: ...orque of 190 Nm Replace the plug screw 6 in the gear box with the vent screw supplied Connect the hose lines 7 to the hydraulic connectors on the lift truck Before initial operation check the functions and the identification of the attachment with the movement directions of the operating elements operating lever joystick etc Mount the residual carrying capacity notice and identification of the ope...

Page 11: ...ystem 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 fully open to the fully closed position Inspect the hydraulic connections for leakage 4 2 2 Adjustment after putting into service The hydraulic system is under pressure During work on hydraulic components oil s...

Page 12: ...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 13: ...icient 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 Only...

Page 14: ...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 15: ...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 16: ... and damage After 50h every 500h thereafter Check screws 1 on the clamp body 2 slewing ring 3 11 on the slide 6 model T4xxZA Replace loose or damaged screws Torque the screws as specified in Chapter 6 1 General Weekly Grease Sliding pieces in brass 7 by way of the greasing nipples 10 Every 200h Check wear on Sliding pieces 7 ...

Page 17: ...e cylinder mount and nut of the cylinder 8 Cylinders are installed with axial clearance of 1 5 to 2 mm Yearly Inspect the heel of the fork 9 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 performed by the manufacturer of the fork or by o...

Page 18: ...Operating Manual 18 Original Operating Manual 6 3 3 Rotator mounting without sideshift 6 3 4 Rotator mounting with sideshift ...

Page 19: ...t 21 on the sideshifter housing 25 26 on the lower hooks 27 Replace loose or damaged screws Torque the screws as specified in Chapter 6 1 General Weekly Grease Sliding pieces 23 by way of the greasing nipples 22 Supporting rollers 28 on the lower hooks 27 as necessary Every 200h Check wear on Sliding pieces 23 Supporting rollers 28 Prevent entry of dirt water or moisture into the slewing ring Grea...

Page 20: ...liders 23 During installation pay close attention that the sliders 23 are seated correctly Then fit the complete rotating fork positioner as described in section 4 1 Replace defective supporting rollers 28 in the hooks 27 by removing the screws 26 Using suitable hoisting gear tilt the complete rotating fork positioner forwards away from the fork carriage on the lift truck Remove the bolts 29 in th...

Page 21: ...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 22: ...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 23: ...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 24: ... pallets 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 Con...