KAUP T 403G-1L, Operating Manual

Page 1: ... covering for white appliances 1 arm swivelling 2 contact pads per arm T403G 2L Appliance Clamp without sideshift and arms with rubber covering for white appliances 1 arm swivelling 2 contact pads per arm T414 1L Appliance Clamp with sideshift and arms with rubber covering for white appliances both arms swivelling T404 1L Appliance Clamp without sideshift and arms with rubber covering for white ap...

Page 2: ...ects 6 3 Design 7 3 1 Clamp with mounting 7 3 2 Clamping arms 7 3 3 Proper use of the equipment 8 3 4 Improper use 8 4 Installation and checking out 9 4 1 Installation 9 4 1 1 Appliance clamp 9 4 1 2 Pressure plate toe in preload adjustment as necessary and depending on attachment design 11 4 2 Checking out 12 4 2 1 Bleeding the hydraulic system 12 4 2 2 Adjustment after putting into service 12 5 ...

Page 3: ...n preload adjustment 25 6 3 9 Identification plate and caution board 26 7 Troubleshooting 27 8 Disposal 28 9 Transport 28 10 Decommissioning and storage 29 11 Spare parts list not part of the Operating Manual 29 12 EC Declaration of Conformity Summary 29 Our service department in Aschaffenburg will be happy to answer your technical questions and to provide additional support Technical Support 0049...

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: ...ed with sliders 3 Sideshift components 5 6 or hooks 7 8 are optionally attached to the clamp body 1 3 2 Clamping arms T403G 1L T413G 1L right or left arm T403G 2L T413G 2L right or left arm T403 1 T413 1 right or left arm T404 1L T414 1L right and left arm T403G 1L T413G 1L right or left arm T404 1 T414 1 right or left arm T404 2L T414 2L right and left arm T403G 2L T413G 2L right or left arm ...

Page 8: ... 1 onto which an arm carrier 2 is welded Two pressure plates 5 per arm are mounted so that they swing in the arm carrier 2 The pressure plates of the arms have rubber coverings that are glued or screwed on and that are adapted to the load requirements 3 3 Proper use of the equipment All models are suitable for the lifting and transport of white appliances e g washing machines refrigerators etc Pro...

Page 9: ... 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 examples of preferred lifting means Capacity 250 kg M16 1200 kg M16 2000 kg M16 Part no 9710160008 0360010201 0360010301 4 1 1 Appliance clamp ...

Page 10: ...ucks equipped with attachments which hold the load by power e g paper clamp shall feature control s with a secondary action to prevent unintentional release of the load Also take note in this respect of the operating instruction of the lift truck Before initial operation check the functions and the identification of the attachment with the movement directions of the operating elements operating le...

Page 11: ...achment design Adjust the toe in a or preload b by loosening the screws 1 Use the adjusting screws 2 to set the pressure plate 3 to the desired position Torque the screws 1 to 77 Nm The maximum clearance between pressure plate 3 and pressure plate support 4 should be 5mm 1 1 1 1 1 1 1 4 2 2 2 2 2 2 2 2 3 2 2 2 2 2 2 a b b 3 4 ...

Page 12: ... 2 1 Bleeding the hydraulic system Start the lift truck Move the sideshifter repeatedly in both directions to maximum extent Repeatedly cycle the clamp 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 spurting out can cause injurie...

Page 13: ...miting valve Attachments are adjusted ex factory to a pressure of 160 bar A change in pressure is necessary only if the load slips or is damaged Make the settings in the numerical sequence and in the direction of the arrows The pressure indication on the manometer gauge drops after clamping This is not a malfunction of the attachment being caused by the installation of a transmission ...

Page 14: ...hment as stated on the rating plate This figure always represents the load carried by two or more arms 5 2 Load handling Set the forks as wide apart as possible for the load to be carried Position the mast vertically and take up the load parallel to the floor Always transport pallets boxes and containers using both forks Drive the attachment up to the load to maximum extent Raise the load about 30...

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: ...idated by a significant modification of the attachment Modifications to the attachment may only be made with prior approval by the manufacturer 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 qual...

Page 17: ...Operating Manual Original Operating Manual 17 6 3 1 Clamp 6 3 2 Mounting with or without sideshift ...

Page 18: ... 200h Check wear on Sliding pieces 2 Sliding pieces 10 Supporting rollers 15 As necessary Renew worn sliders 10 by removing the hooks 14 Remove the complete clamp body 7 in the reverse order to that described in section 4 1 Replace the sliders 10 During installation pay close attention that the sliders 10 are seated correctly Then fit the clamp as described in section 4 1 Replace worn sliders 2 by...

Page 19: ...ove the defective supporting rollers 15 and replace them with new ones Remount the clamp body 7 in the reverse order After installing or removing a cylinder 6 always check the clearance between the cylinder mount and nut of the cylinder 8 Cylinders are installed with axial clearance of 1 5 to 2 mm 6 3 3 Clamping arms model T403G 1L T413 G 1L and T403G L T413G L As necessary Replace the worn rubber...

Page 20: ...20 Original Operating Manual 6 3 4 Right hand or left hand appliance polystyrene clamp arms for T403 1 T413 1 and T404 1 T414 1 models As necessary Replace the worn rubber covering 1 worn bars 2 by removing the screws 3 ...

Page 21: ...arings Screws 10 on the pressure plates 4 bars 2 and wear off bars 6 Screws 15 16 on the wear off bar 7 and cover sheets 5 Screws 19 20 on the clamping arm plates coated with rubber 21 22 optional Replace loose or damaged screws Torque the screws as specified in Chapter 6 1 General Every 200h Check wear on Coating 8 the coating on the clamping arm plates 21 22 optional Wear off bar 6 7 Bushes 14 1...

Page 22: ...arts again in the reverse order Renew the clamping arm plates coated with rubber 21 22 by removing the screws 19 20 Replace the plates 21 22 and reinsert the screws 19 20 Renew defective wear off bars 7 by removing the screws 15 and replacing the wear off bar 7 Refit the screws again 15 Renew the worn bushes 14 in the swing arm 1 by removing the nuts 13 and screws 12 Replace the bushes 14 Refit th...

Page 23: ...e screw 10 and bushes 9 Take off the pressure plate 4 to the side Replace the covering 8 or wear off bar 6 If the wear is only slight you can also turn the pressure plate 4 and wear off bar 6 through 180 Refit all parts again in the reverse order Renew defective wear off bars 7 by removing the screws 15 and replacing the wear off bar 7 Refit the screws again 15 Replace warn bushings 14 in the rock...

Page 24: ...413 1 and T404 1 T414 1 models After 50h then every 500h Check the screws 1 at the strips 2 3 at the spring plate 4 and spacer 5 Replace loose or damaged screws Tighten the screws to the torque given in Chapter 6 1 General Every 200h Check wear Of the strips 2 Of the pins 6 Of the pin 7 for the optional stop 8 Of the spring plate 4 ...

Page 25: ... and pin 6 Tap the pin 6 out of the arm 9 and remove the bale clamp 12 Remove the screw 3 from the spring plate 4 spacer 5 and bale clamp 12 Replace the spring plate 4 and re install spacer 5 spring plate 4 and the screw 3 Reinstall the bale clamp 12 using pin 6 washer 11 and cotter pin 10 Renew worn industrial grade hose 13 or pin 7 at the optional stop 8 by removing cotter pin 14 and washer 15 R...

Page 26: ...mber 1 Identification plate only by quality department 2 Before putting into operation carefully read and take note of the operating and security instructions 0100016401 3 Never reach into the unit as long as parts could still be moving due to the danger of squashing or shearing 0100016601 4 Use suspension point 0100015001 ...

Page 27: ...f truck s hydraulics Load not holding Pressure too low Increase the pressure from the lift truck Pressure too low on pressure relief valve Increase pressure on the pressure relief valve Cylinders have internal leaks Replace sealing kits Clearance Carriage has too much clearance Slider is worn Replace sliders Carriage tilts at outer limit Slider is worn Replace sliders Carriage rubbing against guid...

Page 28: ... kit defective Replace sealing kit Piston rod scored Replace piston rod and sealing kit Solenoid valve Not functioning Solenoid coil defective Replace solenoid coil No power to the magnet Inspect power cable and connections Legend FFZ lift truck DBV Pressure relief valve WE Drossel elbow type screwed throttle 8 Disposal Prevent environmental damage by disposing of the following items properly in a...

Page 29: ...list not part of the Operating Manual 12 EC Declaration of Conformity Summary KAUP GMBH Co KG Braunstraße 17 D 63741 Aschaffenburg we hereby declare that the machinery Model Appliance Clamp Type T403 1 T413 1 T403G 1L T413G 1L T403G 2L T413G 2L T404 1 T414 1 T404 1L T414 1L T404 2L T414 2L conforms to the latest valid version of the Machinery Directive 2006 42 EG The person authorised to compile t...