KAUP T 405B, Operating Manual

Page 1: ...SAP 100603 en Operating Manual Original Operating Manual 1 Edition 09 14 Subject to modifications Drum clamp T 415B T 405B T 415B Drum clamp with sideshift T 405B Drum clamp without sideshift ...

Page 2: ...lation 8 4 1 1 Drum clamp with sideshift 9 4 1 2 Drum clamp without sideshift 10 4 2 Checking out 11 4 2 1 Bleeding the hydraulic system 11 4 2 2 Adjustment after putting into service 12 5 Operation 13 5 1 General 13 5 2 Load handling 14 5 3 Driving 14 6 Maintenance and servicing 14 6 1 General 14 6 2 Significant modification 15 6 3 Schedule for routine maintenance and lubricants 16 6 3 1 Pressure...

Page 3: ...ions 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 6021 865348 Outside of normal business hours the Kaup Service Hotline is available to you 365 days a year 0049 0 172 6295 297 Monday Friday 17 00 7 00 Uhr Sa...

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: ...ping body 1 A middle frame 8 is operated by a hydraulic cylinder 9 which then moves the inner slide 11 with a chain 10 A pivoting pressure plate 13 is attached to the arm 12 This pressure plate 13 has replaceable rubber elements 14 For sideshift versions the beer keg clamp is installed to the fork carriage using upper sideshift elements 15 roller bearing supported spacers 16 and lower hooks 17 or ...

Page 8: ...nce of the technical data on the identification plate on the attachment Adherence to the specified inspection and maintenance instructions 3 2 Improper use Exceeding the allowable load capacity and load centre Dragging or pushing loads with the attachment Transporting persons with the load or load handling devices Mounting auxiliary equipment on the attachment such that the original mode of usage ...

Page 9: ...ower 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 Ensure correct seating of the spacers 7 Mount the lower hooks 2 tightening the screws 5 with a torque of 190 Nm Connect the hose lines 6 to the hydraulic connectors on the lift truck 1 2 3 4 7 5 6 6 ...

Page 10: ...ction 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 lever joystick etc Mount the residual carrying capacity notice and identification of the operating elements if not already present of the combination of lift truck attached equipment on the lift truck 4 1 2 Drum clamp without...

Page 11: ... identification of the operating elements if not already present of the combination of lift truck attached equipment on the lift truck 4 2 Checking out KAUP attachments are delivered pre lubricated If the attachment has been in storage for a longer period we recommend that it be lubricated again before being placed in service See 6 Maintenance and onwards Failure of the safety devices e g the pres...

Page 12: ...ek out a specialist immediately Synchronising the arms The synchronization of arms is adjusted ex factory This can alter for different friction conditions wear temperatures and volumes conveyed Perform a readjustment The recommended working temperature of the hydraulic fluid is approx 35 C The synchronisation or speed of the cylinders can be set with two valves on the cylinder bottoms X Setting th...

Page 13: ... defects Repeat faults to your superior and have them rectified without delay Be aware of persons present in the area where you are working or driving and ensure that they are not endangered Do not transport any load exceeding that specified on the residual load plate for the particular combination of lift truck and attachment Operate the sideshifter only with the load raised freely 10 cm Close th...

Page 14: ...o contact with the ground Driving with the load stabiliser opened may cause damage to supporting components During driving make sure that the load stabiliser either abuts on the load or is closed completely 6 Maintenance and servicing 6 1 General Regular maintenance is essential to ensure reliable operation and long service life of the KAUP attachment Ensure that maintenance and servicing are perf...

Page 15: ...which are visibly damaged Note the following tightening torques which are valid for screws with connecting surfaces according to ISO 4762 ISO 4014 ISO 4032 etc Screw bolt rating 8 8 10 9 12 9 M6 thread 9 3Nm 14Nm 16Nm M8 thread 23Nm 33Nm 39Nm M10 thread 45Nm 66Nm 77Nm Μ12 thread 77Nm 115Nm 135Nm Μ16 thread 190Nm 280Nm 330Nm Μ20 thread 385Nm 550Nm 640Nm Failure of the safety devices e g the pressur...

Page 16: ...n into account by the owner With other loads such as fork arms with a length of over 2 400 mm or raised load centres amended shorter maintenance intervals should be agreed by the user with the manufacturer 6 3 1 Pressure plate Daily Ensure that the screw 1 with plain washers 10 is mounted and tightened This screw is used as a limit stop and prevents uncontrolled moving out of the slide 2 As necess...

Page 17: ...Operating Manual Original Operating Manual 17 6 3 2 Load stabilizer 41 26 23 27 41 5 10 11 2 3 18 22 4 24 20 19 21 25 13 16 1 12 23 32 ...

Page 18: ...for leakage and damage After 50h every 500h thereafter Check screws 1 on the slide 2 3 on the picket 4 and clamping body 5 6 and nuts 7 on the forks 8 and slide 9 Replace loose or damaged screws Torque the screws as specified in Chapter 6 1 General 6 7 8 9 26 27 30 31 34 35 39 38 40 37 5 29 28 15 14 36 ...

Page 19: ...ng 21 and lock nut 22 to the slide 2 Ensure that the screw 1 and washer 16 is mounted on the slide 2 Renew worn sliders 14 by removing the nuts 26 of the cylinder 27 Pull the slide 9 out of the clamping body 5 to the side Demount the grease nipple 15 screw 28 and replace slider 14 Ensure correct seating of the axial retainer 29 during installation of the new sliders Mount the scrwe 28 and grease n...

Page 20: ... the fork 36 Pull the pin 35 out to the side and the fork 36 to the front of the support 37 of the clamping body 5 Remove screw 38 and pin 40 and replace wear plate 39 Reinstall screw 38 and pin 40 insert the fork 36 into the support 37 of the clamping body 5 from the front insert the pin into the fork 36 from the side and secure it using the linchpin 34 Take forks out of service if the wear repre...

Page 21: ...to the clamp body 5 Renew worn sliding pieces 12 by removing the bolt 1 Remove the bolt 19 bush 20 pressure spring 21 and lock nut 22 from the slide 2 Pull the slide 2 upwards out of the centre frame 24 Remove the grease nipple 13 bolt 25 and replace the sliding piece 12 Remove the bolt 25 with grease nipple 13 and place the slide 2 into the centre frame 24 from the top Connect the bolt 19 bush 20...

Page 22: ...22 Original Operating Manual 6 3 5 Mounting without sideshift After 50h every 500h thereafter Check screws 1 on the lower hook 2 Replace loose or damaged screws Torque the screws as specified in Chapter 6 1 General 2 1 ...

Page 23: ...stment and maintenance The load stabiliser is equipped with chain redirection Due to the hydraulic cylinder the chain is subject to a high load This is evidenced by increased wear and stretching of the chain 15 2 3 1 6 1 2 2 4 3 5 7 16 10 12 9 11 13 21 18 19 20 8 ...

Page 24: ...move the picket 2 upwards or downwards on the clamping body 3 to the next possible position and remount the screws 1 Afterwards proceed as described in point 1 Renew worn parts of the chain redirection by removing the screw 1 and the picket 2 on the clamping body 3 Demount the nut 4 on the cylinder 5 and pull the middle frame 6 with the slide 7 upwards out of the clamping body 3 Remove the cotter ...

Page 25: ...AUP order number 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 3 2 1 5 ...

Page 26: ...rease flow rate of 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 rub...

Page 27: ...s 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 backward p...

Page 28: ...of support e g 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 Decl...