KAUP 3T450A Operating Manual Download Page 3

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Operating Manual

Original Operating Manual

Maintenance and servicing

................................................................................................................... 14

6.1

General ................................................................................................................................... 14

6.2

Significant modification ........................................................................................................... 15

6.3

Schedule for routine maintenance and lubricants .................................................................. 15

6.3.1

Clamp .......................................................................................................................... 16

6.3.2

Clamp and flange ........................................................................................................ 17

6.3.3

Rotator and flange ...................................................................................................... 18

6.3.4

Rotator mounting without sideshift ............................................................................. 19

6.3.5

Rotator mounting with sideshift................................................................................... 19

6.3.6

Identification plate and caution board ......................................................................... 21

Troubleshooting

..................................................................................................................................... 22

Disposal

.................................................................................................................................................. 25

Transport

................................................................................................................................................ 25

10.

Decommissioning and storage

............................................................................................................ 25

11.

Spare parts list

(not part of the Operating Manual) ............................................................................... 25

12.

EC declaration of incorporation of partly completed machinery (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
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: 5 pm to 7 am

Saturday and Sunday: 8 am to 6 pm

Kaup GmbH & Co KG • Braunstr. 17 • D-63741 Aschaffenburg • email: [email protected] •

www.kaup.de

Summary of Contents for 3T450A

Page 1: ...p with bolt on plates without arms forks with sideshift This attachment does not have an EC declaration of conformity and CE marking As it is an incomplete machine only the EC declaration of incorporation is supplied The operator is required before initial startup to extend the chapter of the operating instructions supplied that has changed due to the installation of the arms fork arms A type labe...

Page 2: ...e 5 2 Safety aspects 6 3 Design 6 3 1 Slides 6 3 2 Rotating Clamp with mounting 7 3 3 Efficient equipment settings on electric vehicles 7 3 4 Proper use of the equipment 7 3 5 Improper use 8 3 6 Hydraulic oil flow required 8 4 Installation and checking out 9 4 1 Installation 9 4 2 Checking out 10 4 2 1 Bleeding the hydraulic system 11 4 2 2 Adjustment after putting into service 11 5 Operation 12 5...

Page 3: ...f the Operating Manual 25 12 EC declaration of incorporation of partly completed machinery 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 Expo...

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: ...ignment of unqualified or non authorised personnel Claims raised by third parties 1 6 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 minimum ambient temperature for attachments intended for indoor use 5 C Allowabl...

Page 6: ...chment 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 on the attachment to be carried out by qualified and authorised persons Adher...

Page 7: ... 14 bolted to the base plate 7 prevents the rotator being deflected off the fork carriage of the lift truck The optional side shift 12 is equipped with support rollers 13 and is bolted or welded onto the base plate 7 3 3 Efficient equipment settings on electric vehicles Please use our reference values for setting the lift trucks and attachments These are found at www kaup de in the Services Produc...

Page 8: ...ng persons with the load or load handling devices Mounting auxiliary equipment on the attachment such that the original mode of usage is changed e g fork extensions must be authorised by the manufacturer 3 6 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...

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

Page 10: ...t 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 2 Checking out KAUP attachments are de...

Page 11: ... cause injuries Unload the system in accordance with the operating instructions of the lift truck manufacturer In the case of injuries caused by high pressure oil inform the works physician and seek 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 ...

Page 12: ...t the machine and equipment must be inspected for visible damage and 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 Not...

Page 13: ...achment nor the load comes into contact with the ground Ensure that multiple items stacked on top of one another are securely fastened 5 4 Rotate Rotation can cause damage to the load and the attachment Ensure sufficient 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 c...

Page 14: ...ay attention to a sufficient load carrying capacity of the lifting means Replace missing or defective warning signs on the attachment Do not use third party spare parts Through poor quality or incorrect matching 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 spar...

Page 15: ... relief valve and the non return valve and incorrect connection of the controls to the actuators can cause malfunctioning of the attachment and damage to it After mounting and 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 6 2 Significant modification Significant modif...

Page 16: ...a Gear RSX 680 DIN 51517 gear box 200 0520990070 e g Klüber Syntheso D 460 EP Filling capacity 9 5 l 0520990071 The specified maintenance schedules can change as a result of the operating conditions such as extreme cold heat and dust or poor ground conditions and this must be taken into account by the owner With other loads such as fork arms with a length of over 2 400 mm or raised load centres am...

Page 17: ...fter 50h every 500h thereafter Check screws 10 on the clamp body 7 9 flange 11 Replace loose or damaged screws Torque the screws as specified in Chapter 6 1 General Weekly Grease Sliding pieces 2 by way of the greasing nipples 1 The supporting rollers in the standard version are maintenance free Every 200h Check wear on Sliding pieces 2 ...

Page 18: ...eplace the sliding pieces 2 When installing the new sliders make sure that the axial stops 4 are correctly seated Refit the screw 3 3a and the greasing nipple 1 Push the arms into clamp body and reinstall nuts 5 of cylinders 6 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...

Page 19: ...Operating Manual Original Operating Manual 19 6 3 4 Rotator mounting without sideshift 6 3 5 Rotator mounting with sideshift ...

Page 20: ...tch 14 26 nut 23 on the sideshifter housing 27 28 on the lower hooks 29 Replace loose or damaged screws Torque the screws as specified in Chapter 6 1 General Weekly Grease Sliding pieces 25 by way of the greasing nipples 24 Supporting rollers 30 on the lower hooks 29 as necessary Every 200h Check wear on Sliding pieces 25 Supporting rollers 30 Prevent entry of dirt water or moisture into the slewi...

Page 21: ...ing installation pay close attention that the sliders 25 are seated correctly Place the equipment on the fork carriage of the lift truck and mount the hooks 29 using screws 28 Replace defective supporting rollers 30 in the hooks 29 by removing the screws 28 Using suitable lifting equipment tilt the complete equipment forwards off the fork carriage of the lift truck and secure this position Remove ...

Page 22: ...KAUP order number without engraved in the material 7 Troubleshooting Troubleshooting should only be performed 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 tru...

Page 23: ...hifting Too slow Pressure supplied by the FFZ too low Increase pressure at the FFZ Bore of the throttle 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 Hous...

Page 24: ...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 25: ...nt should be disposed of in accordance with local legislation and regulations 9 Transport During transport of the attachment care should be given to using appropriate means 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 hydraul...

Page 26: ... Appendix 1 of the above mentioned directive have been applied and adhered to Articles 1 1 2 1 1 3 1 1 5 1 3 2 and 1 3 4 The special technical documentation according to Appendix VII B has been produced The manufacturer commits itself to electronically transfer spezial documents for partly completed machinery to Community National authorities upon request The person authorised to compile the techn...

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