KAUP 5T 456BZ Operating Manual Download Page 1

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SAP 100592

Operating Manual

Original Operating Manual

Edition 07/15

Subject to modifications

Rotating Fork Positioner

5T 456BZ / BZA
5T 496BZ / BZA

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

Summary of Contents for 5T 456BZ

Page 1: ...cations Rotating Fork Positioner 5T 456BZ BZA 5T 496BZ BZA 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: ...able use 5 2 Safety aspects 6 3 Design 7 3 1 Slide 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 Installation Uninstallation screw on forks 12 4 2 Checking out 12 4 2 1 Bleeding the hydraulic system 13 4 2 2 Adjustment after putting into service 13 5 Operat...

Page 3: ...ing Manual 24 12 EC Declaration of Conformity Summary 25 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 Outs...

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: ...nual Original Operating Manual 7 3 Design 3 1 Slide and flange A fork positioner consists of two slides 1 on which sliders 2 are mounted In the clamping body 3 the slides 1 are moved by means of cylinders 4 3 2 1 4 ...

Page 8: ...ng of a bevel gear gear box and hydraulic motor 4 attached The rotator is attached to the fork carriage of the lift truck with upper 5 and lower brackets 6 The optional side shift 7 is equipped with support rollers 8 and is bolted onto the base 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 wit...

Page 9: ...n the forks It is not permitted to clamp loads Transporting 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 5 Hydraulic oil flow required When the hydraulic oil flow is insufficient the speed of rotation of the rotary units at the attachments wi...

Page 10: ...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 11: ...Operating Manual Original Operating Manual 11 ohne Seitenschub mit Seitenschub 2 4 1 1 3 5 6 2 4 1 1 3 6 7 ...

Page 12: ... of the operating elements if not already present of the combination of lift truck attached equipment on the lift truck 4 1 1 Installation Uninstallation screw on forks When installating or uninstalling the screw on forks torque the scews as specified in Chapter 6 1 General 4 2 Checking out KAUP attachments are delivered pre lubricated If the attachment has been in storage for a longer period we r...

Page 13: ... 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 Note the load be...

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: ... Manual Original Operating Manual 17 6 3 1 Slide clamp body and slewing ring Daily Check all lines hoses and connections for leakage and damage 4 1 6 5 3 6 6a 2 7 9 7 8 6a Modell T4xxBZA Modell T4xxBZ 9 10 11 12 ...

Page 18: ...ders 7 by removing the hydraulic lines from the cylinder with the hydraulic system depressurised and nut 6 and 6a Replace the cylinder 7 Attach the nut 6 and 6a for the cylinder 7 and the hydraulic lines After installing or removing a cylinder 7 always check the clearance between the cylinder mount and nut 6 and 6a of the cylinder 7 Cylinders are installed with axial clearance of 1 5 to 2 mm Yearl...

Page 19: ...Operating Manual Original Operating Manual 19 6 3 2 Rotator with mounting with or without sideshift ohne Seitenschub 13 6 11 10 12 1 2 8 5 4 3 9 7 mit Seitenschub 14 15 16 17 18 19 20 21 21a ...

Page 20: ...ase Sliding pieces 16 by way of the greasing nipples 17 Supporting rollers 18 on the lower hooks 15 as necessary Every 200h Check wear on Sliding pieces 16 Supporting rollers 18 Prevent entry of dirt water or moisture into the slewing ring Grease Slewing ring 2 by way of the greasing nipples 12 Gearing of the slewing ring 2 by way of the greasing nipples 13 Every 500h Check the oil level of the ge...

Page 21: ...ollers 18 by removing the screws 14 in the hooks 15 Tilt the fork positioner forward off the fork carriage so that the support roller 18 no longer rests and secure this position Tap the bolt 19 out of the hook 15 Replace the defective supporting rollers 18 Now reinstall the bolt 19 and hook 15 using screws 14 Renew the faulty cylinders 20 by removing the hydraulic lines from the cylinder with the ...

Page 22: ...4 Use suspension point 0100015001 5 koxxxxxx KAUP order number without engraved in the material 7 Troubleshooting Troubleshooting should only be performed by qualified and authorised personnel Fault Possible cause Correction Fork positioner Opening and closing Movement too slow Insufficient fluid flow from truck s hydraulics Increase flow rate of truck s hydraulics Clearance Carriage has too much ...

Page 23: ...rotation Couplings are not engaged Check couplings and engage Hydraulic motor defective Change hydraulic motor is overloaded Check weight and torque required Slips is overloaded 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...

Page 24: ...d working materials Cleaning rags etc Packaging material Pallets straps cartons and plastic sheeting After decommissioning the attachment 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 slip...

Page 25: ...ße 17 D 63741 Aschaffenburg we hereby declare that the machinery Model Rotating fork positioner Type T 456BZ T456BZA T496BZ T496BZA conforms to the latest valid version of the Machinery Directive 2006 42 EG The person authorised to compile the technical documents see EC Declaration of Conformity KAUP GmbH Co KG ...

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