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Operating Manual

 

 

 

Original Operating Manual 

 

1.4 

CE-Mark 

 
KAUP-Attachments carry the CE-mark. The EC Declaration of Conformity ensures that the 
attachment conforms to the EC machinery guideline. 

1.5 

Qualified and authorised personnel 

 
Qualified and authorised personnel are equipped by way of their education and training to perform 
the tasks assigned to them in accordance with accepted practice and safety regulations. They are 
assigned tasks by the equipment owner. 

1.6 

Warranty claims based on defects 

 
KAUP shall not be liable for any damage to the equipment resulting from: 
 

 

Improper use / operation.

 

 

Modifications to components.

 

 

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 minimum ambient temperature for attachments intended for 
indoor use: 

+5°C 

 

Allowable minimum ambient temperature for attachments intended for 
outdoor use: 

-20°C 

 

 

Standard models of KAUP-attachments are NOT suitable for: 

 

Use in cold storage facilities.

 

 

Use in explosive environments.

 

 

Use in conjunction with hydraulic systems involving biological oils.

 

 

Use in rough environmental conditions (e.g. seawater)

 

 

The transport of acidic liquids.

 

 
 

Summary of Contents for T 458P Series

Page 1: ...perating Manual 1 Edition 07 15 Subject to modifications Rotating Roll Clamp 2T458P 2T498P Rotator Version xxx 2 T 458P T 498P Rotating Roll Clamp continous contact pad without sideshift Rotating Roll Clamp continous contact pad with sideshift ...

Page 2: ...fety aspects 6 3 Design 7 3 1 Slides and arms 7 3 2 Rotating clamp 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 Modell T458 without sideshift 10 4 1 2 Modell T498 with sideshift 11 4 2 Checking out 12 4 2 1 Bleeding the hydraulic system 12 4 2 2 Adjustment after putting into servi...

Page 3: ...rage 27 11 Spare parts list not part of the Operating Manual 27 12 EC Declaration of Conformity Summary 27 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...

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: ... plate 3 in the arm 2 with a floating mounting The upper slide consists of a profile 4 and an arm retainer 5 in which the arm 6 and pressure plate 7 are mounted To ensure optimum lifting the arm 6 can be mechanically adjusted by demounting and remounting the pin 8 Various linings for the plates 3 7 suitable for the load to be transported are available ...

Page 8: ... 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 onto the base plate 7 3 3 Proper use of the equipment Rotating roll clamps are designed to rotate loads such as paper rolls concrete pipes etc The rotation can be continuous or limited to 180 to the left or right as required The optional...

Page 9: ...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 will be reduced When the hydraulic oil flow is too high the hydraulic oil temperature will raise which will reduce efficiency and increase wear Please refer to the follow...

Page 10: ...sioning 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 Modell T458 without sideshift ...

Page 11: ... 7 to the hydraulic connectors on the lift truck Trucks 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 movemen...

Page 12: ...ick etc 4 2 1 Bleeding the hydraulic system 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 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 o...

Page 13: ...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 5 2 Load handling Select the diameter range of the clamp by adjusting the short clamping arm at a 45 angle to the rotator Set the arms to the greatest possible width of the load Position the mast vertically and ...

Page 14: ...late refers to the pressure difference of 125 bar at the hydraulic motor Only rotate loads parallel to the floor set lifting frame vertically Do not rotate loads if there are people in the working area Rrotate raised loads slowly Fast rotating can influence the stability of the lift truck 6 Maintenance and servicing 6 1 General Regular maintenance is essential to ensure reliable operation and long...

Page 15: ...correctly torqued and replace screws 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 ...

Page 16: ...0990080 e g Klüber Syntheso D 460 EP gear box 125 0520990037 e g Avia Gear RSX 680 DIN 51517 Filling capacity 2 0 l 0520990075 e g Klüber Syntheso D 460 EP gear box 200 0520990070 e g Avia Gear RSX 680 DIN 51517 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 th...

Page 17: ... new buffers Renew the worn pressure plates 4 6 or their linings by demounting the bolt 1 and pin 2 Replace worn pressure plates and or linings Remount pin 2 and close the bearing with the bolt 1 Renew worn pins 8 10 in the arm 3 and arm retainer 12 by demounting the linch pin 9 or retainer ring 11 Replace worn pins Remount pins 8 10 and linch pin 9 or retainer ring 11 For optimum lifting the arm ...

Page 18: ...Operating Manual 18 Original Operating Manual 6 3 2 Clamp 6 3 3 Clamp and flange ...

Page 19: ... 200h Check wear on Sliding pieces 2 As necessary Replace worn sliders 2 by removing nut 5 from each cylinder 6 Pull the arms to the side to remove see chapter 3 1 Remove the greasing nipple 1 and the screws 3 3a Replace the sliders 2 When installing the new sliders make sure that the axial stops 4 are correctly seated Remount the screws 3 3a and the greasing nipple 1 Push the arms into clamp body...

Page 20: ...Operating Manual 20 Original Operating Manual 6 3 4 Rotator and flange 6 3 5 Rotator mounting without sideshift ...

Page 21: ...ck screws 1 on the slewing ring 3 flange 2 4 5 on the slewing ring 3 base plate 7 8 9 11 on the gear 10 12 on the oil motor 13 15 and 15 16 on the spacers 18 and upper hooks 17 19 on the lower spacers 21 and hooks 20 22 on the central catch 23 26 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 ...

Page 22: ...arly Check the clearance in the rotary joint 3 Information KAUP customer service As necessary Renew worn sliders 25 by removing the hooks 29 Remove the complete rotating clamp in the reverse order to that described in section 4 1 Replace the sliders 25 During installation pay close attention that the sliders 25 are seated correctly Then fit the complete rotating clamp as described in section 4 1 R...

Page 23: ...allation pay close attention that the sliders 25 are seated correctly in the sideshifter housings Mount the complete rotating roll clamp again afterwards as described in Chapter 4 1 and ensure that the nut 32 for the cylinder 33 has been replaced After every mounting or demounting of a cylinder 33 and nut 32 check the clearance 35 between cylinder retainer and nut 32 of the cylinder 33 Cylinders a...

Page 24: ...leshooting Troubleshooting should only be performed by qualified and authorised personnel Fault Possible cause Correction Clamp Opening and closing 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 on pressure relief valve Increase pressure on the pr...

Page 25: ...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 26: ...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 27: ...pport 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 Declarati...

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