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SAP 100204

Operating Manual

Original Operating Manual

Edition 07/14

Subject to modifications

Fork Positioner

T156

T 156

Fork positioner with sideshift

Summary of Contents for T156

Page 1: ...SAP 100204 en Operating Manual Original Operating Manual 1 Edition 07 14 Subject to modifications Fork Positioner T156 T 156 Fork positioner with sideshift ...

Page 2: ...rranty claims based on defects 5 1 7 Limits of applicable use 5 2 Safety aspects 6 3 Design 7 3 1 Proper use of the equipment 7 3 2 Improper use 8 4 Installation and checking out 8 4 1 Installation 8 4 1 1 Modell 2T156 9 4 1 2 Modell 3 6T 156 10 4 2 Checking out 11 4 2 1 Bleeding the hydraulic system 11 4 2 2 Adjustment after putting into service 11 5 Operation 12 5 1 General 12 5 2 Load handling ...

Page 3: ...anual 23 12 EC Declaration of Conformity Summary 24 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 o...

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: ... installed on the fork carriage 1 at the back 3 1 Proper use of the equipment Fork positioners are designed for carrying loads on pallets or in skeleton containers Proper use of the machine and or equipment includes the following Observance of the operating manual at all times Observance of the technical data on the identification plate on the attachment Adherence to the specified inspection and m...

Page 8: ...ndling 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 4 Installation and checking out 4 1 Installation Installation 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 ...

Page 9: ...entre lock 4 Slide the lower hooks 5 into the fork carriage from the side Screw in the screws 6 and tighten the locknuts 7 The hook 5 must remain free to move and must exhibit a clearance of 1 2 mm from the fork carriage of the lift truck Connect the hydraulic connectors 8 to those on the lift truck using tube or hose lines Remove the safety retaining stops 9 and slide the fork arms onto the fork ...

Page 10: ...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 Modell 3 6T 156 Hoist the attachment at the positions indicated 1 Demount the lower hooks 2 Mount the attachment on the fork carriage of the lift truck 3 Check that the attachment is correctly seated in the c...

Page 11: ...in before being placed in service See 6 Maintenance and onwards Failure of the safety devices e g the pressure 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 di...

Page 12: ...the load carried by two or more fork arms The nominal capacity of the forks must exceed the load 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 300 mm a...

Page 13: ...hey 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 l...

Page 14: ...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 15: ... hoses and connections for leakage and damage Ensure that all fork safety retaining stops 1 are present and undamaged After 50h every 500h thereafter Check screws 14 on the fork safety retaining stops 1 Replace loose or damaged screws Torque the screws as specified in Chapter 6 1 General ...

Page 16: ...arriage onto the fork carriage 6 of the lift truck from above and use the nut 8 and screw 7 to secure the hook 5 Replace worn sliding pieces 4 by removing the nut 8 and the screw 7 Slide the hook 5 and the sliding pieces 4 sideways out of the fork carriage Exchange the sliders 4 Reinstall the nut 8 and screw 7 Piston rod 9 guide bushing 10 sealing kit 11 12 Renew worn parts 3 by removing the nut 8...

Page 17: ...play between the cylinder retainer 22 and the cylinder nut 15 The cylinders are installed with a clearance of from 1 5 to 2 mm Replace defective or worn plain bearings 20 in the slides 19 by removing the screws 16 and the entire fork adjusting unit from the fork carriage 17 Remove the nuts 18 and the shaft 21 Pull the slide 19 out to the side and replace any defective or worn plain bearings 20 Pus...

Page 18: ...uipment to lift the fork carriage 9 off the fork carriage base of the lift truck Replace the sliding pieces 5 Ensure correct seating of the sliding pieces 5 during installation Use appropriate lifting equipment to lower the fork carriage 9 onto the fork carriage base of the lift truck from above and use the screws 2 to secure the hooks 3 Renew defective support rollers 8 in the hooks 3 by removing...

Page 19: ...ws 13 and the entire fork adjusting unit from the fork carriage 9 Remove the nuts 14 and the shaft 18 Pull the slide 15 out to the side and replace any defective or worn plain bearings 17 Push the slide 15 back onto the shaft 18 and the cylinder 12 Put the nuts 14 on Insert the entire fork adjusting unit into the fork carriage 9 and attach it with the screws 13 6 3 3 Forks Annually Inspect the hee...

Page 20: ... 17 for wear Render the fork positioner inoperative when at least one of the three wear limits c2 k2 or d2 is underrun Wear limit z in mm ISO Kl 2 ISO Kl 3 ISO Kl 4 c2 k2 d2 c2 k2 d2 c2 k2 d2 13 5 11 5 9 3 18 5 14 5 13 2 22 0 17 5 15 6 As necessary For replacing the fork carriage please contact our service department ...

Page 21: ...ty 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 5 Test and operate the fork positioner with the fork arms attached only 0100000717 ...

Page 22: ... sliders Oil leakage At cylinder Screw fitting is leaking Tighten seal screw fitting Sealing kit defective Replace sealing kit Piston rod scored Replace piston rod and sealing kit Sideshifter When shifting Too slow Pressure supplied by the FFZ too low Increase pressure at the FFZ Jerky shifting action Supporting roller defective Replace supporting roller Supporting roller not properly lubricated L...

Page 23: ...ons Hydraulic fluids greases lubricants and soiled 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 da...

Page 24: ...BH Co KG Braunstraße 17 D 63741 Aschaffenburg we hereby declare that the machinery Model Fork positioner Type T156 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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