KINSHOFER KM920-11, Operating Instructions Manual

Page: 14 / 66

12 22.05.2018
English
Read the the operating instructions carefully and ensure they are understood
before use.
This manual is only valid in combination with the sheet „Safety Instructions“,
which is delivered with every attachment.
This manual is for the attachment without rotator; see also the separate manual for
the rotator and for any other equipment in use.
Failure to observe these instructions may lead to accidents, downtimes, and loss
of warranty.
KM920-5 hydraulic load hook for attachments and loads with ring eyes, with optional
weld-on hook for the transport of loads by means of slings or steel rope
For number references , see the NEUTRAL section
Part identifications
1.
Rotator,
2.
Cylinder,
3.
Hydraulic hook,
4.
Welded hook (optional),
5.
Stamped serial number,
6. Type plate
Proper intended use
The hydraulic hook is used to pick up crane forks with an upright receptacle for crane hooks and
to then release the loads hydraulically. It can be equipped with an optional welded hook to pick
up loads using ropes, lashing straps, etc. For use on the HGV loading crane.
Limitations of proper intended use
For loads of up to 4500 kg
For foreseeable misuse or limitations of use, refer to 41-44.
WARNING
Do not use hydraulic load hook KM920-5 for emptying containers.
Operation
7. Hook in open state, load is resting on the ground. Close hook with crane’s hydraulic system.
Load the hook by raising the crane arm, the housing of the hydraulic hook is pulled up approx.
18 mm.
The mechanical safety block engages and prevents the hook from opening.
The lock indicator becomes visible.
8. The hook can only be opened when it is unladen.
By setting down the load, the mechanical safety block is released.
Open hook with crane’s hydraulic system.
The lock indicator is no longer visible
9.
Hang the sling or the cable into both the hydraulic hook and the welded hook, in order to
distribute the load evenly on both hooks.
10. Use of crane forks with a lifting eye.
11. Use of KM461 universal forks (without switch valve) with lifting eyes.
Installation
Install the attachment with rotator and a cardanic upper link on the carrier machine. If using
without a rotator, the attachment must also be installed on the carrier machine with a cardanic
upper link.
12. Technical data for the hydraulic hook:
13. Requirements of the carrier machine: Operating pressure: max. 37 MPa (370 bar),
Recommended litre performance 2 – max. 10 l/min
14. Load capacity max. 4500 kg
15. Type, 16. Weight without rotator
17. KM920-5 for attachments and loads with ring eyes, 18. Without weld-on hook,
19. KM920-5 for KM461 universal forks with switch valve
20. Standard hydraulic plan
21.
(A) Open hook,
22.
(B) Close hook,
23.
(C) Non return valve,
24.
(Z) Unblock line
25. Greasing points: Hook guide with spray grease, in the area of the arrow; grease fitting on
hook pin, see arrow.
26. Use of universal forks KM461 with switch valve
To switch between operation of the KM920-5 hydraulic hook and the KM461 universal hook:
Hook open, load on the ground.
27.
To actuate the hydraulic hook, the universal valve's switching lever must be on the right. For
this purpose, pull down the safety lock (1) and move the switching lever to the right (2). The
safety lock must now latch back into the hole. Use the crane's hydraulic system to close or open
the hook.
28. To move the tines of the universal fork, the switching lever on the switching valve must be
on the left hand side. For this purpose, pull down the safety lock (1) and move the switching
lever to the left (2).
29. See the separate operating instructions for the KM461 universal fork.
30.
Hydraulic plan for the KM461 universal fork with switching valve
31.
Hydraulic Connections
for the switching valve (SV) 32. Hydraulic connections
33. Abbreviations
SV: Switching valve, SL: Switching lever
Connections on the switching valve Connect to
A: Close connection Connection (→←) on the rotator
B: Open connection Connection (←→) on the rotator
C: Close the KM920-5 hook Cylinder for the KM920-5 hydraulic hook
D: Open the KM920-5 hook Cylinder for the KM920-5 hydraulic hook
E:
Close the KM461 tines Cylinder on the KM461 universal fork,
via hydraulic coupling
F: Open the KM461 tines Cylinder on the KM461 universal fork,
via hydraulic coupling
KM920-5 troubleshooting
Functional
fault
Cause Remedial measures
Hook cannot be
opened
Hook is loaded Lower the crane boom
Pressure spring broken Replace spring
Blockage due to foreign
object inside the unit
Remove the foreign object
Pin blocked Lubricate the guide surfaces on the pin
with grease spray
Piston rod does not retract Check the non return valve, replace if
necessary
KM920-11 discharge unit for container with ring eyes
For number references, see the NEUTRAL section
Part identifications
1. Rotator, 2. Cylinder, 5. Stamped serial number, 6. Type plate, 34. Fixed hooks,
35. Adjustable stop plate, 36. Tension hook, 37. Tension hook pin
Intended use
The discharge unit is used to hydraulically latch onto and empty material collection containers
with a ring system. To be used on the HGV loading crane.
NOTICE
The weight of the container must be at least 30 kg heavier than the tensile force
required to pull up the ring eye or mobile disk when the container is suspended.
Otherwise the container flaps will not close.
38. Ring system on the container
Only use for containers with a ring eyelets with dimensions as displayed.
39. Mobile ring, 40. Fixed ring
41. Load must hang straight 43. Do not drag container along the ground
42. Do not lift container if it is tilted 44. Do not lift using chains or ropes
45. KM920-11 operation
46. Hook onto the container:
Insert the fixed hook (34) laterally into the fixed ring (40) on the container, so that the mobile
ring (39) on the container is centred under the pin (37).
47. WARNING
Load capacity for fixed hook (34) max. 1000 kg
Only the container empty weight is applied to the fixed hook when used
correctly.
48. Locking: The “close grab” function drives the tension hook (36) into the mobile ring (39)
and pulls it up into the discharge unit's housing.
49. Emptying the container:
The “open grab” function pushes down the tension hook and
opens the container floor. Use the "close grab" function to close the container floor
50. Setting down and releasing the container: Set the container onto the ground and activate
the “open grab” function until the tension hook has opened completely. Then detach the fixed
hook by moving the crane boom.
51. Adjustments
52. Adjust for the difference in height between the mobile ring (40) and the fixed ring (39): Set
the fixed hook (34) to the correct position. Re-adjust the shut-off rod (53) if necessary.
Check adjustment: the hydraulic cylinder's lifting action must stop when the fixed hook (34)
reaches the upper limit stop.
53. Shut-off rod
54. Adjust for the distance between the container rings (39 and 40): Loosen the locking screws
(55) and adjust the stop plate (35). Tighten the locking screws (55) to a tightening torque of 390
Nm.
55. Locking screws
56.
Setting the pressure relief valves in the control block
"Lift" function "Lower" function
120 bar at 30 l/min 65 bar at 30 l/min
145 bar at 60 l/min 80 bar at 60 l/min
57. KM 920-11 technical data:
58. Max. stroke of hook
59. Requirements of the carrier machine
NOTICE
Operating pressure dependent on litre performance
max. 20 MPa (200 bar) at max. 75 l/min
20 - 37 MPa (200 - 370 bar) at max. 40 l/min
60. Greasing points KM920-11 as marked with arrows:
Grease nipple on the rotator Fixed hook guide spray grease
Grease fitting on the cylinder bearing Spray grease on the main pin tension hook
Grease the limit stops (61) for the tension
hook
62. Tow hook wear test
Ensure that the minimum material thickness on the tension hook is not too thin as illustrated,
replace otherwise.
63. KM920-11 hydraulic diagram
KM920-11 troubleshooting
Functional fault Cause Remedial measures
Tension hook (36) not
pulled up
Shut-off valve actuated Raise the crane to pull the fixed
hook (34) downwards, free the
guide if necessary
Tension hook (36) swings
in with a delay or not
completely
Limit stop (61) or cylinder
pin (37-2) worn
Replace
Tension hook (36) does
not open or does not open
completely
Leg spring (37-1) broken
or stretched, pin (37)
sluggish
Replace
clean and grease
The piston rod does not
extend, tension hook
remains up
Container linkage
jammed,
non return valve is not
unlocked
Free it.
Check the pressure on pressure
relief valve B (see 56), contact the
manufacturer if necessary
The jammed container
linkage is bent
The unit develops too
much force
Check the pressure on pressure
relief valves A and B (see 56),
contact the manufacturer if
necessary
KM920-12 discharge unit for container with mushroom system
For number references, see the NEUTRAL section
Part identifications
1.
Rotator,
2.
Cylinder,
5.
Stamped serial number,
6.
Type plate,
64.
Height monitor,
65. Mobile hooks, 66. Fixed hook, 67. Locking indicator
Also see positions for the safety stickers (90)
Intended use
The discharge unit is used to hydraulically latch onto and empty material collection containers
with a mushroom system. To be used on the HGV loading crane.
All other uses are considered improper use of the attachment and can lead to hazardous
situations, operational interruptions and to the voiding of the warranty.
During the emptying process the lifted recycling container should be suspended as low as
possible over the container of the HGV in order to avoid material falling to the ground.
It is recommended to control the attachment with a remote control in order to be better able to
see the functions.
NOTICE
The weight of the container must be at least 30 kg heavier than the tensile force
required to pull up the ring eye or mobile disk when the container is suspended.
Otherwise the container flaps will not close.
68. Mushroom system on the container
Only use for containers with a mushroom system, with dimensions as illustrated and on the
safety sticker for “Original Kinshofer fixed and mobile disks” (69). See 90.
For foreseeable misuse or limitations of use, refer to 41-44.
70. Safety sticker: Function switch via height monitor (64):
Function switch via height monitor (64).
The height monitor (64) swaps the "open/close grab" crane function for two different unit
functions (71) and (72):