KAUP T456Z Series Operating Manual Download

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SAP 100104

Operating Manual

Original Operating Manual

Edition 07/15

Subject to modifications

Rotating Fork Positioner

2T456Z, 2T456ZA, 2T496Z, 2T496ZA

T456Z

T496Z

Rotating Fork Positioner without sideshift

Rotating Fork Positioner with sideshift

T456ZA

T496ZA

Rotating Fork Positioner without sideshift with bolt-on forks

Rotating Fork Positioner with sideshift with bolt-on forks

Summary of Contents for T456Z Series

Page 1: ...cations Rotating Fork Positioner 2T456Z 2T456ZA 2T496Z 2T496ZA T456Z T496Z Rotating Fork Positioner without sideshift Rotating Fork Positioner with sideshift T456ZA T496ZA Rotating Fork Positioner without sideshift with bolt on forks Rotating Fork Positioner with sideshift with bolt on forks ...

Page 2: ...5 2 Safety aspects 6 3 Design 7 3 1 Slide and flange 7 3 2 Rotator with mounting 7 3 3 Proper use of the equipment 8 3 4 Improper use 8 4 Installation and checking out 9 4 1 Installation 9 4 1 1 Model T456Z without sideshift 10 4 1 2 Model T496Z with sideshift 11 4 2 Checking out 12 4 2 1 Bleeding the hydraulic system 12 4 2 2 Adjustment after putting into service 12 5 Operation 13 5 1 General 13 ...

Page 3: ...erating Manual 26 12 EC Declaration of Conformity 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 ...

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: ...anual 7 3 Design 3 1 Slide and flange An fork positioner consists of two carriages 1 on which sliders 2 are mounted The slides 1 are moved with cylinders 5 in the guide profiles 3 which are welded to the flange 4 3 2 Rotator with mounting ...

Page 8: ...ainers etc that have been picked up with fork arms 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 maintenance instructions 3 4 Improper use Exceeding the allowable load capacity and load centre Dragging or pushin...

Page 9: ...crease wear Please refer to the following Specifications ISO Class Model family Oil flow 2328 l min 2 1T 2 5T 20 5 3 2 5T 4 8T 40 10 4 4 5T 5T 50 20 6T 8T 60 15 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 are exam...

Page 10: ...Operating Manual 10 Original Operating Manual 4 1 1 Model T456Z without sideshift ...

Page 11: ...screws 5 with a torque of 190 Nm Replace the plug screw 6 in the gear box with the vent screw supplied Connect the hose lines 7 to the hydraulic connectors on the lift 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 identifi...

Page 12: ...ystem 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 fork positioner 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 on hydraulic components oil s...

Page 13: ...sport any load exceeding that specified on the residual load plate for the particular combination of lift truck and attachment Note the load bearing capacity of the attachment as stated on the rating plate This figure always represents 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 l...

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: ... and damage After 50h every 500h thereafter Check screws 1 on the clamp body 2 slewing ring 3 11 on the slide 6 model T4xxZA Replace loose or damaged screws Torque the screws as specified in Chapter 6 1 General Weekly Grease Sliding pieces in brass 7 by way of the greasing nipples 10 Every 200h Check wear on Sliding pieces 7 ...

Page 18: ...ween the cylinder mount and nut of the cylinder 8 Cylinders are installed with axial clearance of 1 5 to 2 mm Yearly Inspect the heel of the fork 9 for wear and cracks Remove forks from service when wear exceeds 10 of the thickness of the fork Bent forks are not safe to operate and their continued use should be prevented Straightening of forks may only be performed by the manufacturer of the fork ...

Page 19: ...Operating Manual Original Operating Manual 19 6 3 2 Rotator and flange 6 3 3 Rotator mounting without sideshift ...

Page 20: ...h every 500h thereafter Check screws 2 on the base plate 7 4 5 on the slewing ring 3 base plate 7 8 9 11 and nut 6 on the gear 10 12 on the oil motor 13 15 on the upper hooks 16 17 on the lower spacer 18 and hooks 19 22 on the sideshifter housing 23 24 on the lower hooks 25 Replace loose or damaged screws Torque the screws as specified in Chapter 6 1 General ...

Page 21: ...nce in the rotary joint 3 Information KAUP customer service As necessary Renew worn sliders 21 by removing the hooks 25 Remove the complete rotating fork positioner in the reverse order to that described in section 4 1 Replace the sliders 21 During installation pay close attention that the sliders 21 are seated correctly Then fit the complete rotating fork positioner as described in section 4 1 Re...

Page 22: ...y by quality 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 koxxxxxx KAUP order number without engraved in the material ...

Page 23: ...olding Pressure too low Increase the pressure from the lift truck Pressure too low on pressure relief valve Increase pressure on the pressure relief valve Cylinders have internal leaks Replace sealing kits Clearance Carriage has too much clearance Slider is worn Replace sliders Carriage tilts at outer limit Slider is worn Replace sliders Carriage rubbing against guide section Slider is worn Replac...

Page 24: ...n for backward position Cusion for backward position defective Replace piston rod Oil leakage Leaking Screw fitting is leaking Tighten seal screw fitting Sealing kit defective Replace sealing kit Piston rod scored Replace piston rod and sealing kit Rotator When rotating Rotates too slowly Oil flow from LT too low Increase oil flow at LT Vibration when rotating Bolts on device loose Tighten bolts B...

Page 25: ...rdance 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 hydraulic connectors must be sealed aga...

Page 26: ...ary KAUP GMBH Co KG Braunstraße 17 D 63741 Aschaffenburg we hereby declare that the machinery Model Rotating fork positioner Type T456Z T456ZA T496Z T496ZA 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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