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Operating Manual

Original Operating Manual

15

Pay attention to a sufficient load-carrying capacity of the lifting means.

Replace missing or defective warning signs on the attachment.

Do not use third party spare parts. Through poor quality or incorrect matching
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 lift truck manufacturer. In the case of injuries caused
by high pressure oil, inform the works physician and seek out a specialist
immediately.

Screw connections can loosen due to vibration of the attachment. During routine
maintenance check that screw connections are 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 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 directions of the
operating elements (operating lever, joystick, etc.).

6.2

Significant modification

Significant modifications are, for example, those which affect the stability, performance, speed and
strength of components.

The EC Declaration of Conformity is invalidated by a significant modification of the attachment.

Modifications to the attachment may only be made with prior approval by the manufacturer.

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Содержание T 458P Series

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

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

Страница 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...

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

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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