Instrukcja Kaup 3,5T351
Instrukcja Kaup 3,5T351
Instrukcja Kaup 3,5T351
Operating Manual
Rotators
3,5T351.2
3,5T391.2
Contents
Page
1. Introduction ............................................................................................................................................. 4
3. Design ...................................................................................................................................................... 7
5. Operation ............................................................................................................................................... 11
5.1 General................................................................................................................................... 11
5.2 Load handling ......................................................................................................................... 12
5.3 Driving .................................................................................................................................... 12
5.4 Rotate ..................................................................................................................................... 12
7. Troubleshooting.....................................................................................................................................20
8. Disposal ..................................................................................................................................................22
9. Transport ................................................................................................................................................22
11. Spare parts list (not part of the Operating Manual) ...............................................................................22
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
Outside of normal business hours the Kaup – Service Hotline is available to you 365 days a year:
1. Introduction
This operating manual contains important information on how to operate the attachment properly,
safely and efficiently.
The operating manual shall be read, understood and applied by all personnel working on or with the
equipment, for example:
The manual must be kept available for ready reference at the equipment’s place of use.
The illustrations in this operating manual may deviate from the actual version
of the equipment.
The 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.
1.3 Copyright
This documentation including all parts is copyrighted. Any use or change outside the narrow limits of
copyright law without permission from KAUP GmbH & Co KG is forbidden and liable to prosecution.
This applies, in particular, to reproduction, translation, microfilming as well as storage and
processing in electronic systems.
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.
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.
KAUP shall not be liable for any damage to the equipment resulting from:
Modifications to components.
KAUP-attachments are intended for use under the following climatic conditions:
2. Safety aspects
As the user, extend the safety instructions with generally applicable, legal and other
measures that ensure a safe and environmentally friendly operation of the
attachment.
Pay close attention to all safety- and danger-related signs on the attachment and in
this operating manual. Failure to observe these can result in severe injury or even
death.
Pay close attention to the operating manual provided by the manufacturer of the fork
lift truck.
Keep a safe distance away from moving, reciprocating or rotating parts of the
attachment to avoid danger of crushing, pinching or entanglement.
Use aids to vision (e.g. mirrors, camera, etc.) where goods being transported obstruct
vision.
Only allow work on the attachment to be carried out by qualified and authorised
persons. Adhere to the legal minimum age in the country of operation!
Never work on or with attachments while under the influence of drugs, alcohol or
medicines which affect reaction time.
3. Design
A rotator consists of a base plate (1) and a rotary joint (2), which is hydraulically driven via a gear
box (3) with bevel gear (4) and an oil motor (5). A flange (6) is bolted with the rotary joint (2) and a
fork carriage (7). The fork carriage (7) has safety retaining stops (8) and limit stops (9) that lock the
fork arms when rotating. This combination is attached to the fork carriage of the lift tr8ck with upper
(10) and lower brackets (11). The optional side shift (12) is equipped with support rollers (13) and is
bolted or welded onto the ground plate (1).
Please use our reference values for setting the lift trucks and attachments. These are
found at www.kaup.de in the Services -> Product Support section.
Rotators are intended for rotating loads such as crates, containers etc. that have been picked up
with fork arms. The rotation can be continuous or limited to 180°, to the left or right as required. The
optional side shift is designed for moving loads that are free of the ground (at least 10 cm high).
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.
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.
2328 l/min
2 1T - 2,5T 20 ±5
3 2,5T - 4,8T 40 ± 10
4,5T - 5T 50 ± 20
4
6T - 8T 60 ± 15
4.1 Installation
Replace the plug screw (6) in the gear box with the vent screw supplied.
Mount the attachment on the fork carriage of the lift truck (3).
Check that the attachment is correctly seated in the centre lock (4).
Mount the lower hooks (2), tightening the screws (5) with a torque of 190 Nm.
Connect the hose lines (7) to the hydraulic connectors on the lift truck.
Demount the safety retaining stops (8) and limit stops (9) and slide the fork arms
from the side onto the fork carriage.
Ensure that all safety retaining stops (8) and limit stops (9) are remounted.
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 identification of the operating
elements (if not already present) of the combination of lift truck/attached equipment
on the lift truck.
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.).
5. Operation
5.1 General
At least once per working shift, the machine and equipment must be inspected for
visible damage and defects.
Repeat faults to your superior and have them rectified without delay.
Be aware of persons present in the area where you are working 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.
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.
Raise the load about 300 mm and tilt the mast backwards.
Centre the load to the middle of the lift truck during take-up and transport.
5.3 Driving
Make sure the load to be lifted and the pressure plates are in perfect condition.
Take care when driving that neither the attachment nor the load comes into contact
with the ground.
5.4 Rotate
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.
Only rotate loads parallel to the floor (set lifting frame vertically).
6.1 General
Regular maintenance is essential to ensure reliable operation and long service life of the KAUP
attachment.
Ensure that maintenance and servicing are performed by qualified and authorised
personnel only.
Lubrication and cleaning work on the attachment may also be performed by the lift truck
operator.
Perform maintenance and servicing work only when the attachment is parked securely
on a stable, level foundation. For installing and removing, it is recommended to use a
pallet to take the attachment. The attachment can thus be securely placed and
transported.
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.
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.:
During any disassembly operations, be sure that parts to be disassembled can easily be
removed. For removing parts, use the clearance between bolts and the parts to be
removed.
Our service videos available at www.kaup.de in the Online Services section may be
used for assistance as necessary.
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.).
Significant modifications are, for example, those which affect the stability, performance, speed and
strength of components.
Modifications to the attachment may only be made with prior approval by the manufacturer.
Hydraulic oil
0520990036 Filling capacity
gear box 80 0520990080 e.g. Avia Gear RSX 680, DIN 51517 0,5.l
0520990019
0520990037 e.g. Avia Gear RSX 680, DIN 51517 Filling capacity
gear box 125 0520990075 e.g. Klüber Syntheso D 460 EP 2,0 l
0520990085 e.g. Avia Gear RSX 680, DIN 51517
0520990070 Filling capacity
gear box 200 e.g. Klüber Syntheso D 460 EP
0520990071 9,5 l
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 this must be taken
into account by the owner.
With other loads, such as fork arms with a length of over 2,400 mm or raised load
centres, amended/shorter maintenance intervals should be agreed by the user with the
manufacturer.
Daily
Check all lines, hoses and connections for leakage and damage.
Check:
(1, 2) on the fork carriage (3) / flange (4) / slewing ring (5).
(6) and washer (7) on the fork carriage (23.
(8) and limit stops (9) on the fork carriage (3).
Replace loose or damaged screws. Torque the screws as specified in Chapter 6.1
General.
Yearly
Check the wear on the safety retaining stops (6, 7). Replace defective bolts (6) and
washers (7).
Check the wear on the bolts (8) and limit stops (9). Replace the defective parts.
Ensure that all safety retaining stops (6, 7) and limit stops (8, 9) are remounted after
mounting or demounting fork arms.
Daily
Check all lines, hoses and connections for leakage and damage.
Check:
(1), spacer (2) on the slewing ring (3) / base plate (4).
(5) on the upper hooks (6).
(7) on the lower hooks (8).
(9) on the cover sheet (10).
(11, 14) and nut (12) on the gear box (13).
(15) on the oil motor (16).
(17) on the lower hooks (18).
Replace loose or damaged screws. Torque the screws as specified in Chapter 6.1
General.
Weekly
Grease:
Sliding pieces (19) by way of the greasing nipples (20) on the guide.
Supporting rollers (21) on the lower hooks (18, 22) as necessary.
Every 200h
Grease:
Slewing ring (3) by way of the greasing nipples (23).
Gearing of the rotary joint (3) by way of the grease nipple (24).
Every 500h
Yearly
Check the clearance in the rotary joint (3). (Information KAUP customer service)
As necessary
Replace defective supporting rollers (21) in the hooks (18) by removing the screws
(17). Using suitable lifting equipment, tilt the complete equipment forwards off the fork
carriage of the lift truck and secure this position. Remove the bolts (22) in the hooks
(18), remove the defective supporting rollers (21) and replace them with new ones.
Mount the equipment with the hooks (28) using screws (17).
Renew worn sliding pieces (19) by removing the hooks (18). Demount the nut (26) of
the cylinder (27). Using suitable lifting equipment lift the equipment off the fork
carriage of the lift truck. Replace the sliding pieces (19). During installation pay close
attention that the sliders (19) are seated correctly in the in the guide (25). Place the
equipment on the fork carriage of the lift truck and mount the hooks (18) using screws
(17).
After installing or removing a cylinder (37) and nut (26), always check the clearance
(28) between the cylinder mount and nut (26) of the cylinder (27). Cylinders are
installed with axial clearance of 1.5 to 2 mm.
only by Quality
1 Identification plate
department
without, engraved in
5 ko xxxxxx KAUP – order number
the material
7. Troubleshooting
Rotator
When rotating
Rotates too slowly Oil flow from LT too low Increase oil flow at LT
Clearance
RJ defective Replace RJ
Tighten bolts or replace if
Flange tip forwards Bolts loose
necessary
Oil leakage
Sideshifter
When shifting
Pressure supplied by the Increase pressure at the
Too slow
FFZ too low FFZ
Bore of the throttle valve is Re-bore the throttle valve or
too small replace it with a larger one
Jerky shifting action Supporting roller defective Replace supporting roller
Sliders not properly
Lubricate sliders
lubricated
Supporting roller does
Supporting roller defective Replace supporting roller
not rotate
Housing scrapes on the
Slider is worn Replace sliders
conduit
No cusion for backward Cusion for backward
Replace piston rod
position position defective
Oil leakage
8. Disposal
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.
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.
Model: Rotator