Bakker Hydraulic Products ROTAQ 55 User manual

Manual
Attachment exchange system for
truck-mounted cranes
55
Bakker Hydraulic Products B.V.
Nijverheidsweg 6
6662 NG ELST
The Netherlands
[phone]
[phone]
@[email protected]
www.bakker-hydraulic.com
- 55 is produced by:

1
© 2010 Bakker Hydraulic Products B.V.
Nijverheidsweg 6
6662 NG Elst (Gld) Holland
Tel : + 31 481 374757 Fax : + 31 481 375280
Site : www.bakker-hydraulic.com E-mail : [e-mail]
Introduction
The RotaQ is a tool exchanger for truck-mounted cranes and hoisting loads up
to 55 kN.
You can operate the RotaQ from the control panel of the mounted crane on your
truck. To exchange and operate your crane tools you no longer have to leave this
position.
We strongly urge you to read this manual and follow the operating instructions.
It is also vital that you ensure that all safety regulations with respect to working
with truck-mounted cranes have been met during work, inspections,
maintenance, etc. We specifically refer to the safety regulations in this manual
and all relevant safety regulations (statutory safety regulations, safety regulations
for the attachments and safety regulations provided with the truck-mounted
crane and truck, and all other safety regulations that apply to the work space
during work, inspections, maintenance, etc. on the installation).
It is not permitted to adjust the RotaQ in any way on pain of lapsing guarantee
and CE certification.
The RotaQ has a CE certification and meets all relevant CE safety requirements.
It is nevertheless not permitted to put the RotaQ into commission before the
machine the RotaQ will be part of as a whole has been found and declared to be
in full compliance with the provisions of the Machinery Directive, 2006/42/EC

2
© 2010 Bakker Hydraulic Products B.V.
Nijverheidsweg 6
6662 NG Elst (Gld) Holland
Tel : + 31 481 374757 Fax : + 31 481 375280
Site : www.bakker-hydraulic.com E-mail : [e-mail]
Contents
Introduction
1
Table of contents
2
1.
Warnings
3
2.
RotaQ –55 description
4
3.
Technical information
8
4.
Using the RotaQ
9
5.
Safety
10
6.
7.
Warranty
Maintenance and repair
10
11-13
8.
Parts
14-25
Connection RotaQ
Operate the switch on the control box supplied. When the switch has been operated, a
beep will sound. Connect the RotaQ to the work tool by positioning the RotaQ on the
connection plate and then turning it clockwise. Then you connect after which the red pin
sinks into the block. Only when that has been done may the switch be turned after
which the beeps stops. You have now coupled without pressure.
If you do not connect correctly, as mentioned above, this can lead to malfunctions
because you connect under pressure and as a result the seals can break and
subsequently cause leaks.
If leaks have occurred, a seal from the bottom valves is generally broken and in some
cases the pin in the valve is bent.

3
© 2010 Bakker Hydraulic Products B.V.
Nijverheidsweg 6
6662 NG Elst (Gld) Holland
Tel : + 31 481 374757 Fax : + 31 481 375280
Site : www.bakker-hydraulic.com E-mail : [e-mail]
1. Warnings
•Only qualified persons can operate the truck-mounted crane with the RotaQ.
•Maintenance and inspections can only be performed by sufficiently technically
qualified personnel.
•When coupling and decoupling the attachments and subsequently using the truck-
mounted crane, the following applies:
✓Ensure that the signal pin is opened fully by checking visually after
decoupling and that it is entirely flush after coupling. Only in these states
will the RotaQ on the truck-mounted crane be unlocked and locked
respectively.
✓From the moment you turn the activation switch for the RotaQ, you can
see a red light directly above the control button and an alarm will sound.
This light signal and the alarm will stop the moment you stop the
decoupling or coupling by pressing this activation switch again.
✓Mechanically test if the decoupling or coupling is successful by moving the
RotaQ gently.
•Prevent hazardous situations. Keep out of reach of moving parts.
•Make sure no people are within reach of the crane when it is operational.
•Turn off the truck's engine before performing inspections or
maintenance.
•Components that need to be replaced may only be replaced using
original parts supplied by Bakker Hydraulic Products
•The RotaQ can be used with industry-standard hydraulic oils for truck-
mounted cranes. Should you have any questions, please contact your
RotaQ supplier.
•The connection to the attachments must be smooth, even when
the attachment plate on the attachment is not placed
horizontally. Calmly use the central axis to find the coupling
position.
•Prevent contamination of the hydraulic connection points of the
support plates and the RotaQ when decoupled.
•Inspect and check the hydraulic connection points for contamination and dirt and clean
them regularly.
•After 20 working hours, check all bolted connections and tighten if necessary.

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© 2010 Bakker Hydraulic Products B.V.
Nijverheidsweg 6
6662 NG Elst (Gld) Holland
Tel : + 31 481 374757 Fax : + 31 481 375280
Site : www.bakker-hydraulic.com E-mail : [e-mail]
2. RotaQ Description
The RotaQ is suitable for truck-mounted cranes and hoisting loads of up to 55 kN and can be used to
automatically couple the crane mechanically and hydraulically from the truck's control panel without
requiring manual actions with respect to the attachment. Attachments with hydraulic components
must be fitted with a so-called hydraulic attachment plate. For attachments such as a hoisting hook a
mechanical attachment plate will suffice. Hoisting hooks, pallet hooks, grippers, stone clamps, big-
bag hooks, ground drills, and other hydraulic attachments for your truck-mounted crane can be
coupled and decoupled automatically, simply and safely without having to leave the control position.
In the following images, you can see the following components:
RotaQ coupling unit (mechanical and hydraulic coupling) with a standard
rotator behind it
Hydraulic attachment plate connected to the attachment
Power switch with red light and sound signal
Default control panel truck-mounted crane





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© 2010 Bakker Hydraulic Products B.V.
Nijverheidsweg 6
6662 NG Elst (Gld) Holland
Tel : + 31 481 374757 Fax : + 31 481 375280
Site : www.bakker-hydraulic.com E-mail : [e-mail]
Signal pin when decoupling
If the red signal pin is up, then the lock between the RotaQ/rotator and the attachment is inactive,
and you can turn the rotator counter-clockwise so the attachment is decoupled.
Signal pin when coupling
If the signal pin is fully flush with the RotaQ block, then the connection between the RotaQ/rotator
and the attachment is locked, and you can start using the crane with the attachment.
Signal pin flush
Lock is active
Signal pin up
Lock is inactive

6
© 2010 Bakker Hydraulic Products B.V.
Nijverheidsweg 6
6662 NG Elst (Gld) Holland
Tel : + 31 481 374757 Fax : + 31 481 375280
Site : www.bakker-hydraulic.com E-mail : [e-mail]
Locking pin recesses and
hydraulic connections
Vergrendelingsposities
Koppelingspositie voor centrale as
Hydraulic hoses to
attachment
Hydraulische
onderplaat
Vergrendelingsposities
Koppelingspositie voor centrale as
Hydraulische
onderplaat
3 x Vergrendelingsposities
Koppelingspositie voor centrale as
Mechanical tool plate
3 x coupling pin positions
Coupling position for central axis
Locking pin recesses
Hydraulische
onderplaat
3 x Vergrendelingsposities
Koppelingspositie voor centrale as
Hydraulische
onderplaat
3 x Vergrendelingposities
Koppelingspositie voor centrale as
Hydraulic tool plate
3 x coupling pin positions
Coupling position for central axis

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© 2010 Bakker Hydraulic Products B.V.
Nijverheidsweg 6
6662 NG Elst (Gld) Holland
Tel : + 31 481 374757 Fax : + 31 481 375280
Site : www.bakker-hydraulic.com E-mail : [e-mail]
RotaQ
Decoupled
and
locked
3 x coupling pins
Locking pins with hydraulic
connections top plate
Central axis
RotaQ
Decoupled
and
unlocked
3 x coupling pins
Central axis
Locking pins with hydraulic
connections top plate
Signal pin up
Lock is inactive
A
B

8
© 2010 Bakker Hydraulic Products B.V.
Nijverheidsweg 6
6662 NG Elst (Gld) Holland
Tel : + 31 481 374757 Fax : + 31 481 375280
Site : www.bakker-hydraulic.com E-mail : [e-mail]
3. Technical information
Technical data RotaQ - 55
Patented
Maximum hoisting load kN ( ton ) 55 (5500 kg)
Maximum torque Nm 1300
Nominal oil flow L/min 20
Maximum operating pressure Mpa ( bar ) 30 ( 300 bar )
Weight kg 45
Rotator type Rotator met as
Rotator shaft mm Ø69
Installation height Height of rotator plus 29 mm

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© 2010 Bakker Hydraulic Products B.V.
Nijverheidsweg 6
6662 NG Elst (Gld) Holland
Tel : + 31 481 374757 Fax : + 31 481 375280
Site : www.bakker-hydraulic.com E-mail : [e-mail]
4. Using the RotaQ
Coupling
1. Switch on the crane.
2. Press the RotaQ power switch (p. 4, button 3).
3. From this moment, a 4-second safety mode will be enabled.
4. After these 4 seconds, operate the crane controls using the function: 'Attachment open'. This
will unlock the RotaQ and the red signal pin will become visible.
5. Use the central axis of the RotaQ (see p. 7) to find the coupling position for the central axis in
the attachment (p. 6) at about 45 degrees counter-clockwise with respect to the coupled
final position.
6. Now turn the rotator clockwise about 45 degrees into the final position. This will allow the
coupling pins to grip into the tool plate.
7. Operate the crane controls using the function: 'Attachment closed'. This will lock the RotaQ.
8. The RotaQ will start the locking action and the red signal pin will be flush with the RotaQ
block.
9. Disengage the RotaQ's power switch.
10. After about 4 seconds the sound and light signal will stop.
11. Visually check if the red signal pin is completely flush.
12. Mechanically test if the coupling is successful by first moving the crane arm gently.
13. The crane with attachment is now ready for use.
1. Decoupling
2. Switch on the crane.
3. Put the attachment connected to the crane in a stable position.
4. Press the RotaQ power switch (p. 4, button 3).
5. From this moment, a 4-second safety mode will be enabled.
6. After these 4 seconds, operate the crane controls using the function: 'Attachment open'. This
will unlock the RotaQ. The red signal pin will become visible.
7. Turn the rotator counter-clockwise about 45 degrees.
8. The attachment is now decoupled.
9. Mechanically test if the decoupling is successful by first moving the crane arm gently.
10. After an upwards motion, the crane can move the RotaQ to a different attachment, or
the crane can be put away (mind any damage and contamination to the hydraulic
connection points).
11. If you want to disengage the crane and lock the RotaQ:
a. Disengage the RotaQ power switch (p. 4, button 3).
b. The RotaQ will start the locking action and the red signal pin will be flushed with the
RotaQ block.
A

10
© 2010 Bakker Hydraulic Products B.V.
Nijverheidsweg 6
6662 NG Elst (Gld) Holland
Tel : + 31 481 374757 Fax : + 31 481 375280
Site : www.bakker-hydraulic.com E-mail : [e-mail]
5. Safety
•The RotaQ cannot be used for hoisting people or attachments designed to hoist people. This
requires special adjustments from the manufacturer!
•Only qualified persons can operate the truck-mounted crane with the RotaQ.
•When coupling and decoupling the attachments and subsequently using the truck-mounted
crane, the following applies:
oEnsure, by visual inspection, that the red signal pin is fully open after decoupling, or
fully flush after coupling. Only in these states will the RotaQ on the truck-mounted
crane be unlocked and locked respectively.
oThe moment you pressed the control button for the RotaQ, you can see a red light
immediately above the control button and an alarm will sound. The attachment can now
no longer be lifted or moved. This light signal and the alarm will stop the moment you
stopped the decoupling or coupling by pressing this activation switch again.
oMechanically test if the decoupling or coupling is successful by first moving the crane
arm gently.
•Prevent hazardous situations. Keep out of reach of moving parts.
•Make sure no people are within the reach of the crane when it is operational.
•Turn of the truck's engine before performing inspections or
maintenance.
•Regularly check (once a month) the condition of the exchange system
including the attachments and load-bearing parts.
6. Warranty
In accordance with our agreement, our general terms and conditions apply to all our
offers and deliveries.
Unless explicitly stated otherwise in our agreement, the following service point is
used:
Bakker Hydraulic Products B.V.
Nijverheidsweg 6, 6662 NG ELST, The Netherlands
[phone]
[phone]
@[e-mail]

11
© 2010 Bakker Hydraulic Products B.V.
Nijverheidsweg 6
6662 NG Elst (Gld) Holland
Tel : + 31 481 374757 Fax : + 31 481 375280
Site : www.bakker-hydraulic.com E-mail : [e-mail]
7. Maintenance and repair
Clean the RotaQ regularly. Potential faults can be discovered sooner.
The RotaQ connection components will be under significant force when used and checking loose
bolts and oil spills of the RotaQ coupling unit (see p. 4) and the tool plates must take place at least
every month.
All inspection and maintenance must be performed on a disengaged unit and depressurised system.
If the RotaQ exhibits any glitches when coupling or decoupling, then immediately
contact the helpdesk as mentioned in chapter 6
To keep the RotaQ in a good state of repair
•Regular inspection and maintenance of the RotaQ - 100 coupling unit
(see p. 4) and the lower plates is required.
•Maintenance and inspections can only be performed by sufficiently
technically qualified personnel.
•Maximum contamination of the hydraulic oil is 10 µm.
•Monthly visual inspection of the operation of all mechanical parts. In
case of any identified deviations, please contact your supplier/installer
before further use.
•Monthly inspection of the state of the seals of the hydraulic lower plate.
It is possible that the seal in the hydraulic lower plate will start leaking
due to damage. In this case, you must replace the seal. A first spare set
of sealing rings will be provided with the RotaQ by default.
•During the monthly inspection, check the RotaQ - 100 for damage to
the coupling unit (see p. 4), lower plates, other components that are part
of the RotaQ - 100 and weld it if possible.
•Repair descriptions have not been included in the manual; for questions
you can always contact your supplier/installer.
•Prevent decontamination of the hydraulic connection points of the
support plates and the RotaQ - 100 when decoupled.
•Inspect and check the hydraulic connection points for decontamination
and dirt and clean them regularly.
•Maximum contamination of the oil may be 10 µm.

12
© 2010 Bakker Hydraulic Products B.V.
Nijverheidsweg 6
6662 NG Elst (Gld) Holland
Tel : + 31 481 374757 Fax : + 31 481 375280
Site : www.bakker-hydraulic.com E-mail : [e-mail]
•Replacement of a sealing ring in a valve of the hydraulic bottom plate
Occasionally it will happen that the seal in the hydraulic bottom plate leaks due to damage. In that
case, you should replace the seal. A first spare set of of sealing rings is supplied as standard with
the RotaQ (part number).
1. The location of the two
hydraulic valves with sealings
in the bottom plate.
2. Unscrew the bushing using a
No. 27 pipe wrench.
3. Now remove the bushing, the
valve and the visible seal.
3. Press the valve down with a
non-sharp pin and remove the
old seal.
4. If the old seal has been
removed, check the inside for
contamination and remove it.
5. Place the new sealing on the
valve with the O-ring at the
bottom.
6. Place the seal straight on top of
7. Push the valve down with a
8. Press down on the seal with

13
© 2010 Bakker Hydraulic Products B.V.
Nijverheidsweg 6
6662 NG Elst (Gld) Holland
Tel : + 31 481 374757 Fax : + 31 481 375280
Site : www.bakker-hydraulic.com E-mail : [e-mail]
the valve.
non-sharp pin (be careful not
to danmage the seal)
your thumb.
9. Once the seal is in place (flush
with the outside of the valve)
the sleeve can be placed over
the valve.
Tighten the bush again with
pipe wrench No. 27. Tightening
torque : 80-100 Nm.
10. View of the tightened bush.
•In case of problems, please contact the supplier.
•Prevent contamination of the hydraulic coupling points in bottom
plates and the RotaQ when they are disconnected.
•Inspect and check the hydraulic coupling points for contamination and clean them
regularly.
•Check all bolt connections after 20 working hours and retighten if necessary.
Without lubrication
Tightening torque
M 6 12.9
17 Nm
M 8 8.8
19 Nm
M 8 12.9
40 Nm
M 10 12.9
85 Nm
M 12 12.9
145 Nm

14
© 2010 Bakker Hydraulic Products B.V.
Nijverheidsweg 6
6662 NG Elst (Gld) Holland
Tel : + 31 481 374757 Fax : + 31 481 375280
Site : www.bakker-hydraulic.com E-mail : [e-mail]

15
© 2010 Bakker Hydraulic Products B.V.
Nijverheidsweg 6
6662 NG Elst (Gld) Holland
Tel : + 31 481 374757 Fax : + 31 481 375280
Site : www.bakker-hydraulic.com E-mail : [e-mail]
Pos.
Quantity
Part number
Specification
1
1
105.141.11
Central block
2
2
106.131.00
Coupling pin complete
3
1
105.140.22
Top cover complete
4
1
105.143.11
Actuator
5
1
105.131.21
Spring plate
6
2
169.017.10
O-ring Ø10,82x1,78
7
10
166.906.01
Expander MB600-060
8
2
169.026.10
O-ring
9
1
105.163.10
Throttle valve
10
1
192.181.00
Pressure regulating valve
11
2
192.117.11
Non-return valve
12
2
105.164.21
Stopper Ø14
13
1
183.220.32
Snap ring DIN 471 Ø32
14
1
193.111.10
Gas spring
15
1
105.144.20
Indicator pin complete
16
2
105.146.00
Bearing bush complete
17
6
171.081.14
Bolt
18
2
171.089.50
Bolt
19
1
105.142.00
Actuator bush complete

16
© 2010 Bakker Hydraulic Products B.V.
Nijverheidsweg 6
6662 NG Elst (Gld) Holland
Tel : + 31 481 374757 Fax : + 31 481 375280
Site : www.bakker-hydraulic.com E-mail : [e-mail]
106.131.00
Pos.
Quantity
Part number
Specification
1
1
105.131.11
Joint
2
1
165.040.45
Guiding band
3
1
182.516.18
Snap ring
4
1
105.132.15
Nipple
5
1
105.132.11
Coupling
6
1
192.201.11
Quick coupler female
7
1
161.013.17
Seal

17
© 2010 Bakker Hydraulic Products B.V.
Nijverheidsweg 6
6662 NG Elst (Gld) Holland
Tel : + 31 481 374757 Fax : + 31 481 375280
Site : www.bakker-hydraulic.com E-mail : [e-mail]
105.140.22
Pos.
Quantity
Part number
Specification
1
1
105.141.12
Top plate
2
2
162.020.28
U-packing
3
2
105.132.14
Bushing
4
1
196.018.15
Iglidur cylinder bushing
5
16
171.063.12
Bolt
6
2
176.812.15
Plug DIN 908 + NBR washer
7
2
169.026.31
O-ring
8
2
165.020.25
Guiding band
9
2
105.132.12
Flanged bush

18
© 2010 Bakker Hydraulic Products B.V.
Nijverheidsweg 6
6662 NG Elst (Gld) Holland
Tel : + 31 481 374757 Fax : + 31 481 375280
Site : www.bakker-hydraulic.com E-mail : [e-mail]
105.144.20
Pos.
Quantity
Part number
Specification
1
1
105.144.21
Indicator pin
2
1
105.144.22
Red bushing
3
1
171.063.12
Bolt

19
© 2010 Bakker Hydraulic Products B.V.
Nijverheidsweg 6
6662 NG Elst (Gld) Holland
Tel : + 31 481 374757 Fax : + 31 481 375280
Site : www.bakker-hydraulic.com E-mail : [e-mail]
105.146.00
Pos.
Quantity
Part number
Specification
1
1
105.146.11
Bearing bush
2
1
196.040.30
Iglidur cylinder bushing