KAUP T156 User manual

SAP 100204
en
Operating Manual
Original Operating Manual
1
Edition 07/14
Subject to modifications
Fork Positioner
T156
T 156
Fork positioner with sideshift

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Original Operating Manual
Contents Page
1. Introduction ............................................................................................................................................. 4
1.1 Working with this manual......................................................................................................... 4
1.2 Warning notes and symbols..................................................................................................... 4
1.3 Copyright.................................................................................................................................. 4
1.4 CE-Mark................................................................................................................................... 5
1.5 Qualified and authorised personnel ......................................................................................... 5
1.6 Warranty claims based on defects........................................................................................... 5
1.7 Limits of applicable use............................................................................................................ 5
2. Safety aspects......................................................................................................................................... 6
3. Design ...................................................................................................................................................... 7
3.1 Proper use of the equipment.................................................................................................... 7
3.2 Improper use............................................................................................................................ 8
4. Installation and checking out ................................................................................................................ 8
4.1 Installation................................................................................................................................ 8
4.1.1 Modell 2T156............................................................................................................... 9
4.1.2 Modell 3 –6T 156...................................................................................................... 10
4.2 Checking out .......................................................................................................................... 11
4.2.1 Bleeding the hydraulic system................................................................................... 11
4.2.2 Adjustment after putting into service ......................................................................... 11
5. Operation ............................................................................................................................................... 12
5.1 General................................................................................................................................... 12
5.2 Load handling......................................................................................................................... 12
5.3 Driving.................................................................................................................................... 12

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6. Maintenance and servicing...................................................................................................................13
6.1 General ...................................................................................................................................13
6.2 Significant modification...........................................................................................................14
6.3 Schedule for routine maintenance and lubricants ..................................................................14
6.3.1 Modell 2T 156.............................................................................................................15
6.3.2 Modell 3 –6T 156.......................................................................................................17
6.3.3 Forks...........................................................................................................................19
6.3.4 Fork carriage ..............................................................................................................20
6.3.5 Identification plate and caution board ........................................................................21
7. Troubleshooting.....................................................................................................................................22
8. Disposal..................................................................................................................................................23
9. Transport ................................................................................................................................................23
10. Decommissioning and storage ............................................................................................................23
11. Spare parts list (not part of the Operating Manual) ...............................................................................23
12. EC Declaration of Conformity (Summary)...........................................................................................24
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
Outside of normal business hours the Kaup –Service Hotline is available to you 365 days a year:
0049 (0) 172 6295 297
Monday - Friday: 5 pm to 7 am
Saturday and Sunday: 8 am to 6 pm
Kaup GmbH & Co KG • Braunstr. 17 • D-63741 Aschaffenburg • email: [e-mail] •
www.kaup.de

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Original Operating Manual
1. Introduction
1.1 Working with this manual
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:
Installation and operating the equipment
Inspection, maintenance and repair
Transport and disposal
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.
1.2 Warning notes and symbols
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.
Lists are denoted by a shadowed box.

Steps to be performed by the operator are denoted by a black dot.
(1)
In illustrations, particular elements have numbered pointers. Numbers in brackets in
the text refer to the corresponding elements.
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.

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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.
1.5 Qualified and authorised personnel
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.
1.6 Warranty claims based on defects
KAUP shall not be liable for any damage to the equipment resulting from:
Improper use / operation.
Modifications to components.
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 minimum ambient temperature for attachments intended for
indoor use:
+5°C
Allowable minimum ambient temperature for attachments intended for
outdoor use:
-20°C
Standard models of KAUP-attachments are NOT suitable for:
Use in cold storage facilities.
Use in explosive environments.
Use in conjunction with hydraulic systems involving biological oils.
Use in rough environmental conditions (e.g. seawater)
The transport of acidic liquids.

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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.
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 on the attachment to be carried out by qualified and authorised
persons. Adhere to the legal minimum age in the country of operation!
The attachment should only be used for the purpose intended.
Never work on or with attachments while under the influence of drugs, alcohol or
medicines which affect reaction time.

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3. Design
The fork positioner consists of a fork carriage (1), in which the slides (3) with stops (4) are moved
hydraulically by a cylinder (2).
Side-shift components (5) and brackets (6) are installed on the fork carriage (1) at the back.
3.1 Proper use of the equipment
Fork positioners are designed for carrying loads on pallets or in skeleton containers.
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.

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3.2 Improper use
Exceeding the allowable load capacity and load centre.
Dragging or pushing loads with the attachment.
It is not permitted to transport loads which cause lateral forces on the forks.
It is not permitteld to clamp loads.
Transporting persons with the load or load handling devices.
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.
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 examples of preferred lifting means:
Capacity
250 kg/M16
1200 kg/M16
2000 kg/M16
Part-no.
9710160008
0360010201
0360010301

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4.1.1 Modell 2T156

Hoist the attachment at the positions indicated (1).

Mount the attachment on the fork carriage of the lift truck (3) and hang the fork
carriage (2) on to the carriage on the lift truck.

Check that the attachment is correctly seated in the centre lock (4).

Slide the lower hooks (5) into the fork carriage from the side.

Screw in the screws (6) and tighten the locknuts (7). The hook (5) must remain free to
move and must exhibit a clearance of 1-2 mm from the fork carriage of the lift truck.

Connect the hydraulic connectors (8) to those on the lift truck using tube or hose
lines.

Remove the safety retaining stops (9) and slide the fork arms onto the fork carrier
from the side.

Make sure that all safety retaining stops (9) have been correctly reinstalled.

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
The fork positioner may only be operated with the fork tines attached.

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.
4.1.2 Modell 3 –6T 156

Hoist the attachment at the positions indicated (1).

Demount the lower hooks (2).

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.

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
Connect the hydraulic connectors (6) to those on the lift truck using tube or hose
lines.

Remove the safety retaining stops (7) and slide the fork arms onto the fork carrier
from the side.

Make sure that all safety retaining stops (7) have been correctly reinstalled.

The fork positioner may only be operated with the fork tines attached.

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.
4.2 Checking out
KAUP-attachments are delivered pre-lubricated. If the attachment has been in storage
for a longer period, we recommend that it be lubricated again before being placed in
service. See 6. Maintenance and onwards.
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.).
4.2.1 Bleeding the hydraulic system

Start the lift truck.

Move the sideshifter repeatedly in both directions to maximum extent.

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 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.

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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.
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 load to be carried.
Position the mast vertically and take up the load parallel to the floor.
Always transport pallets, boxes and containers using both forks.
Drive the attachment up to the load to maximum extent.
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
Ensure that pallets, boxes, containers and packaging are in good condition.
Do not drive with the mast tilted forward.
Take care when driving that neither the attachment nor the load comes into contact
with the ground.
Ensure that multiple items stacked on top of one another are securely fastened.

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6. Maintenance and servicing
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.
Pay attention to a sufficient load-carrying capacity of the stop device.
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

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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.
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
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 1600 mm or raised load
centres, amended/shorter maintenance intervals should be agreed by the user with the
manufacturer.

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6.3.1 Modell 2T 156
Daily
Check all lines, hoses and connections for leakage and damage.
Ensure that all fork safety retaining stops (1) are present and undamaged.
After 50h / every 500h thereafter
Check screws:
(14) on the fork safety retaining stops (1).
Replace loose or damaged screws. Torque the screws as specified in Chapter 6.1
General.

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Weekly
Grease:
Sliding pieces (3) by way of the greasing nipples (23).
Sliding pieces (4) by way of the greasing nipples (2).
Every 200h
Check wear on:
Sliding pieces (3).
Piston rod (9).
Check the clearance
between the fork carriage on the lift truck (6) and the lower hooks (5). The
clearance should be 1-2 mm. Correct the amount of clearance using the
screw (7) and then tighten the lock nut (8).
Every 500h
Check wear on:
Sliding pieces (4).
As necessary
Renew worn sliders (3) by removing the nut (8) and screw (7). Push the hook (5)
with the slider (4) to the side out of the fork carriage. Use appropriate lifting
equipment to lift the fork carriage off the fork carriage (6) of the lift truck. Replace
the sliding pieces (3). Ensure correct seating of the sliding pieces (3) during
installation. Use appropriate lifting equipment to lower the fork carriage onto the
fork carriage (6) of the lift truck from above and use the nut (8) and screw (7) to
secure the hook (5).
Replace worn sliding pieces (4) by removing the nut (8) and the screw (7). Slide
the hook (5) and the sliding pieces (4) sideways out of the fork carriage.
Exchange the sliders (4). Reinstall the nut (8) and screw (7).
Piston rod (9), guide bushing (10), sealing kit (11, 12): Renew worn parts (3)
by removing the nut (8) and screw (7). Push the hook (5) with the sliding pieces
(4) to the side out of the fork carriage. Use appropriate lifting equipment to lift the
fork carriage off the fork carriage (6) of the lift truck. Pull out the piston rod (9) to
the side with the hydraulic system depressurised. Push the washer (13) out of the
upper rail. Replace the faulty parts and reinstall the sealing kit (11, 12), guide
bushing (10), washer (13), and piston rod (9). Use appropriate lifting equipment to
lower the fork carriage onto the fork carriage (6) of the lift truck from above and
move the hook (5) and sliding pieces (4) onto the fork carriage from the side.
Secure them using the nut (8) and screw (7).

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Renew defective cylinders (15) by removing the screws (16) at the fork carriage
(17). Take the entire fork adjusting unit from the fork carriage (17). Remove the
nuts (18) and replace the defective cylinder (15). Insert the entire fork adjusting
unit into the fork carriage (17) and attach it with the screws (16).
Each time a cylinder (15) is mounted or removed, check the play between the
cylinder retainer (22) and the cylinder nut (15). The cylinders are installed with a
clearance of from 1.5 to 2 mm.
Replace defective or worn plain bearings (20) in the slides (19) by removing the
screws (16) and the entire fork adjusting unit from the fork carriage (17). Remove
the nuts (18) and the shaft (21). Pull the slide (19) out to the side and replace any
defective or worn plain bearings (20). Push the slide (19) back onto the shaft (21)
and attach the cylinder (15) with the nut (18). Insert the entire fork adjusting unit
into the fork carriage (17) and attach it with the screws (16).
6.3.2 Modell 3 –6T 156

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Daily
Check all lines, hoses and connections for leakage and damage.
Ensure that all fork safety retaining stops (1) are present and undamaged.
After 50h / every 500h thereafter
Check screws:
(2) on the hooks (3).
(4) on the fork safety retaining stops (1).
Replace loose or damaged screws. Torque the screws as specified in Chapter
6.1 General.
Weekly
Grease:
Sliding pieces (5) by way of the greasing nipples (8).
Supporting rollers on the lower hooks (7) (option):
The supporting rollers in the standard version are maintenance-free.
Every 200h
Check wear on:
Sliding pieces (5).
Supporting rollers (8).
As necessary
Renew worn sliders (5) by removing the screws (2) of the hooks (3). Use
appropriate lifting equipment to lift the fork carriage (9) off the fork carriage base
of the lift truck. Replace the sliding pieces (5). Ensure correct seating of the
sliding pieces (5) during installation. Use appropriate lifting equipment to lower
the fork carriage (9) onto the fork carriage base of the lift truck from above and
use the screws (2) to secure the hooks (3).
Renew defective support rollers (8) in the hooks (3) by removing the screws (2)
for the hooks (3). Tilt the fork carriage (9) forward and off the fork carriage of the
lift truck so that the support roller (8) no longer rests, and secure this position.
Remove the pin in the hooks (3), remove the defective support rollers (8) and
replace them with new support rollers. Tilt the fork carrier (9) back onto the fork
carriage of the lift truck and install the hook (3) using the screw (2).
Renew the defective cylinder (10) by removing the nuts (11). Replace the
defective cylinder (10) and put the nuts (11) back on.

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Renew defective cylinders (12) by removing the screws (13) at the fork carriage
(9). Take the entire fork adjusting unit from the fork carriage (9). Remove the nuts
(14) and replace the defective cylinder (12). Insert the entire fork adjusting unit
into the fork carriage (9) and attach it with the screws (13).
Each time a cylinder (10 / 12) is mounted or removed, check the play between the
cylinder retainer (15) and the cylinder nut (10 / 12). The cylinders are installed
with a clearance of from 1.5 to 2 mm.
Replace defective or worn plain bearings (17) in the slide (15) by removing the
screws (13) and the entire fork adjusting unit from the fork carriage (9). Remove
the nuts (14) and the shaft (18). Pull the slide (15) out to the side and replace any
defective or worn plain bearings (17). Push the slide (15) back onto the shaft (18)
and the cylinder (12). Put the nuts (14) on. Insert the entire fork adjusting unit into
the fork carriage (9) and attach it with the screws (13).
6.3.3 Forks
Annually
Inspect the heel of the fork for wear and cracks.
Remove forks from service when wear exceeds 10 % of the thickness of the fork.
As necessary
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 or by
one of his authorised workshops.
You can increase the service life of forks by using forks especially protected
against wear.

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6.3.4 Fork carriage
Yearly
Check the ISO strips at the fork carriage (9 / 17) for wear.
Render the fork positioner inoperative when at least one of the three wear limits
c2, k2, or d2 is underrun.
Wear limit (z) in [mm]
ISO-Kl.2
ISO-Kl.3
ISO-Kl.4
c2
k2
d2
c2
k2
d2
c2
k2
d2
13.5
11.5
9.3
18.5
14.5
13.2
22.0
17.5
15.6
As necessary
For replacing the fork carriage, please contact our service department.