KAUP T456Z Series User manual

SAP 100105
en
Operating Manual
Original Operating Manual
1
Edition 07/15
Subject to modifications
Rotating Fork Positioner
3T456ZA, 3T496Z, 3T496ZA
4T456Z, 4T456ZA, 4T496Z, 4T496ZA
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

Operating Manual
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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 Slide and flange ....................................................................................................................... 7
3.2 Rotator with mounting.............................................................................................................. 7
3.3 Proper use of the equipment.................................................................................................... 8
3.4 Improper use............................................................................................................................ 8
3.5 Hydraulic oil flow required........................................................................................................ 9
4. Installation and checking out ................................................................................................................ 9
4.1 Installation................................................................................................................................ 9
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.................................................................................................................................... 13
5.4 Rotate..................................................................................................................................... 13

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6. Maintenance and servicing...................................................................................................................14
6.1 General ...................................................................................................................................14
6.2 Significant modification...........................................................................................................15
6.3 Schedule for routine maintenance and lubricants ..................................................................15
6.3.1 Slide and flange..........................................................................................................16
6.3.2 Rotator........................................................................................................................17
6.3.3 Rotator mounting without sideshift .............................................................................18
6.3.4 Rotator mounting with sideshift...................................................................................18
6.3.5 Identification plate and caution board.........................................................................20
7. Troubleshooting.....................................................................................................................................21
8. Disposal..................................................................................................................................................24
9. Transport ................................................................................................................................................24
10. Decommissioning and storage ............................................................................................................24
11. Spare parts list (not part of the Operating Manual) ...............................................................................24
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: 17:00 –7:00 Uhr
Saturday and Sunday: 8:00 –18:00 Uhr
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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Original Operating Manual
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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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Original Operating Manual
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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Original Operating Manual
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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

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Original Operating Manual
The rotator with hanger assembly consists of a rotary joint (1), which is bolted to a base plate (2).
There is a drive (3) on the base plate (2) consisting of a bevel gear, gear box and hydraulic motor (4)
attached. This combination is attached to the fork carriage of the lift truck with upper (5) and lower
brackets (6). A central catch (9) bolted to the base plate (2) prevents the rotator being deflected off
the fork carriage of the lift truck.
The optional side shift (7) is equipped with support rollers (8) and is bolted onto the base plate (2).
3.3 Proper use of the equipment
Rotating fork positioner are intended for rotating loads such as crates, containers 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 pushing loads with the attachment
It is not permitted to transport loads which cause lateral forces on the forks.
It is not permitted 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.

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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 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 examples of preferred lifting means:
Capacity
250 kg/M16
1200 kg/M16
2000 kg/M16
Part-no.
9710160008
0360010201
0360010301

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Original Operating Manual

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.

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 identification of the operating elements (if
not already present) of the combination of lift truck/attached equipment on the lift truck.