KAUP T 413GT User manual

SAP 100082 en
Operating Manual
Original Operating Manual 1
Edition 07/13 Subject to modifications
Telescopic Appliance
Clamp
T 413GT, T 403GT
T 413GT-1L, T 403GT-1L
T 414GT-1L, T 404GT-1L
T 414GT-2L, T 404GT-2L
T413GT Telescopic Appliance Clamp with sideshift and arms with rubber covering for
„white appliances“, arms fix
T403GT Telescopic Appliance Clamp without sideshift and arms with rubber covering for
„ white appliances“,arms fix
T413GT-1L Telescopic Appliance Clamp with sideshift and arms with rubber covering for „
white appliances“, 1 arm swivelling, one arm fix
T403GT-1L Telescopic Appliance Clamp without sideshift and arms with rubber covering for
„ white appliances“, 1 arm swivelling, one arm fix
T414GT-1L Telescopic Appliance Clamp with sideshift and arms with rubber covering for „
white appliances“, both arms swivelling
T404GT-1L Telescopic Appliance Clamp without sideshift and arms with rubber covering for
„ white appliances“, both arms swivelling
T414GT-1L Telescopic Appliance Clamp with sideshift and arms with rubber covering for „
white appliances“, both arms swivelling, 2 contact pads per arm
T404GT-1L Telescopic Appliance Clamp without sideshift and arms with rubber covering for
„ white appliances“, both arms swivelling, 2 contact pads per arm

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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 Clamp with mounting................................................................................................................ 7
3.2 Appliance clamp arms.............................................................................................................. 8
3.3 Proper use of the equipment.................................................................................................... 9
3.4 Improper use............................................................................................................................ 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 ............................................................................................................................................... 13
5.1 General................................................................................................................................... 13
5.2 Load handling......................................................................................................................... 13
5.3 Driving.................................................................................................................................... 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 Clamp .........................................................................................................................16
6.3.2 Mounting (with or without sideshift)............................................................................16
6.3.3 Clamping arms, model T 413GT and model T 413GT-1L..........................................18
6.3.4 Clamping arms model T413GT-1L and model T414GT-1L........................................19
6.3.5 Clamping arms right and left, model T 414-2L...........................................................20
6.3.6 Setting arm pre-load, all arms without 1 – 1,5T413GT ..............................................22
6.3.7 Identification plate and caution board ........................................................................23
7. Troubleshooting.....................................................................................................................................24
8. Disposal..................................................................................................................................................25
9. Transport ................................................................................................................................................25
10. Decommissioning and storage ............................................................................................................26
11. Spare parts list (not part of the Operating Manual) ...............................................................................26
12. EC Declaration of Conformity (Summary)...........................................................................................26
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 und Sunday: 8:00 – 18:00 Uhr
Kaup GmbH & Co KG • Braunstr. 17 • D-63741 Aschaffenburg • email: [email protected] •
www.kaup.de

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4 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
3.1 Clamp with mounting
A model T413GT clamp consists of a clamping body (1), on which the slide (2) is mounted with
sliders (3, 4). Guide profiles (5) are mounted in the slides (2), onto which clamp arms (see Chapter
3.2) are welded or mounted adjustably. Cylinders (6) move the slide (2) in the clamping body (1) and
cylinders (7) also move the clamping arms attached to the guide profiles (5) in the slide (2). Sideshift
components (8, 9) or hooks (10, 11) are optionally attached to the clamp body (1). A stop plate (12)
prevents damage of the transported goods when closing the clamp.

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3.2 Appliance clamp arms
The right and left arms of the 1-1,5T413GT model consist of guide profiles (1) and fixed, welded
arms (3).
The right and left arms of the 2-3T413GT model consist of guide profiles (1) and arms (4) in a box
design with adjustable pre-load.
The left arm of the 2-3T413GT-1L model consists of guide profiles (1), arm brackets (2) and a
pressure plate (5), which has a floating mounting. The right arm of the 2-3T413GT-1L model consists
of guide profiles (1) and an arm (4) in a box design. Both arms are equipped with adjustable pre-
load.
Both arms of the 2-3T414GT-1L model consist of guide profiles (1), arm brackets (2) and pressure
plates (5), which have floating mountings. Both arms are equipped with adjustable pre-load. The arm
pressure plates are glued or bolted to the rubber layer, adapted to the load requirements.
Both arms of the model 2T414GT-2L consist of conduits (1) onto which an arm carrier (2) is welded.
Two pressure plates (5) per arm are mounted so that they swing in the arm carrier (2).

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3.3 Proper use of the equipment
All models are suitable for the lifting and transport of “white appliances”, e.g. washing machines,
refrigerators etc.
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
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
Exceeding the allowable load capacity and load centre.
Dragging or pushing loads with the attachment
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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•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.
•Connect the hose lines (6) 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
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.

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Original Operating Manual 11
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 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 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.
The synchronization of arms is adjusted ex-factory. This can alter for different friction
conditions (wear), temperatures and volumes conveyed. Perform a readjustment. The
recommended working temperature of the hydraulic fluid is approx. 35 °C.
Synchronising the arms

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The synchronization is adjustable by means of two throttles on the bottom of the cylinders.
Setting the clamping pressure with a pressure limiting valve
Attachments are adjusted ex-factory to a pressure of 160 bar.
A change in pressure is necessary only, if the load
slips or
is damaged.
Make the settings in the numerical sequence and in the direction of the arrows.
The pressure indication on the manometer gauge drops after clamping.
This is not a malfunction of the attachment, being caused by the installation of a
transmission.

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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 arms.
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
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 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

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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 2,400 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 Clamp
6.3.2 Mounting (with or without sideshift)

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Daily
Check all lines, hoses and connections for leakage and damage.
After 50h / every 500h thereafter
Check screws:
(13, 16) on the conduits (12).
(20) on the sideshifter housing (21).
(22) on the lower hooks (23).
(26) on the upper hooks (27).
(28) on the spacers (29).
Replace loose or damaged screws. Torque the screws as specified in Chapter 6.1
General.
Weekly
Grease:
Sliding pieces (2, 3) by way of the greasing nipples (1).
Sliding pieces (19) by way of the greasing nipples (18).
Supporting rollers on the lower hooks (25) as necessary.
Every 200h
Check wear on:
Sliding pieces (2, 3).
Sliding pieces (19).
bolt (14).
Supporting rollers (24).
As necessary
Renew worn sliders (19) by removing the hooks (23). Remove the complete. clamp
body (8)in the reverse order to that described in section 4.1. Replace the sliders (19).
During installation pay close attention that the sliders (19) are seated correctly. Then fit
the clamp as described in section 4.1.
Replace worn sliding pieces (3) by removing nut (6) from each cylinder (7). Separate
the hydraulic connection of the cylinder (10). Pull the arms (see Chapter 3.2) and slides
(9) out to the side. Remove the screw (4). Replace the sliders (3). When installing the
new sliders, make sure that the axial stops (5) are correctly seated. Remount the screw
(4). Push the arms and slides (9) into the clamping body (8) and connect the hydraulic
connection to the cylinder (10). Attach the nut (6) for the cylinder (7).

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Replace worn sliding pieces (2) by removing nut (11) from each cylinder (10). Pull the
arms to the side to remove (see Chapter 3.2). Remove the screw (4). Replace the
sliders (2). When installing the new sliders, make sure that the axial stops (5) are
correctly seated (5). Remount the screw (4). Push the arms into the slides (9) and
remount the cylinder (10) nuts (11).
Replace defective supporting rollers (24) in the hooks (23) by removing the screws
(22). Using suitable hoisting gear tilt the clamp body (8) forwards away from the fork
carriage on the lift truck. Remove the bolts (25) in the hooks (23), remove the defective
supporting rollers (24) and replace them with new ones. Remount the clamp body (8) in
the reverse order.
After installing or removing a cylinder (7, 10), always check the clearance between the
cylinder mount (17) and nut (6, 11) of the cylinder (7, 10). Cylinders are installed with
axial clearance of 1.5 to 2 mm.
Renew defective pins (14) by removing the bolts (13) and retaining ring (15). Mount the
new pins (14) and then the retaining ring (15) and bolts (13). Make the adjustment of
the arm pre-load in accordance with section 6.3.5. Only replace the pins (14) in pairs.
6.3.3 Clamping arms, model T 413GT and model T 413GT-1L
As necessary
Replace the
worn rubber covering (1).
worn bars (2, 4) by removing the screws (3, 5).

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6.3.4 Clamping arms model T413GT-1L and model T414GT-1L
After 50h / every 500h thereafter
Check:
Screws (11) of the bars (2) and (3).
Screws (12) and nuts (13) of the swing bearings.
Screws (10) on the pressure plates (4), bars (2) and wear-off bars (6).
Screws (15, 16) on the wear-off-bar (7) and cover sheets (5).
Replace loose or damaged screws. Torque the screws as specified in Chapter 6.1
General.
Every 200h
Check wear on:
Coating (8).
Wear-off bar (6, 7).
Bushes (14).
As necessary
Renew the worn covering (8) or wear-off bar (6) by removing the cover plate (5) and
screws (16). Remove the screw (10) and bushes (9). Take off the pressure plate (4) to
the side. Replace the covering (8) or wear-off bar (6). If the wear is only slight, you can
also turn the pressure plate (4) and wear-off bar (6) through 180°. Refit all parts again
in the reverse order.

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Renew defective wear-off bars (7) by removing the screws (15) and replacing the wear-
off bar (7). Refit the screws again (15).
Renew the worn bushes (14) in the swing arm (1) by removing the nuts (13) and
screws (12). Replace the bushes (14). Refit the nuts (13) and screws (12) again.
Ensure that all plugs (18) are put back into the open borings (17) in the pressure plate
(4).
6.3.5 Clamping arms right and left, model T 414-2L
After 50h / every 500h thereafter
Check:
Screws (10) on the rocker arms (3).
Screws (12) and nuts (13) on the rocker arms (2).
Screws (11) and nuts (13) on the rocker arms (3).