KAUP 3T450A User manual

SAP 100099
en
Operating Manual
Original Operating Manual
1
Edition 09/17
Subject to modifications
Rotating Clamp-
Fork Positioner
3T450A, 4T450A, 4.8T450A,
3T490A, 4T490A, 4.8T490A
T 450A
T 490A
Rotating Clamp with bolt-on plates without arms / forks without sideshift
Rotating Clamp with bolt-on plates without arms / forks with sideshift
This attachment does not have an EC declaration of
conformity and CE marking!
As it is an incomplete machine, only the EC declaration
of incorporation is supplied.
The operator is required before initial startup to extend
the chapter of the operating instructions supplied that
has changed due to the installation of the arms/fork
arms.
A type label and an EC declaration of conformity must
also be produced by the operator.

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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 Qualified and authorised personnel ......................................................................................... 5
1.5 Warranty claims based on defects........................................................................................... 5
1.6 Limits of applicable use............................................................................................................ 5
2. Safety aspects......................................................................................................................................... 6
3. Design ...................................................................................................................................................... 6
3.1 Slides........................................................................................................................................ 6
3.2 Rotating Clamp with mounting................................................................................................. 7
3.3 Efficient equipment settings on electric vehicles ..................................................................... 7
3.4 Proper use of the equipment.................................................................................................... 7
3.5 Improper use............................................................................................................................ 8
3.6 Hydraulic oil flow required........................................................................................................ 8
4. Installation and checking out ................................................................................................................ 9
4.1 Installation................................................................................................................................ 9
4.2 Checking out .......................................................................................................................... 10
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......................................................................................................................... 13
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 Clamp..........................................................................................................................16
6.3.2 Clamp and flange........................................................................................................17
6.3.3 Rotator and flange ......................................................................................................18
6.3.4 Rotator mounting without sideshift .............................................................................19
6.3.5 Rotator mounting with sideshift...................................................................................19
6.3.6 Identification plate and caution board.........................................................................21
7. Troubleshooting.....................................................................................................................................22
8. Disposal..................................................................................................................................................25
9. Transport ................................................................................................................................................25
10. Decommissioning and storage ............................................................................................................25
11. Spare parts list (not part of the Operating Manual) ...............................................................................25
12. EC declaration of incorporation of partly completed machinery (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: 5 pm to 7 am
Saturday and Sunday: 8 am to 6 pm
Kaup GmbH & Co KG • Braunstr. 17 • D-63741 Aschaffenburg • email: [email protected] •
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 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.
1.5 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.
1.6 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.
3. Design
3.1 Slides
Model T 450A / T 490A consists of guide profiles (1) and a plate welded on (2). Arms are bolted onto
these welded plates (2) by the operator.

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3.2 Rotating Clamp with mounting
A Rotating Clamp consists of a clamp body (1) on which conduits (2) are mounted. Cylinders (4)
move the conduits (2), which are equipped with sliders (3). The clamp body (1) is mounted on a
flange (5) that is bolted to a rotary joint (6). There is a drive (8) on the base plate (7) consisting of a
bevel gear, gear box and hydraulic motor (9) attached. This combination is attached to the fork
carriage of the lift truck with upper (10) and lower brackets (11). A central catch (14) bolted to the
base plate (7) prevents the rotator being deflected off the fork carriage of the lift truck. The optional
side shift (12) is equipped with support rollers (13) and is bolted or welded onto the base plate (7).
3.3 Efficient equipment settings on electric vehicles
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.
3.4 Proper use of the equipment
Arms/fork arms can be bolted onto models T450A and T490A by the operator. These can either be
simply pushed or loads can be clamped with them.
The operator is required to define proper and improper use for its bolted on arms/fork arms in
combination with the machine supplied.

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Original Operating Manual
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.
3.5 Improper use
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.
3.6 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

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Original Operating Manual
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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

Replace the plug screw (6) in the gear box with the vent screw supplied.
Ensure that no oil leaks out of the gear transmission.

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.

Use pipes or hoses to connect the hydraulic ports (7) to the hydraulic ports of 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.
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.).