KAUP T 163SN User manual

SAP 100029
en
Operating Manual
Original Operating Manual
1
Edition 03/15
Subject to modifications
Fork Positioner
T 163SN / T 163N
T 163SN
Fork positioner with fork carrier for ISO 2330 forks with sideshift and mechanical
synchronism
T 163N
Fork positioner with fork carrier for ISO 2330 forks without sideshift and
mechanical synchronism

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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
1.4CE-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 Fork Positioner with sideshift ....................................................................................... 9
4.1.2 Fork Positioner without sideshift ................................................................................ 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 ............................................................................................................................................... 11
5.1 General................................................................................................................................... 11
5.2 Load handling......................................................................................................................... 12
5.3 Driving.................................................................................................................................... 12

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6. Maintenance and servicing...................................................................................................................12
6.1 General ...................................................................................................................................12
6.2 Significant modification...........................................................................................................13
6.3 Schedule for routine maintenance and lubricants ..................................................................14
6.3.1 Fork Positioner with sideshift......................................................................................14
6.3.2 Fork Positioner without sideshift.................................................................................15
6.3.3 Forks...........................................................................................................................16
6.3.4 Fork carriage...............................................................................................................17
6.3.5 Identification plate and caution board.........................................................................18
7. Troubleshooting.....................................................................................................................................19
8. Disposal..................................................................................................................................................20
9. Transport ................................................................................................................................................20
10. Decommissioning and storage ............................................................................................................20
11. Spare parts list (not part of the Operating Manual) ...............................................................................20
12. EC Declaration of Conformity (Summary)...........................................................................................21
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: [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 a holder for forks (4) with a safety
retaining stop (5) is hydraulically moved by way of a cylinder (2) and chain (3). A guide rail (6),
sideshift components (7) and hooks (8) are fitted from the rear side onto the fork carriage (1). On the
version without sideshift the upper hooks (9) and lower hooks (10) are screwed onto the fork
carriage (1).
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
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.
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.

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4.1.1 Fork Positioner with sideshift

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) and (7) to the hydraulic connectors on the lift truck.

Remove safety retaining stops (8) and slide the fork tines onto the holder of the forks from the
centre outward.

Make sure that all safety retaining stops (8) have been correctly reinstalled.

The fork positioner may only be operated with the fork tines attached.

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
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 Fork Positioner without sideshift

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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.
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.

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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.
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.

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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
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.

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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.
6.3.1 Fork Positioner with sideshift

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6.3.2 Fork Positioner without sideshift
Daily
Check all lines, hoses and connections for leakage and damage.
After 50h / every 500h thereafter
Check:
Screws (4) on the hooks (6).
Screws (5) on the sideshift components (29).
Screws (23) on the hooks (24).
Screws (25) on the intermediate plates (26).
Screws (27) on the hooks (28).
Screws on the fork safety retaining stops (22).
Screws on the chain tightener (15) und (16).
Replace loose or damaged screws. Torque the screws as specified in Chapter 6.1
General.
Weekly
Grease:
Sliding pieces (2) by way of the greasing nipples (1).
Supporting rollers (7) on the lower hooks (3) as necessary.

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Every 200h
Check wear on:
Sliding pieces (2).
Deviating roller (21).
Supporting rollers (7) on the hooks (6).
Sliding pieces (30) on the holder for forks (13).
As necessary
Renew worn sliders (2) by removing the hooks (6). Remove the fork positioner in the
reverse order to that described in section 4.1. Replace the sliders (2). During installation
pay close attention that the sliders (2) are seated correctly. Then fit the fork positioner
as described in section 4.1.
Renew worn sliders (30) by removing the circlip (12) on the holder for the forks (13) and
removing the nut (9). Remove the holder for the forks to the front and out of the fork
carriage (8). Replace the sliders (30). Refit the holder for the forks back into the fork
carriage (8) in the reverse order.
Replace worn or defective parts of the chain tightener device (17 –21) by removing the
circlip (12) on the bolt of the holder for the forks (13) and the nut (9). Remove the holder
for the forks to the front and out of the fork carriage (8).Loosen the lock nut (15) and
turn the screw (16) fully out of the bolt (17). Replace the defective parts. Refit the chain
tightener device and holder for the forks again in the reverse order.
Replace defective supporting rollers (7) in the hooks (6) by removing the screws (4).
Using suitable hoisting gear tilt the fork carriage (8) forwards away from the fork
carriage on the lift truck. Remove the bolts in the hooks, remove the defective
supporting rollers (7) and replace them with new ones. Remount the fork carriage (8) in
the reverse order.
After installing or removing a cylinder (10), always check the clearance between the
cylinder mount and nut of the cylinder (16). Cylinders are installed with axial clearance
of 1.5 to 2 mm.
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 (8) 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.

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6.3.5 Identification plate and caution board
Number
Description
KAUP order number
1
Identification plate
only by quality
department
2
Before putting into operation
carefully read and take note of the
operating and security instructions.
0100016401
3
Never reach into the unit as long
as parts could still be moving due
to the danger of squashing or
shearing.
0100016601
4
Use suspension point!
0100015001
5
Test and operate the fork
positioner with the fork arms
attached only!
0100000717

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6
ko xxxxxx
KAUP –order number
without, engraved in
the material
7. Troubleshooting
Troubleshooting should only be performed by qualified and authorised personnel.
Fault
Possible cause
Correction
Fork Positioner
Opening and closing
Movement too slow
Insufficient fluid flow from
truck's hydraulics
Increase flow rate of truck's
hydraulics
Clearance
Holder of the fork tine
Slider is worn
Replace sliders
Chain
Chain is loose
Retension the chain
Parts of the chain tightener
device are defective or worn
Change the defective or worn
parts
Oil leakage
At cylinder
Screw fitting is leaking
Tighten / seal screw fitting
Sealing kit defective
Replace sealing kit
Piston rod scored
Replace piston rod and
sealing kit
Sideshifter
When shifting
Too slow
Pressure supplied by the FFZ
too low
Increase pressure at the FFZ
Bore of the throttle valve is too
small
Re-bore the throttle valve or
replace it with a larger one
Jerky shifting action
Supporting roller defective
Replace supporting roller
Supporting roller not properly
lubricated
Lubricate supporting rolller
Sliders not properly lubricated
Lubricate sliders
Supporting roller does
not rotate
Supporting roller defective
Replace supporting roller
Supporting roller not properly
lubricated
Lubricate supporting rolller
Housing scrapes on the
conduit
Slider is worn
Replace sliders

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Fault
Possible cause
Correction
Oil leakage
Leaking
Screw fitting is leaking
Tighten / seal screw fitting
Sealing kit defective
Replace sealing kit
Piston rod scored
Replace piston rod and
sealing kit
Fault
Possible cause
Correction
Solenoid valve
Not functioning
Solenoid coil defective
Replace solenoid coil
No power to the magnet
Inspect power cable and
connections
Legend: FFZ = lift truck
8. Disposal
Prevent environmental damage by disposing of the following items properly in
accordance with relevant national regulations:
Hydraulic fluids, greases, lubricants and soiled working materials (Cleaning
rags, etc.)
Packaging material (Pallets, straps, cartons and plastic sheeting)
After decommissioning, the attachment should be disposed of in accordance with
local legislation and regulations.
9. Transport
During transport of the attachment, care should be given to using appropriate means of support (e.g.
pallets). These must not be damaged. The attachment must be secured against slipping or tipping
over on the support.
10. Decommissioning and storage
If the attachment is to be stored for an extended period, the clutches must be sealed against
contamination and damage. Store the attachment in a clean, dry environment.
11. Spare parts list (not part of the Operating Manual)