KINSHOFER KM 506 HD User manual

Betriebsanleitung für
hydraulischen Schnellwechsler
Operating Instructions for
Hydraulic Quick Change System
Mode d’emploi pour
système d'accrochage
rapide hydraulique
KM 506 HD Smart Flow
January 2022 [en]

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Copyright
Alle Rechte sind vorbehalten.
Diese Dokumentation darf ohne ausdrückliche Einwilligung des Herstellers weder vervielfältigt,
bearbeitet, übersetzt, digital gespeichert noch an Dritte weitergegeben werden. Änderungen vorbehalten,
die durch stetige Produktentwicklung und Produktverbesserung entstehen.
All rights reserved.
Do not duplicate, edit, translate, distribute this document to third parties, nor save as a digital document,
without explicit authorization by the manufacturer. Subject to changes incurred through continuing product
development and improvement.
Tous droits réservés.
Cette documentation ne peut être reproduite, éditée, traduite, sauvegardée ou transmise à un tiers que
sur accord exprès du fabricant. Sous réserve de modifications résultant du développement et de
l'amélioration continu des produits.
Herausgeber der Originalbetriebsanleitung und Hersteller des Anbaugerätes:
Editor of the original operating instructions and manufacturer of the attachment:
Éditeur du mode d’emploi original et fabricant d’outil est:
KINSHOFER GmbH
Raiffeisenstrasse 12
83607 Holzkirchen
Germany
www.kinshofer.com
[email protected]
* Die Originalbetriebsanleitung, für die der Hersteller die Verantwortung übernimmt, ist die Sprachfassung Deutsch.
Alle andere Sprachfassungen sind Übersetzungen der Originalbetriebsanleitung.
* The Original Operating Instructions, for which the manufacturer accepts responsibility, is in the language German.
All other languages are a translation of the original operating instructions.
* Le mode d’emploi original pour quel le fabricant est responsable, est composé en allemand. Toutes les autres
langues sont des traductions du mode d’emploi original.
Typenschild / Type plate / Plaque d’identification
Das Typenschild auf dem Anbaugerät muss immer deutlich lesbar sein. Das Typenschild wie
unten abgebildet oder ähnlich ist auf dem Anbaugerät befestigt:
The type plate on the attachment must be clearly legible at all times. The type plate pictured
below or similar is fastened onto the attachment:
La plaque signalétique de l'outil doit toujours être bien lisible. La plaque signalétique comme
représentée au-dessous ou semblable est fixée sur l'outil:

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Technische Daten / Technical Data / Données Techniques
KM506 HD
KM 506 03 HD
KM 506 01 HD
KM 506 02 HD
KM 506 04 HD
Drehmotor / Rotator
KM 506 05

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Typ
für Drehmotor
Tragfähigkeit
zul. Biegemoment
Gewicht
zul. Hubmoment
am Kran
Type
for Rotator
Load
capacitiy
Allowable bending
moment
Weight
Allowable lifting
moment of crane
pour Rotator
Capacité
Moment de flexion
admissible
Poids
Couple de levage
admissible de
grue
kg / lbs
Nm / ft.lbs.
kg / lbs
kNm (mt) / ft.lbs.
KM 506 HD
KM04S68-30US
4500 / 9900
4500 / 3320
45 / 100
120 (12) / 88500
KM04S68-30IT
4500 / 9900
4500 / 3320
KM06S68-35
6000 / 13200
8500 / 6270
KM06S68-40
6000 / 13200
4500 / 3320
Typ
Artikelnr.
Beschreibung
Type
Article no.
Description
KM 506 HD
534084099
komplett inkl. Ober- und Unterteil mit Kupplungen /
Complete incl. upper and lower part with hydraulic couplings /
Complet, y compris les parties supérieure et inférieure avec
couplages
KM 506 01 HD
534082267
Oberteil / Upper part / Partie supérieure
KM 506 02 HD
534082333
Unterteil mit Kupplungen / Lower part with couplings /
Partie inférieure avec couplages
KM 506 03 HD
534095927
Drehstarrer Lasthaken mit mechanischem Unterteil /
Non-rotating hook with mechanical lower part /
Crochet avec partie inférieure mécanique
KM 506 04 HD
534086396
Unterteil ohne Kupplungen / Lower part without couplings /
Partie inférieure sans couplages
KM 506 05
151089703
Witterungsschutz / Weather protection cap / Barrière d'étanchéité
Öffnen-Schließen (Anbaugerät) /
Open-close (attachment) / Ouvrir-fermer (outil)
Verriegeln-Entriegeln /
Lock-unlock / Verrouillage - déverrouillage
Betriebsdruck
Operating pressure
Pression de service
max.
empfohlene Literleistung
Recommended Oil flow
Débit recommandé
Betriebsdruck
Operating pressure
Pression de service
max.
empfohlene Literleistung
Recommended Oil flow
Débit recommandé
370 bar / 37 MPa
5350 psi
50 l/min
13 GPM
150 bar / 15 MPa
2175 psi
5 l/min
1.3 GPM

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Content
1. Important notes ............................................................................................................ 7
Safety instructions .................................................................................................................................... 7
Statutory safety and accident prevention ................................................................................................. 7
Transport, unloading and unpacking........................................................................................................ 8
Inspection upon delivery........................................................................................................................... 8
Service link ............................................................................................................................................... 8
2. Product information ..................................................................................................... 9
Product overview...................................................................................................................................... 9
Proper intended use ............................................................................................................................... 10
Foreseeable misuse ............................................................................................................................... 10
Limitations .............................................................................................................................................. 10
Safety sticker .......................................................................................................................................... 11
2.5.1 Safety sticker for indicator pin: green for „locked“. ................................................................. 12
3. Installation and Initial operation ............................................................................... 12
Installation requirements on the crane ................................................................................................... 12
3.1.1 Installation of the upper part of the quick coupler onto the rotator.................................................. 13
3.1.2 Installation of the lower part of the quick coupler onto the attachment........................................... 15
3.1.3 Hydraulic diagram with valve block................................................................................................. 17
3.1.4 Mounting holes at valve block ......................................................................................................... 18
3.1.5 Connections at rotator..................................................................................................................... 18
3.1.6 Pressure and oil flow....................................................................................................................... 18
3.1.7 Functional test................................................................................................................................. 18
Operation................................................................................................................................................ 19
3.2.1 Exchanging attachments................................................................................................................. 19
3.2.2 Non-rotating load hook with mechanical lower part KM 506 03 HD ............................................... 21
Troubleshooting...................................................................................................................................... 22
4. Shut down and removal............................................................................................. 22
5. Cleaning and care ...................................................................................................... 23
6. Maintenance and service........................................................................................... 24
Maintenance ........................................................................................................................................... 24
Maintenance check list ........................................................................................................................... 25
Daily inspection ...................................................................................................................................... 26
Check after 50 operating hours .............................................................................................................. 26
6.4.1 Tightening torques for bolted connections ...................................................................................... 29
6.4.2 Check locking sleeves for wear visually.......................................................................................... 26
Annual check .......................................................................................................................................... 26
6.5.1 Check locking sleeves for wear by measuring their protrusion and by checking the safety latch for
tightness ........................................................................................................................................................ 26
6.5.2 Replace locking sleeve ................................................................................................................... 27
Replacement of the hydraulic components every 6 years ..................................................................... 32
Commissioning after being shut down for one month or more .............................................................. 32
Oil and grease ........................................................................................................................................ 32
Repairs and welding............................................................................................................................... 32
Disposal .............................................................................................................................................. 32
7. Claims, warranty, and liability................................................................................... 33
Complaint ............................................................................................................................................... 33
Warranty and liability .............................................................................................................................. 33
8. Certificate of Inspection ............................................................................................ 34
9. EC-Declaration of conformity.................................................................................... 35

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1. Important notes
These operating instructions apply to the attachment described on the title page, which was developed
and produced with the utmost dedication. Technical information, mounting and maintenance
instructions are provided in this manual.
Service manual and spare parts list
A service manual is available upon request for carrying out repairs on premium line products. A spare
parts list can be ordered for all products.
We will be happy to help if you have any questions about the product. The telephone/fax numbers and
the e-mail/Internet addresses are provided at the end of this operating manual.
In order to receive quick and accurate service, state the serial number of the attachment.
The serial number is provided on the type plate, as an embossed number on the product, on the
delivery documents, on the receipt, and on the conformity declaration.
WARNING
If the delivered attachment is not properly installed, operated and maintained, or if it is misused, the
attachment and/or carried load could fall down causing serious injuries or damage to property.
Installation, operation and maintenance of the attachment may only be carried out by authorized,
trained and experienced personnel.
Before beginning, these personnel must read and understand
• the operating and safety instructions for the attachment as described in this manual.
• the separate sheet "Safety Instructions“, see chapter 1.1.
• the instructions for the carrier and other equipment, such as a quick coupler.
Failure to observe these instructions may lead to accidents, downtimes, and loss of warranty.
Safety instructions
These instructions are valid only in conjunction with the 'Safety instructions' sheet, which accompanies
every attachment.
In the event of discrepancies between these instructions and the safety instructions sheet, the
information in the instructions shall have priority.
In the event that the 'Safety instructions' sheet is misplaced or lost, this may be requested free of
charge by quoting article number 194079333 - for all EU languages.
Statutory safety and accident prevention
The following regulations apply:
EC - European Directives
Directive 2006/42/EC
Directive 2003/37/EC
DIN EN ISO - Applicable European standards
DIN EN ISO 4413 Hydraulic fluid power – General rules
DIN EN 474-1 Earth-moving machinery – Safety
DIN EN ISO 12100 Safety of machinery –General design principles

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Applied German standards:
DIN 15428 Lifting equipment - Technical delivery conditions
BGR Safety and health rules at work
BGR A1 Basic principle of prevention
BGR 137 Handling of hydraulic liquids
BGR 500 Operation of work equipment
LOCAL - Country-specific health and safety directives
Safety Guidelines for Quick Change Devices
DIN EN - regulation for quick-change devices
DIN EN 474 series - Earth-moving machinery – Safety
Part 1: General requirements
Appendix B: Quick-change devices
Safety Instructions for Controls
EC - European Directives
Directive 2006/42 / EC
Directive 2003/108 / EC (EMC)
DIN EN
Safety of machinery - General design principles
DIN EN 60204-1 Safety of machinery - Electrical equipment of machines,
Part 1: General requirements
DIN EN ISO 13849-1 Safety of machinery - Safety related parts of control systems
Transport, unloading and unpacking
The attachment is carefully packed by the manufacturer in order to avoid damage during
transportation.
WARNING
Personal injuries and damage to property can be caused by lifted loads falling down.
•Observe the weight information and any symbols which are attached to the transportation
packaging.
•Use lifting equipment with sufficient carrying capacity to unload the attachment from the transport
vehicle.
Inspection upon delivery
Unpack the delivered goods carefully so that no parts remain in the packaging. Immediately after
unpacking, check:
•The attachment and any accessories included in the delivery for transport damage and defects.
•The completeness of the delivery with reference to delivery note.
Use the original packaging for any return shipping. Otherwise, dispose of the packaging in
accordance with the regional regulations.
Service link
•Replacement parts
•Technical support
•Returns
Service link http://www.kinshofer.com/de/index.php/de/service

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2. Product information
Product overview
Attachment
(shown here:
KM 605
Clamshell
bucket)
For example:
Quick change
system
KM 506 HD
Rotator
KM04S68-30US
For example:
Rotator
KM 04S68-30US
Quick change upper part
KM 506 01 HD
Weather protection cover
KM 506 05
Quick change lower part
KM 506 02 HD with hydraulic
KM 506 04 HD without
hydraulic for mechanical
attachments
Non-rotating hook
with mechanical
lower part
KM 506 03 HD
Mechanical
lower part
Non-rotating
hook

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Proper intended use
The Quick Change System KM 506 HD is for exchanging attachments such as clamshell buckets and
hooks from rotator KM04 or KM06, mounted on a crane.
There is no need for manual handling when exchanging attachments.
NOTICE
The forces, cycles and working speed of larger cranes will overload the system.
Damage and hydraulic oil leakage to the KM506HD if used on Z-cranes (timber cranes) with
lifting moment over 120 kNm (12mt).
Do not use the KM506HD on Z-cranes (timber cranes) with lifting moment over 120 kNm
(12 mt).
For the lower part with hook KM 506 03 HD, a support stand KM 506 06 is available as an accessory.
The lower part with hook KM 506 03 HD should be placed in the support stand KM 506 06, because it
does not have a flat surface its own to be set down safely on. Important functions of the support stand
are for safe exchange between hook and attachment and secure storage of KM 506 03 HD.
WARNING
Possibility of injury when exchanging between hook KM 506 03 HD and attachment. For example,
fingers can be squashed.
For safe coupling or uncoupling of the upper part, place the hook KM 506 03 HD in the
support stand KM 506 06.
The electro-hydraulic control of the exchange uses a valve block (included in the scope of delivery)
and the operating unit of the crane.
Foreseeable misuse
During routine daily work, it is possible that mistakes occur or instructions are not followed. This could
be caused by the operator not paying attention or lack of knowledge.
Examples of foreseeable misuse
Do not beat or hammer with the attachment to break up conglomerate rock or other material
Do not use the attachment for compacting material.
For cardanically mounted attachment: Do not use the attachment to pull or push a load by
applying lateral pressure.
Do not operate the attachment in such a manner, in which external forces are caused that
exceed the allowable loads and moments.
Limitations
NOTICE
Any use other than those specified in the chapter "Intended use" is misuse of the equipment and can
lead to dangerous situations, operational disturbances and to the extinction of the warranty

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WARNING
Danger of injury, possible property damage and loss of functional safety if the instructions are not
observed.
Use a carrier with operating weight as stated in chapter Technical data.
Mount the attachment to the carrier using a cardanic suspension or a quick change adapter for
cardanic suspension.
Other regional safety and environmental requirements must be complied with.
Warranty and liability claims for personal or material damage are excluded if not observed.
Safety sticker
All safety stickers on the attachment must remain legible.
DANGER / WARNING / CAUTION
of hazardous situation:
Pay attention to the risk of injuries,
material or property damage.
Follow the instructions.
Adhere to the safety clearance:
At least 10 m / 30 ft.
Before carrying out maintenance
and repair work:
Switch the machine off, read and
comprehend the operating
instructions and the safety
instructions.
Warning of hand injuries:
Do not guide the attachment by
hand. Keep hands away from
moveable / moving parts.
Read the operating instructions,
safety instructions and regional
regulations carefully, and ensure
you understand them to guarantee
safe and proper operation and
maintenance.
Warning of suspended load:
Do not stand under the
suspended load.

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2.5.1 Safety sticker for indicator pin: green for „locked“.
In correctly locked postion, the green indicator pin protruds approx. 5 mm. See Chater Operation.
3. Installation and Initial operation
Installation requirements on the crane
On the crane, prepare the installation of the electro-hydraulic control system of the coupler.
WARNING
Possibility of accidents and property damage due to incorrect operation of the hydraulic quick
coupler
Safeguarding against incorrect operation must be provided on the crane and is of top priority.
Implement the following safety measures at the crane:
•Operation of the coupler is only possible using both hands (two-hand operation).
•Protection from unwanted operation through a key locked switch or similar.
•An acoustic signal sounds when the "disengage quick coupler" function is activated.
•Ensure that the attachment cannot be disengaged from the coupler during use.
•Protect the quick coupler functions from unwanted operation.
Mount the valve block
The valve block is included in the scope of delivery and must be installed onto the crane, see
hydraulic diagram.
Normally the valve block is mounted onto the crane tip, Alternatively, the valve block can be
installed on the crane’s main valve.
For installation of the valve block, the following additional components are required:
•A 5th hydraulic line to the crane tip (only required for installation on the crane’s main
valve)
•An electrical cable 6x1.5mm² or similar cable
•3 valve plugs according to DIN EN 175301-803, Form A, for the hydraulic connection to
the valve block
Install an electric selector switch or similar onto the crane.
Enable the following three functions to be selected with the switch:
1. Engage quick coupler
2. Normal operation
3. Disengage quick coupler: Install an acoustic signal (such as a buzzer), which must sound
during this function.
Operating with remote control

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When operating with remote control, program the buttons on the remote control e.g., so that all 3
solenoid coils of the valve block are programmed separately on 3 buttons. This means different
combinations are used for locking and unlocking.
In addition to the pushbuttons, enable the hydraulic function "close attachment" (see chapter
3.1.3).
3.1.1 Installation of the upper part of the quick coupler onto the rotator
Mount parts 1 to 12 on the shaft of the rotator, see figure next page.
Remove paint and dirt (sand paper or grind) from the lower housing of the rotator where release
unit (1) is to be mounted. Re-paint this surface, where visible, after installation.
1. Push the release unit (1) onto the bottom of the rotator.
Make sure that the 3 balls (2) are placed in their boreholes.
Align the connection (3) approximately midway between the 2 lower hydraulic connections
on the motor head of the rotator. This way the hydraulic hose for the hydraulic quick coupler
can be attached without interference.
Tighten the 3 threaded studs (4). They are accessible from below.
2. Screw the fitting (5) with the seal (6) inserted into the shaft of the rotator and tighten.
3. Push the sleeve (7) onto the shaft of the rotator.
Align the sleeve so that the pin (8) can be pushed through.
Secure the pin with 2 screws (9).
4. Rotate the shaft of the motor (with the sleeve (7) mounted) until the fittings (5) align with the
holes in the unlocking unit (1).
Turn the connection adapters (11) so that the holes are also aligned with the holes in the
unlocking unit (1).
Insert the connecting pipes (10) through the connection adapters (11) and into the seal (11)
of the fitting (5). Grease the pipes for easier assembly.
Close the connection adapters (11) with screw plugs (12).
5. Connect the connection (3) to the valve block (part of the scope of delivery, see hydraulic
diagram).
6. To ensure the hydraulic connections do not leak, execute functions "Rotate rotator", "Open /
Close Grab" and "Disengage Quick Changer". Tighten the connections if necessary.
7. Glue the colored stickers into the appropriate recesses on the pin (8).

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3.1.2 Installation of the lower part of the quick coupler onto the attachment
The parts 12 to 22 must be dismantled and then reassembled. See figure next page.
Dismantling of parts
1. Remove the countersunk screws (15).
2. Remove cover plate (14), 2 protective plates (12), 4 washers (13).
3. Remove 2 springs (16).
WARNING: The springs are under tension.
4. Remove 2 control pins (22).
The opening ring (20) is pushed upwards by the 4 springs (21).
Remove these parts.
Reassembly of parts
1. Insert the cylinder screws M16 DIN 912 8.8 / ISO 4762 8.8, with length suitable to the
attachment, into the recesses under the springs (21).
Screw the lower part (10) to the attachment.
2. Reinsert the springs (21)
Slide the opening ring (20) with the metal wedges into the corresponding slots in the lower
unit and press down with a screw clamp or similar tool against the spring force.
3. Screw 2 control pins (22) into the opening ring (20) so that the tip engages the vertical
longitudinal holes of the lower part.
Remove screw clamps or tools.
4. Place 2 springs (16) in the grooves in the lower part (10).
Spray the 2 protective plates (12) with grease spray and install them in the lower part.
The springs (16) become pre-stressed at the installation of the protective slides (12).
5. Insert 4 washers (13) into the long holes of the protective plates (12) so that they lie
centrically on the threads in the lower part (10).
6. Place cover disc (14) and secure with 4 countersunk screws (15).
7. For lower parts with hydraulic couplings:
Connect the hydraulic connections at the sides of the lower part to the attachment using
hydraulic hoses.
Glue the colored stickers on the lower part so that the hydraulic quick couplings within
the quick coupler for "grab open" and "grab close" cannot be interchanged.
NOTICE
Breakdown and hydraulic oil leaks can be caused by incorrect installation.

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3.1.3 Hydraulic diagram with valve block
"Engage quick coupler" function:
Activation of valves 2 and 8, plus: "Close grab"
By executing these functions, the hydraulic lines for the open / close grab function at the crane are
depressurized. This facilitates engaging on the quick coupler.
"Disengage quick coupler" function:
Activation of valves 2 and 3, plus: "Close grab"
Abbreviation
Function
Connection thread at
valve block
Oil flow
Pressure
GO
Open grab
M18x1,5
max. 50 l/min
370 bar
GC
Close grab
M18x1,5
max. 50 l/min
370 bar
QO
Disengage quick coupler
M10x1
max. 5 l/min
260 bar
1
2, 3, 8
Valve block
Valve block:
Solenoid valves 2, 3, 8:
Nominal voltage 24 Volt
Coil power 19 Watt
Nominal resistance 30 Ohm
Nominal current 0.8 Amp
Connector DIN EN175-301-803

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3.1.4 Mounting holes at valve block
3.1.5 Connections at rotator
Abbreviation
Function
Connection thread at rotator
GO
Open grab
M18x1,5
GC
Close grab
M18x1,5
RR
Rotate rotator
M18x1,5
QO
Disengage quick coupler
M10x1
3.1.6 Pressure and oil flow
Requirements of the carrier machine
To operate the attachment correctly, set the operating pressure and oil flow at the truck crane
as indicated at section Technical data of these operating instructions.
These values also appear on the type plate.
3.1.7 Functional test
•After installation, actuate the control functions of the attachment and the rotator
sequentially and hold for approx. three seconds.
•Ensure that all functions are working correctly.
•Check that all connected lines can move freely.
•Ensure that no hydraulic fluid escapes from the connections.
•Ensure screw connections are tight.
•If necessary retighten connections in accordance with the appropriate tightening torques as
described in the Maintenance chapter, under Screwed connections

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21.01.2022 19
Operation
WARNING
Installation, operation and maintenance of the attachment may only be carried out by
authorized, trained and experienced personnel.
3.2.1 Exchanging attachments
Prior to operation, ensure that
•the upper part of the quick coupler KM 506 01 HD is mounted on the rotator. The rotator is
mounted onto the crane.
•the lower part of the quick coupler KM 506 02 HD or KM 506 04 HD is mounted on the
attachment.
KM 506 02 HD: with hydraulic connections
KM 506 04 HD: without hydraulic connections
The operational procedure for lower parts with or without hydraulic couplings is identical.
Engage quick coupler
1. Insert the upper part with the boom down onto the lower part.
2. Using the function „rotate rotator“, align the hydraulic couplings, while paying attention to the
colored markings. This way, the functions “open grab / close grab” cannot be interchanged.
Insert the upper part into the lower part
3. Execute the function „ Engage quick coupler“.
NOTICE: Execute the function "engage quick coupler" only for as long as necessary to prevent
overheating of the magnetic coils.
4. Activate the function „close grab“.
Steps 3. and 4. are only necessary for lower parts with hydraulic couplings.
5. Use the crane to lower the upper part straight down to the stop.
Through the depressurization (see explanation in section „Hydraulic diagramm with valve
block“), a force of only 20 - 50 kg is required to engage the quick coupler.

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6. Visual check of the lock indicator. Ensure the green indicator pin is visible.
Correctly locked
Incorrectly locked
The green indicator pin is
visible.
All 4 safety catches are correctly locked. In
locked position, the green indicator pin
protrudes approx. 5 mm.
At least 1 of the 4 safety catches is not
correctly locked. The green indicator pin is
not visible.
WARNING
Possible injury and property damage if operated if in correctly
locked.
Ensure the green indicator pin is visible.
When correctly locked, the green indicator pin is visible and
protrudes approx. 5 mm.
Pay attention to the safety sticker for the indicator pin:
7. Execute the function „normal operation”.
Disengage quick coupler
1. Set the attachment on a suitable flat surface so that it is standing firmly, and so that the crane is
fully relieved of the weight of the attachment.
2. Execute the function „Disengage quick coupler“.
An acoustic signal (buzzer) sounds.
3. Activate the function „close grab“.
4. Use the crane to pull the upper part vertically upwards out of the lower part.
NOTICE
Possible damage to solenoid coils through overheating, if the “disengage quick coupler "
function (to unlock) is operated for too long.
Execute the function "disengage quick coupler" only for as long as necessary to prevent
overheating of the magnetic coils.
5. Execute the function „Normal operation“.
The acoustic signal (buzzer) ceases.