WIFO K54A-I Operator's manual

WIFO-Anema B.V.
Hegebeintumerdyk 37 – 9172 GP Ferwert – Holland
Telefoon (0031) 518411318 – Telefax (0031) 518411563
www.wifo.nl – email: [email protected]l
Manual and safety instructions
K54A-(Z)/K54C-(Z)/SK54A-(Z)/SK54C-(Z)
Box rotator
GB
K54A-O/K54C-O
SK54A-O/SK54C-O
K54A-I/K54C-I
K54A-Z-O/K54C-Z-O

1
English
Table of contents
1. TO THE USER...................................................................................................................................................................2
1.1 INTRODUCTION ...................................................................................................................................................................... 2
1.2 SAFETY PRECAUTIONS AND WARNINGS ........................................................................................................................................ 3
1.2.1 Safety precautions .................................................................................................................................................... 3
1.2.2 Safety stickers and warning signs............................................................................................................................. 5
1.2.3 Placement of the safety stickers on the machine ..................................................................................................... 6
1.3 PURPOSE OF USE .................................................................................................................................................................... 7
1.4 LIABILITY............................................................................................................................................................................... 8
1.5 WARRANTY ........................................................................................................................................................................... 8
2. TECHNICAL DATA............................................................................................................................................................9
2.1 GENERAL TECHNICAL DATA...................................................................................................................................................... 9
2.2 K54A-I AND K54C-I............................................................................................................................................................ 10
2.2.1 Parts list ................................................................................................................................................................. 10
2.2.2 Commencement of operation K54A-I and K54C-I ................................................................................................... 12
2.3 K54A-O AND K54C-O......................................................................................................................................................... 13
2.3.1 Parts list ................................................................................................................................................................. 13
2.3.2 Commencement of operation K54A-O and K54C-O ................................................................................................ 15
2.4 K54A-Z-O/K54C-Z-O......................................................................................................................................................... 16
2.4.1 Parts list .................................................................................................................................................................. 16
2.4.2 Commencement of operation K54A-Z-O and K54C-Z-O.......................................................................................... 18
2.5 SK54A-O/SK54C-O ........................................................................................................................................................... 19
2.5.1 Parts list .................................................................................................................................................................. 19
2.5.2 Provisions for connecting SK54A-O and SK54C-O ................................................................................................... 21
2.5.3 Commencement of operation SK54A-O and SK54C-O ............................................................................................ 22
3. FAULTS AND MAINTENANCE....................................................................................................................................................... 23
3.1 PREVENTIVE MAINTENANCE AND LUBRICATION .......................................................................................................................... 23
3.2 TROUBLESHOOTING.............................................................................................................................................................. 24
3.3 WORK TO BE CARRIED OUT BY A COMPETENT MECHANIC.............................................................................................................. 25
3.3.1 Instructions for replacing the sleeve bearing of K54A/K54C/SK54A/SK54C ........................................................... 25
3.3.2 Instructions for replacing the tapered roller bearings of K54A-Z/K54C-Z/SK5A-Z/SK54C-Z.................................... 26

2
1. To the user
1.1 Introduction
This manual gives information about the commencement of operation, use and maintenance of your newly
purchased WIFO box rotator. Also included in this manual are a number of safety instructions to create a safe
working environment.
WIFO-Anema B.V. continuously aims to improve its products. WIFO-Anema B.V. reserves the right to introduce any
changes and improvements deemed necessary without prior notice.
Please read the manual thoroughly and observe the safety procedures before putting the unit into operation.
Contact your dealer for any further questions or concerns you may have.
We hope you will enjoy working with your WIFO box rotator.
Keep this manual in a safe place for future reference!
WIFO-Anema B.V.
Dealer:
PLEASE NOTE:
Carefully read this manual before you put the machine into operation and act upon all directions that are
given. This is to guarantee its safe, trouble-free operation.

3
1.2 Safety precautions and warnings
Please read this manual before you put the machine into operation for the first time, and observe the safety
instructions at all times. The most important instructions are marked with a symbol.
Any person in charge of the commencement of operation, the operation itself or the maintenance of the machine is
urged to carefully read and observe the following instructions.
1.2.1 Safety precautions
Centre the load;
Place the forks as widely as possible;
Position the third fork against the side of the box.
Restrict driving with the load in elevated position;
Do no tilt the load during transport;
Slightly tilt the forklift mast backwards during transport.
Do not allow any person to ride on the forks.
This symbol is used for all important safety instructions throughout this manual. Carefully observe the
instructions and be very cautious!
This symbol is used for all important actions that should not be carried out under any circumstances.
Carefully observe these prohibitions!
Do not allow any person to stand under the load, and
stay out of the working area of the box rotator.

4
Keep at least 150 mm of the fork positioner of the folding
fork in the slot and secure the same using the two bolts
and lock nuts (140Nm).
Operate the box rotator from the driver’s seat of the
forklift/tractor only.
Park the forklift truck / mast with the box rotator in the lowest position only. Make sure that unexpected
movements are ruled out if the forklift
truck / tractor is not being used. Place the box rotator on its back on a
flat, stable surface after it has been removed from the forklift truck / mast for storage.
For tilting work, use only durable boxes with flooring or grooves.
Make sure the operating lever for rotating is not mixed up with any other operating lever to prevent
inadvertent tilting or side-shifting. Only the side-shift function remains in the event of a power cut while
operating an electrically controlled valve. Disable the tilting motion by closing the ball valve next to the
balancing valve. Unintentional operation is no longer possible.
Make sure the hydraulic hoses and any power cables do not get jammed and that the box rotator is able to
move freely.
During the controlled tilting action, be aware of the back-tilt moment of the rotating cylinder.

5
1.2.2 Safety stickers and warning signs
Several safety stickers have been put onto the machine. The meaning of the stickers on the machine is as follows:
NB:
Regularly tighten the bolts of the guide block using the correct tightening
moment (60Nm)!
3
NB:
Please read the instructions from the manual prior to any maintenance to the
machine!
Turn of the engine and remove the key from the ignition for the time
maintenance on the machine is carried out!
1
Danger:
Always keep a safe distance from the machine!
2
A safe working environment also requires personnel to be well-informed about the various safety stickers on
the machine. Be aware of the hazards they warn you to look out for.
Replace any loose, illegible or missing stickers.

6
3
2
1
3
2
1
Figure 1.2.1- Position safety stickers for K54A-O and K54C-O Figure 1.2.2- Position safety stickers for SK54A-O-(Z) and SK54C-O-(Z)
3
2
1
3
2
1
Figure 1.2.3- Position safety stickers for K54A-I and K54C-I Figure 1.2.4- Position safety stickers for K54A-Z-O and K54C-Z-O
1.2.3 Placement of the safety stickers on the machine

7
1.3 Purpose of use
The WIFO box rotator is exclusively used for transporting and sideways tilting boxes with flooring or grooves,
provided that the overall weight of the box including its load does not exceed the carrying capacity of the box
rotator. The box rotator must be attached to a FEM II (K54A and SK54A) or FEM III (K54C and SK54C) fork carrier of a
forklift truck or forklift mast.
Do not use the box rotator for carrying people under any circumstances!
The overall weight of the box rotator including its load may not exceed the capacity of the forklift truck or the
forklift mast. (See the name plate on the forklift truck/forklift mast)

8
1.4 Liability
Any person working with or on the machine must have read this manual. The machine is to be used for its intended
purpose only. Included in the intended purpose are, among other things:
1. Work must be carried out in accordance with the directions and within the functional restrictions (e.g.
maximum hydraulic working pressure) as outlined in the regulations. Use only sound and appropriate tools.
2. Electric/electronic equipment and accessories (e.g. cables) must be treated in accordance with the general
accepted policy for using non-waterproof portable electric and electronic equipment, such as:
a) Storing and keeping in a clean, dry environment away from rodents and the like; and
b) Protecting the equipment against severe, uncushioned shocks and water (precipitation).
3. Use only original or compatible spare parts. Such parts must be assembled as directed (e.g. by observing the
recommended tightening moments). Spare parts (as well as lubricants) are considered compatible only if
explicitly approved by WIFO or in the event that the customer is able to prove they possess the required
properties for the purpose(s) they are used.
4. Use only lubricants that meet the specifications as described in the directions.
5. Always observe the local regulations in terms of accident prevention, safety, traffic and transport.
6. Only trained personnel with knowledge of the possible hazards have permission to work with/on the
machine.
7. WIFO-Anema B.V. will assume no liability in any shape or form for losses or damage caused following
modifications to the machine, which have not been explicitly approved by WIFO.
1.5 Warranty
WIFO-Anema B.V. guarantees the soundness of its products in terms of materials used and/or structural defects.
However, in any event this warranty is limited to the free-of-charge replacement or repairs of the defect product, or
part thereof. WIFO-Anema B.V. assumes no liability for any loss or damage arising from faulty deliveries and/or the
breakdown of purchased goods before the warranty period has expired. The warranty period for this product is
twelve months.
Noncompliance with the rules and directions from this manual will be considered as serious negligence, for
the consequences of which WIFO-Anema B.V. accepts no liability whatsoever. In such cases, the user will
bear the full risk of his actions.
WIFO-Anema B.V. is continuously working on the improvement of its products. For that reason, WIFO-
Anema B.V. reserves the right to introduce any changes and improvements deemed necessary without
prior notice. However, it does not imply an obligation to make any such changes or improvements to
machines bought by customers in the past.

9
2. Technical data
2.1 General technical data
1With plastic bearing/roller bearings (z-type).
2The back-tilt moment has been calculated at 18 Mpa (180 bar) working pressure.
3Two positions from inside fork to centre of rotating shaft.
4Continuously adjustable from inside fork to centre of rotating shaft.
Model
Letter
Description
K54A/K54C/SK54A/SK54C
L
Rotating to the left
R
Rotating to the right
Z
Industrial model with adjustable tapered roller bearings
K54A/K54C
I
Plug-in third fork
O
Foldaway third fork
SK54A/SK54C
E
Electrically controlled reversing valve
S
4-hose connection
Table 2.1.2- Description data on model plate
Model
K54A-I
K54A-(Z)-O
K54C-I
K54C-(Z)-O
Max. carrying capacity
2500 kg
2500 kg
3500 kg
3500 kg
Weight 1
240 kg
270/285 kg
315 kg
345/360kg
Max. working pressure
22Mpa (220 bar)
22Mpa (220 bar)
22Mpa (220 bar)
22Mpa (220 bar)
Back-tilt moment 2
6,84 KNm
6,84 KNm
6,84 KNm
6,84 KNm
Center of gravity
133 mm
158 mm
134 mm
158 mm
Frontal extension length
165 mm
185 mm
185 mm
Height of the fork carrier
407 mm (FEM II)
407 mm (FEM II)
508 mm (FEM III)
508 mm (FEM III)
Rotation angle
180°
180°
180°
180°
Fork carrier width
1000 mm
1000 mm
1200 mm
1200 mm
Side-shift
Nee
Nee
Nee
Nee
Third fork plug-in 3
675 of 775 mm
-
775 of 875 mm
-
Third fork foldaway 4
-
580 – 800 mm
-
680 – 900 mm
Model
SK54A-(Z)-O
SK54C-(Z)-O
Max. carrying capacity
2500 kg
3500 kg
Weight 1
335/350 kg
405/420 kg
Max. working pressure
22Mpa (220 bar)
22Mpa (220 bar)
Back-tilt moment 2
6,84 KNm
6,84 KNm
Center of gravity
141 mm
145 mm
Frontal extension length
173 mm
188 mm
Height of the fork carrier
407 mm (FEM II)
508 mm (FEM III)
Rotation angle
180°
180°
Fork carrier width
1000 mm
1200 mm
Side-shift
Ja, 200mm
Ja, 200mm
Third fork plug-in 3
-
-
Third fork foldaway 4
580 – 800 mm
680 – 900 mm
Table 2.1.1- Various models of the WIFO box rotator

10
2.2 K54A-I and K54C-I
2.2.1 Parts list
Figure 2.2.1-Parts drawing for K54A-I and K54C-I

11
Table 2.2.1-Parts list for K54A-I and K54C-I
Type: K54A-I/K54C-I
Nr.
Part:
Part nr..:
Nr.
Part:
Part nr..:
1
Back plate K54A
-
15
Fork carrier K54A plug-in model
-
Back plate K54C
-
Fork carrier K54C plug-in model
-
2
Clamping strip 40x20-L300 (for K54A)
4290081
16
Gearwheel C45-M5-Z=60
4290114
Clamping strip 47x30-L300 (for K54C)
4290091
17
Roll pin Ø14x90
-
3
Bolt M16x60
-
18
Hex sock bolt M12x80 12.9
-
4
Spring washer M16
-
19
Plastic bearing Ø137x125-L124 (for K54A)
429027
5
Guide Block holder 85x70x15
429016
Plastic bearing Ø137x125-L134 (for K54C)
429028
6
Guide block 85x82x55
4290135
20
Locking plate Ø160x10
429007
7
Bolt M16x60
-
21
Bolt M12x30
-
8
Nut M16
-
22
Spring washer M12
-
9
Balancing valve 3/8” EW
429057
23
Nameplate WIFO
-
10
Bolt M8x50
-
24
Spring washer M16
-
11
Locking nut M8
-
25
Bolt M16x25
-
12
Grease nipple M8
-
26
Lock pin plug-in fork Ø16-L100
-
13
Rotating cylinder DW70-30-377 (180°)
4290463
27
R-clip Ø4
-
Rotating cylinder DW70-30-377 (200°)
4290466
28
Plug-in fork 100x50
429001
14
Circlip shaft Ø30
-
29
Ball valve 3/8”2-way
429062

12
2.2.2 Commencement of operation K54A-I and K54C-I
1. Remove the clamping strip (2).
2. Remove the forks from the forklift truck or forklift mast.
3. Make sure the fork carrier is straight and clean.
4. Place the box rotator onto the fork carrier of the forklift truck or forklift mast.
5. Make sure the locking cam slots into the recess in the centre of the fork carrier. If no recess is available:
a) Grind such a recess, or
b) Grind the locking cam from the box rotator and attach a sound locking cam on the spot of an existing recess
in the fork carrier. In doing so, make sure the box rotator sits secure in the centre in front of the fork carrier,
so it is unable to slide sideways.
6. Attach the clamping strip (8) using two bolts M16x60 (3). Secure these bolts tight! (140 Nm)!
7. Check to make sure the hydraulic hoses are clean before connecting them to the rapid-action couplings, to
prevent any debris from entering the hydraulics of the machine.
8. Connect the hydraulic hoses to the dual-action connection on the fork carrier.
9. Remove the check nuts M16x25 (25) in the lower plate of the fork carrier of the box rotator. Suspend the
forks to the fork carrier and attach the check nuts M16x25 (25).
10. Adjust the plug-in fork (28), depending on the width of the boxes to be rotated.
11. Secure the plug-in fork (28) using the lock pin plug-in fork (26) and secure this with the r-clip Ø4 (27).
12. Turn the lever of the ball valve (29) so it opens, before rotating. It will be open when the lever is parallel to
the hydraulic pipe.
13. Subsequently check that the hydraulic hoses can move freely and check that the system is not leaking oil.
14. Check the correct operation of the box rotator by controlling the hydraulic functions.
The WIFO box rotator is now ready to be used.

13
2.3 K54A-O and K54C-O
2.3.1 Parts list
Figure 2.3.1-Parts drawing for K54A-O and K54C-O

14
Type: K54A-O/K54C-O
Nr.
Part:
Part nr..:
Nr.
Part:
Part nr..:
1
Back plate K54A
-
20
Locking plate Ø160x10
429007
Back plate K54C
-
21
Bolt M12x30
-
2
Clamping strip 40x20-L300 (for K54A)
4290081
22
Spring washer M12
-
Clamping strip 47x30-L300 (for K54C)
4290091
23
Nut M16
-
3
Bolt M16x60
-
24
Bolt M16x45
-
4
Spring washer M16
-
25
Nameplate WIFO
-
5
Guide Block holder 85x70x15
429016
26
Fork positioner 100x50 folding fork
4290027
6
Guide block 85x82x55
4290135
27
Grease nipple M8
-
7
Bolt M16x60
-
28
Bolt M16x70
-
8
Nut M16
-
29
Nut M16
-
9
Balancing valve 3/8” EW
429057
30
Gas spring
4290029
10
Bolt M8x50
-
31
Gas spring pin folding fork Ø20-L60
4290028
11
Locking nut M8
-
32
Pin folding fork Ø30-L145
429076
12
Grease nipple M8
-
33
Bolt M10x20
-
13
Rotating cylinder DW70-30-377 (180°)
4290463
34
Spring washer M10
-
Rotating cylinder DW70-30-377 (200°)
4290466
35
Fork folding fork
4290022
14
Circlip shaft Ø30
-
36
Grub screw M16x16
-
15
Fork carrier K54a folding fork
-
37
Hex sock screw M16x30
-
Fork carrier K54c folding fork
-
38
Spring washer M16
-
16
Gearwheel C45-M5-Z=60
4290114
39
Bolt M16x25
-
17
Roll pin Ø14x90
-
40
Ball valve 3/8”2-way
429062
18
Hex sock bolt M12x80 12.9
-
19
Plastic bearing Ø137x125-L124 (for K54A)
429027
Plastic bearing Ø137x125-L134 (for K54C)
429028
Table 2.3.1-Parts list for K54A-O and K54C-O

15
2.3.2 Commencement of operation K54A-O and K54C-O
1. Remove the clamping strip (2).
2. Remove the forks from the forklift truck or forklift mast.
3. Make sure the fork carrier is straight and clean.
4. Place the box rotator onto the fork carrier of the forklift truck or forklift mast.
5. Make sure the locking cam slots into the recess in the centre of the fork carrier. If no recess is available:
a) Grind such a recess, or
b) Grind the locking cam from the box rotator and attach a sound locking cam on the spot of an existing recess
in the fork carrier. In doing so, make sure the box rotator sits secure in the centre in front of the fork carrier,
so it is unable to slide sideways.
6. Attach the clamping strip (2) using two bolts M16x60 (3). Secure these bolts tight! (140 Nm)!
7. Check to make sure the hydraulic hoses are clean before connecting them to the rapid-action couplings, to
prevent any debris from entering the hydraulics of the machine.
8. Connect the hydraulic hoses to the dual-action connection on the fork carrier.
9. Remove the check nuts M16x25 (39) in the lower plate of the fork carrier of the box rotator. Suspend the
forks to the fork carrier and attach the check nuts M16x25 (39).
10. Adjust the third fork, foldaway model (35), depending on the width of the boxes to be rotated. The fork
positioner (26) of the folding fork must reach at least 150mm into the slot.
11. Secure the fork positioner, foldaway model (26) using the pressure bolts M16x45 (24); tightly secure first
the bolts and then the lock nuts M16 (23).
12. Turn the lever of the ball valve (40) so it opens, before rotating. It will be open when the lever is parallel to
the hydraulic pipe.
13. Subsequently check that the hydraulic hoses can move freely and check that the system is not leaking oil.
14. Check the correct operation of the box rotator by controlling the hydraulic functions.
The WIFO box rotator is now ready to be used

16
2.4 K54A-Z-O/K54C-Z-O
2.4.1 Parts list
Figure 2.4.1-Parts drawing for K54A-Z-O and K54C-Z-O

17
Type: K54A-Z-O/K54C-Z-O
Nr.
Part:
Part nr..:
Nr.
Part:
Part nr..:
1
Back plate K54A-Z
-
23
Tapered roller bearing 33117
429030
Back plate K54C-Z
-
24
Packing seal Ø145x125-L14 H9
429035
2
Clamping strip 40x20-L300 (for K54A)
4290081
25
Packing seal Ø145x125-L14 H9
429035
Clamping strip 47x30-L300 (for K54C)
4290091
26
Locking plate Ø160x10
4290073
3
Bolt M16x60
-
27
Grease nipple M8
-
4
Spring washer M16
-
28
Adjusting screw M10x35
-
5
Guide Block holder 85x70x15
429016
29
Nut M10
-
6
Guide block 85x82x55
4290135
30
Bolt M12x50
-
7
Bolt M16x60
-
31
Spring washer M12
-
8
Nut M16
-
32
Spring washer M16
-
9
Balancing valve 3/8” EW
429057
33
Bolt M16x25
-
10
Bolt M8x50
-
34
Nameplate WIFO
-
11
Locking nut M8
-
35
Nut M16
-
12
Adjusting screw M16x16
-
36
Bolt M16x45
-
13
Adjusting screw M10x20
-
37
Fork positioner 100x50 folding fork
4290027
14
Adjusting strip gear rack
-
38
Grease nipple M8
-
15
Pivot pin Ø125-L166 (for K54A-Z)
4290048
39
Bolt M16x70
-
Pivot pin Ø125-L174 (for K54C-Z)
4290049
40
Nus M16
-
16
Rotating cylinder DW70-30-377 (180°)
4290463
41
Gas spring
4290029
Rotating cylinder DW70-30-377 (200°)
4290466
42
Gas spring pin folding fork Ø20-L60
4290028
17
Circlip external Ø30
-
43
Pin folding fork Ø30-L145
429076
18
Fork carrier K54A folding fork
-
44
Bolt M10x20
-
Fork carrier K54C folding fork
-
45
Spring washer M10
-
19
Gearwheel C45-M5-Z=60
4290114
46
Fork folding fork
4290022
20
Roll pin Ø14x90
-
47
Adjusting screw M16x16
-
21
Hex sock bolt M12x80 12.9
-
48
Hex sock screw M16x30
-
22
Tapered roller bearing 33018
429029
49
Ball valve 3/8”2-way
429062
Table 2.4.1-Parts list for K54A-Z-O and K54C-Z-O

18
2.4.2 Commencement of operation K54A-Z-O and K54C-Z-O
1. Remove the clamping strip (2).
2. Remove the forks from the forklift truck or forklift mast.
3. Make sure the fork carrier is straight and clean.
4. Place the box rotator onto the fork carrier of the forklift truck or forklift mast.
5. Make sure the locking cam slots into the recess in the centre of the fork carrier. If no recess is available:
a) Grind such a recess, or
b) Grind the locking cam from the box rotator and attach a sound locking cam on the spot of an existing recess
in the fork carrier. In doing so, make sure the box rotator sits secure in the centre in front of the fork carrier,
so it is unable to slide sideways.
6. Attach the clamping strip (2)using two bolts M16x60 (3). Secure these bolts tight! (140 Nm)!
7. Check to make sure the hydraulic hoses are clean before connecting them to the rapid-action couplings, to
prevent any debris from entering the hydraulics of the machine.
8. Connect the hydraulic hoses to the dual-action connection on the fork carrier.
9. Remove the check nuts M16x25 (33)in the lower plate of the fork carrier of the box rotator. Suspend the
forks to the fork carrier and attach the check nuts M16x25 (33).
10. Adjust the third fork, foldaway model (46), depending on the width of the boxes to be rotated. The fork
positioner (37) of the folding fork must reach at least 150mm into the slot.
11. Secure the fork positioner, foldaway model (37)using the pressure bolts M16x45 (36); tightly secure first
the bolts and then the lock nuts M16 (35).
12. Turn the lever of the ball valve (49) so it opens, before rotating. It will be open when the lever is parallel to
the hydraulic pipe.
13. Subsequently check that the hydraulic hoses can move freely and check that the system is not leaking oil.
14. Check the correct operation of the box rotator by controlling the hydraulic functions.
The WIFO box rotator is now ready to be used