1 Introduction ........................................................................................................................... 3 1.1 Working with this manual ............................................................................................. 3 1.2 Warning notes and symbols ........................................................................................ 3 1.3 Copyright ..................................................................................................................... 3 1.4 Qualified and authorized personnel .............................................................................. 3 1.5 Warranty claims based on defects ............................................................................... 3 1.6 Limits of applicable use ................................................................................................ 4
3.1 Proper use of the equipment ....................................................................................... 5 3.2 Improper use ............................................................................................................... 6
4 Installation and Inspection .................................................................................................... 6 4.1 Installation ................................................................................................................... 6
4.1.1 Model 4.5T156B Installation ............................................................................................... 7 4.2 Inspection .................................................................................................................... 8
4.2.1 Bleeding the hydraulic system ............................................................................................ 8 4.2.2 Adjustment after putting into service ................................................................................... 8
7 Troubleshooting ..................................................................................................................18 8 Decommissioning and disposal .........................................................................................19 9 Transport ..............................................................................................................................19 10 Storage .................................................................................................................................19 11 Parts identification ..............................................................................................................20
11.1 4.5T156B ....................................................................................................................20 11.2 Figure A –Valve Block ................................................................................................22 11.3 Figure B – Fork Positioner ..........................................................................................22
12 Recommended Spare Parts ................................................................................................23
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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 parentheses 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 and Lift Technologies, Inc. is forbidden and liable to prosecution. This applies, in particular, to reproduction, translation, microfilming as well as storage and processing in electronic systems.
1.4 Qualified and authorized personnel
Qualified and authorized 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 and/or Lift Technologies, Inc. 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-authorized personnel.
Claims raised by third parties.
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1.6 Limits of applicable use
KAUP and/or Lift Technologies, Inc. attachments are intended for use under the following climatic conditions:
Average ambient temperature for continuous operation: 77°F (25°C)
Allowable maximum ambient temperature, short term (up to 1h): 104°F (40°C)
Allowable minimum ambient temperature for attachments intended for indoor use: 41°F (5°C)
Allowable minimum ambient temperature for attachments intended for outdoor use: -4°F (-20°C)
Standard models of KAUP and/or Lift Technologies, Inc. attachments are NOT suitable for:
Continuous use (more than 2 hours) in cold storage facilities.
Conditions where temperatures are outside the allowable ambient temperature ranges as defined above.
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.
Several attachments from the KAUP range are, after appropriate modifications, suitable for operation in these special environments. Please consult Lift Technologies, Inside Sales and Customer Support.
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 authorized 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 the fork carriers (3) with stops (4) are moved hydraulically by cylinders (2).
Side-shift components (5) and hooks (6) are installed on the fork carriage (1) at the back
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
• Exceeding the allowable load capacity and load center.
• Dragging or pushing loads with the attachment.
• It is not permitted to transport loads which cause lateral forces on the forks
• It is not permitted 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 or HCG is changed, (e.g. fork extensions, hang on attachments) must be authorized by the manufacturer.
4 Installation and Inspection
4.1 Installation
Installation and commissioning should be performed by qualified and authorized personnel only.
Pay attention to a sufficient load-carrying capacity of the lifting means.
The following are examples of preferred lifting means
Capacity Kg 250 kg/M16 1200 kg/M16 2000 kg/M16 (lb.) (550 lbs) (2640 lbs) (4400 lbs) Part No. 9710160008 0360010201 0360010301
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4.1.1 Model 4.5T156B Installation
• Using appropriate lifting means, lift the attachment at the positions indicated (1).
• Remove the lower hooks (2).
• Mount the attachment on the fork carriage of the lift truck.
• Check that the attachment is seated with the center lock (3) in the center ITA notch of spine.
• Mount the lower hooks (2), tightening the screws (4) with a torque of 140 Ft.lb.
• Connect the hydraulic connectors (5A-sideshifting) and (5B- fork positioning) to those on the lift truck using tube or hose lines.
• Remove the safety retaining stops (6) from the fork carrier and install the forks onto the fork carrier.
• Make sure that all safety retaining stops (6) have been correctly reinstalled.
• The fork positioner may only be operated with the fork tines attached.
• Before initial operation, check the functions and the identification of the attachment with the movement directions of the operating elements (operating lever, joystick, etc.).
• Mount the residual carrying capacity notice and identification of the operating elements (if not already present) of the combination of lift truck/attached equipment on the lift truck.
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4.2 Inspection
KAUP-and/or Lift Technologies, Inc. attachments are delivered pre-lubricated. If the attachment has been in storage for a long period, we recommend that it be lubricated again before being placed in service. See Section 6. Maintenance and Servicing.
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. 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.
Report faults to your superior 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 (11.8 in.) and tilt the mast backwards.
Center 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 and/or Lift Technologies, Inc. attachment.
Ensure that maintenance and servicing are performed by qualified and authorized 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 warranty 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, and ISO 4032 etc.:
Screw / bolt rating 8.8 10.9 12.9
M6 thread 6 ft.lb. 9 ft.lb. 10 ft.lb.
M8 thread 15 ft.lb. 22 ft.lb. 28 ft.lb.
M10 thread 30 ft.lb. 44 ft.lb. 55 ft.lb.
Μ12 thread 52 ft.lb. 74 ft.lb. 95 ft.lb.
Μ16 thread 125 ft.lb. 177 ft.lb. 240 ft.lb.
Μ20 thread 244 ft.lb. 337 ft.lb. 394 ft.lb.
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. 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 warranty 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
Designation DIN51825: K 2 K-30
Complex soap grease NLGI Class 2 Foundry quality
Teflon spray 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 (94.5 in.) or raised load centers, amended/shorter maintenance intervals should be agreed by the user with the manufacturer.
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6.3.1 Sideshift
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Daily Check all lines, hoses and connections for leakage and damage.
After 50 hours / every 500 hours thereafter Check screws (1) on the lower hooks (2).
Replace missing or damaged screws. Torque the screws as specified in Section 6.1: General.
Weekly Grease:
Upper wear pads (5) through grease fitting (6) in the fork carrier (7).
Note: Additional grease nipples can be installed by removing upper wear pads from unit; drilling out remaining plastic of grease port; installing self-taping or drive-in grease nipple; and reinstalling upper wear pad.
Every 200 hours Check wear on:
Upper wear pads (5)
As necessary
Replace lower hook assembly (2) by removing screws (1). Remove the faulty lower hook assembly (2). Replace the lower hook assembly. Install hooks (2) using screws (1) to secure. Torque as specified (see table in Section 6.1 on page 10).
Replace upper wear pads (5) by removing screws (1) and hooks (2). With the hydraulic system depressurized, remove retaining ring (8) slide in cylinder rods. Use appropriate lifting equipment lift the fork carriage (7) off the carriage base of the lift truck. Replace upper wear pads (5). Place the fork carrier (7) onto carriage base of the lift truck, install retaining ring (8) and install hooks (2) using screws (1). Torque as specified (see table in Section 6.1 on page 10).
Replace the faulty cylinder (11) by removing the hydraulic lines from the cylinder (11) with the hydraulic system depressurized. Remove screws (1) and hooks (2). Use appropriate lifting equipment to lift the fork carriage (7) off the fork carriage base of the lift truck. Remove the retaining ring (12) washer (9), guide (10), and retaining ring (8). Replace the faulty cylinder (11) and reinstall the retaining ring (8), guide (10), washer (9), and retaining ring (12). Place the fork carrier (7) onto the fork carriage base of the lift truck and install hooks (2) and screws (1), and the hydraulic lines.
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6.3.2 Fork positioner
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Daily Check all lines, hoses and connections for leakage and damage.
Ensure that all fork safety retaining stops (1) are present and undamaged.
After 50 hours / every 500 hours thereafter Check:
Screws (2) on the fork safety retaining stops (1).
Replace loose or damaged screws. Torque the screws as specified in Section 6.1: General.
As necessary
Replace faulty cylinder (3) by removing hydraulic lines from cylinder (3) with the hydraulic system depressurized. Remove screws (8 and 8a) from the fork carriage (9) and holder (13 and 13a) remove the entire fork positioning unit from the fork carriage (9). Remove the nut (4) from the damaged cylinder (3), loosen the lock nuts (5, 6), and remove the nut (7, 7a) from the holder (13, 13a). Replace the faulty cylinder (3) and install the nut (7, 7a) to the holder (13, 13a), lock nuts (5, 6), and nut (4) to the slide (11). Tighten the lock nuts (5, 6), check for proper clearance of 0.06 to 0.08 in. (see inset in diagram on page 14) and place the entire fork positioning unit in the fork carriage (9). Secure it to the fork carriage (9) using the screws (8 and 8a) and reinstall the hydraulic lines.
Each time a cylinder (3) is mounted or removed, check the clearance between the cylinder retainer and the cylinder nut (4, 7, 7a). The cylinders are installed with a clearance of from 0.06 to 0.08 in. (see inset in diagram on page 14).
Replace faulty or worn plain bearings (10) in the fork carrier (11) by removing the hydraulic lines from the cylinder (3) with the hydraulic system depressurized. Remove the screws (8 and 8a) from the fork carriage (9) / holder (13 and 13a) and remove the entire fork positioning unit from the fork carriage (9). Remove the nut (7, 7a) from the holder (13, 13a) / shaft (12) and the nut (4) from the slide (11). Pull the fork carrier (11) out to the side and replace any defective or worn plain bearings (10). Push the fork carrier (11) back onto the shaft (12) and the cylinder (3). Install the nut (7, 7a) to the slide (11) and the nut (7, 7a) to the holder (13). Place the entire fork positioning unit in the fork carriage (9) and secure it using the screws (8 and 8a). Reinstall the hydraulic lines. Torque to proper specs.(see table in Section 6.1 on page 10)
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6.3.3 Forks Inspect per ANSI / ITSDF B56.1-2012 Sections 6.2.8.1-6.2.8.2
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
authorized workshops. You can increase the service life of forks by using forks especially protected against wear.
6.3.4 ITA Fork carriage
Annually
Check the ISO strips at the fork carriage (9) and (17) for wear. Render the fork positioner inoperative when at least one of the three wear limits c2, k2, or d2 is
below safety specifications. Wear Limit (z)
ISO Cl 2 ISO Cl 3 ISO Cl 4
c2 k2 d2 c2 k2 d2 c2 k2 d2
13.5 11.5 9.3 mm 18.5 14.5 13.2 mm 22.0 17.5 15.6
0.53 0.45 0.37 In. 0.73 0.57 0.52 In. 0.87 0.69 0.61
As necessary
For replacing the fork carriage, please contact Inside Customer Sales and Support (contact information on cover page.)
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6.3.5 Identification plate and caution board
Number Description
1
Identification plate
2
Before putting into operation, carefully read and take note of the operating and security instructions.
3
Never reach into the unit as long as parts could still be moving due to the danger of squashing or shearing.
4
Use suspension point!
5
Test and operate the fork positioner with the fork arms attached only!
6
Never reach into the unit as long as parts could still be moving due to the danger of squashing or shearing.
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7 Troubleshooting
Troubleshooting should only be performed by qualified and authorized 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
Slide of the fork tine Slider is worn Replace sliders
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 truck’s hydraulics too low
Increase pressure at the truck’s hydraulics
Too fast Pressure supplied by the truck’s hydraulics too high
Decrease pressure at the truck’s hydraulics
Purchase speed control kit from LTI (part# K520048)
Jerky shifting action Sliders not properly lubricated Lubricate sliders
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
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8 Decommissioning and 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 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.
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11 Parts identification
11.1 4.5T156B
NOTES: A) See Figure A on page 22. B) See Figure B on page 22.
B
A
Figure B
Figure A
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4.5T156 Picture
Number Total Qty
required
Part Number Sold in Qty
Description Remarks
1 1 Upon Request 1 ea. Frame, Front SSFP
2 2 KS20034 1 ea. Guide, Top Slide
3 1 K20034 1 ea. Cylinder, Side Shift for seal kit
4 9 Sold in kit
Pad, Upper Wear
5 2 K40024 1 ea. Washer, Flat M30x56x4
6 2 K40023 1 ea. Clip, External Safety M30x1.5
7 1 Upon Request 1 ea. Tube, Cylinder, Left Supply Image not shown
8 1 Upon Request 1 ea. Tube, Cylinder, Right Supply
K30032 1 kit Upper FP Cylinder Seal kit K30033 1 kit Lower FP Cylinder Seal kit
12 Recommended Spare Parts
Number of Units Serviced Part No. Description 1 2-10 11+ K30031 SS Cylinder Seal Kit 1 1 1 per every 10 units K30030 Upper Wear Pad Kit 1 1 1 per every 5 units K30029 Lower Roller Kit 1 1 1 per every 20 units K30032 Upper FP Cylinder Seal kit 1 1 2 per every 20 units K30033 Lower FP Cylinder Seal Kit 1 1 2 per every 20 units K20034 Sideshifting Cylinder 0 0 1 per every 25 units
