Operating Manual

Sideshifter T 151 P2
Subject to modifications

1
Edition 07/99 Techdok\Anbaugeräte\T151P2\Betriebsanleitung\englisch\T151P2
 Operating Manual

Contents

1. Introduction

1.1 Working with this manual

1.2 Warning notes and symbols

1.3 Proper use of equipment

1.4 Codes and regulations

1.5 Guarantee

2. Safety

2.1 Organizational notes

2.2 Operator's safety notes

2.3 General hazard notes

3. Design

4. Installation and checking out

5. Operation

6. Maintenance

7. Trouble - Cause - Correction

8. Spare parts list

Contents 2
 Operating Manual

1. Introduction

1.1 Working with this manual

This operating manual is designed to familiarize operators with the equipment

and its intended application.

The manual contains important notes concerning safe, proper and economic
working with the equipment. Strict observation of these notes will help to
avoid risks, reduce repair costs and down time, and increase the reliability
and useful life of the equipment.

In addition to the instructions contained in this manual, all pertinent national

and local codes and regulations relating to safety and environmental
protection must be observed in full.

This operating manual must be kept availale for ready reference at the
equipment's place of use.

The manual must be kept available for ready reference at the equipment's
place of use.

The manual must be read and followed by all persons involved in work with
or on the equipment. This work includes:

- Operating the equipment, including setting up for use, correcting

trouble in use, collection and disposal of production scrap, cleaning
and routine servicing, disposal of spent lubricants and other wastes.

- Inspection, maintenance and repair

- Handling

In addition to this operating manual and the safety codes and regulations in
force at the place of use, standard practice relating to safe and proper working
with tools and machines must be observed at all times.

Introduction 3
 Operating Manual

1.2 Warning notes and symbols

The following marks and symbols are used in this operating manual to
highlight details holding special importance:

Important note:
Identifies special details relating to economic working
with the equipment.

Caution:
Identifies special details relating to do's and dont's for
the purpose of avoiding damage to the equipment.

Danger:
Identifies details relating to do's and dont's for the
purpose of avoiding injury and property damage.

1.3 Proper Use of Equipment

The equipment must only be used in accordance with the operating manual
and when it is in fully satisfactory working condition. It must only be
used for the purpose intended with all due consideration to safety aspects
and awareness of the dangers associated with its use. Any and all faults
or malfunctions that may affect the safety of the machine and/or equipment
must be corrected immediately.

Proper use of the machine and/or equipment includes the following:

- Observance of the operating manual at all times.

- Adherence to the specified inspection and maintenance intructions.

The following constitutes improper use of the machine and/or equipment:

- Exceeding the allowable load capacity and load center.

- Dragging or pushing loads with the attachment.
- Transporting persons with the load or load handling devices.
- Use of other equipment on the attachment which alters or
conflicts with its intended application.

Introduction 4
 Operating Manual

1.4 Codes and Regulations

Kaup forklift truck attachments are designed and constructed in accordance

with European and German standards, rules and codes and must be operated
in accordance with these.

Allowance has been made for the following regulations, which must be observed
in use by the operator:

98/37/EC European Directive on Machinery

EN 292 European Standard on Safety of Machines
EN 1726 European Standard on Power-Driven Industrial Trucks
to 10,000 kg Capacity
EN 1551 European Standard on Power-Driven Industrial Trucks
over 10,000 kg Capacity
EN 1050 European Standard on Assessment of Risks

These include the associate standards and regulations.

1.5 Guarantee

Kaup shall not be liable for any and all damage to the equipment resulting
from improper use of the equipment or from work carried out improperly or
by improperly trained persons. Kaup shall also not be liable for third-party
damages.

Caution!
Unauthorized alterations to any parts and assembly or
installation other than as specified in the instructions will
render all guarantees null and void.

Caution!
Use exclusively original Kaup spare parts.
Maintenance and repair work must be carried out by
properly trained personnel only.

Introduction 5
 Operating Manual

2. Safety

2.1 Organizational Notes

- Operating, maintenance and servicing/repair personnel must have read

and understood the operating manual before commencing work with
or on the equipment.
- The operating manual must be kept available for ready reference at
the equipment's place of use.
- In addition to the instructions contained in the operating manual, all
pertinent general, legal and other regulations relating to safety and
environmental protection must be enforced and observed.
- All safety and danger notices on the machine and equipment must be
observed.
- The machine and/or equipment must be shut down immediately in the
occurrence of any safety-related change on the machine or equipment
or in its workings and the fault or malfunction must be reported to the
officer responsible.
- Work with and on the machine and/or equipment may only be carried
out by responsible and properly trained personnel, who must be of the
legally required minimum age.

2.2 Operator's Safety Notes

2.2.1 Assembly, installation and commissioning

Use exclusively suitable handling and lifting equipment of adequate load

capacity.

2.2.2 Operation

At least once every working shift, the machine and equipment must be
inspected for visible damage and defects. Any changes occurring (on or in
the machine or equipment itself and its workings) must be reported
immediately to the officer responsible. The machine and equipment must be
shut down immediately if conditions warrant.

All faults and malfunctions must be corrected immediately.

When working with the machine and equipment, make sure that risk of
injury to all persons due to the machine and equipment is satisfactory ruled
out.

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 Operating Manual

The lift truck operator must watch out for persons within his range of work
and travel.

All activities detrimental to the stability of the machine and equipment must
be avoided.

Attention is required to the payload capacity (residual capacity) of the lift

truck fitted with the attachment. This may be smaller than the load capacity
of the attachment.

Maximum capacity always denotes lifting with two or more forks or load
handling arms.

Attention is required to the maximum load capacity, maximum working

pressure and load center stated on the nameplate.

Moving, reciprocating or rotating parts of the attachment entail danger of

pinching, crushing, snagging and dragging. Safe distance must be maintained
at all times to prevent clothing, body parts or hair from being caught by such
parts.

Loads may only be handled when their pallets, crates, containers and
packaging are in satisfactory condition.

Load handling devices must be kept above the floor or ground while
travelling.

2.2.3 Maintenance

Mandatory regular inspection intervals, including those specified in the

operating manual, must be observed. Inspection may only be carried out by
authorized and qualified personnel.

Maintenance and repair work must only be carried out when the machine
and equipment is supported on a level and firm surface and is secured from
rolling and tipping.

When replacing components and assemblies, they must be fastened securely

to hoisting equipment so as to eliminate all danger.
Use exclusively appropriate hoisting equipment and load handling devices
in satisfactory condition and of adequate capacity.
Keep clear of suspended loads.

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Do not make any alterations, additions or conversions to the machine or

equipment that might affect their safety unless duly authorized by the supplier.
This includes fitting and adjusting safety valves and other safety devices and
welding work on supporting members.

If safety devices need to be dismantled for setting up, maintenance or repair

work, they must be re-installed and checked for proper function immediately
on completion of the work.

Spare parts must meet the manufacturer's technical specifications. This is

assured by using exclusively original spare parts.

All screws or bolts loosened for maintenance and repair

work must be tightened at the permissible torque. Replace
screws and bolts that have been retightened three times.

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

M 10 thread 45 Nm 66 Nm 77 Nm
M 12 thread 77 Nm 115 Nm 135 Nm
M 16 thread 190 Nm 280 Nm 330 Nm
M 20 thread 385 Nm 550 Nm 640 Nm

Castellated or self-locking nuts on cylinders must be tightened firm by hand,

loosened 1/3 to 1/2 turn, and then secured.
Cylinders are installed with 1.5 to 2 mm axial clearance.

Work on electrical equipment or auxiliaries may only be carried out by

qualified electricians or by trained personnel directed and supervised by an
electrician and in accordance with standard electrical practice.

Work on hydraulic equipment may only be carried out by personnel specially

trained and experienced in hydraulics.

All hydraulic pipes, hose lines and couplings must be inspected regularly for
leaks and visible damage. All damage must be repaired immediately. Leaking
oil can cause accidents and is a fire hazard.

Safety 8
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Pressurized lines (hydraulic lines) must be depressurized before opening

them to commence repair work.

Hydraulic lines must be installed and connected in regulation manner.

Never connect lines to the wrong ports. Fittings and the length and quality
of hose lines must conform to the technical requirements.
(See standard specifications DIN 20066 and DIN 20066 Part 4)

Hydraulic hose lines must be replaced not later than when they have been in
use for 6 years, regardless of any recognizable safety - related defects. See
DIN 20066 Part 5 for assessment of functional condition.

On lift truck attachments with mounted sideshift the hose lines for these
components remain stationary and therefore should be installed in as short
bends as possible. For other functions the hose lines travel with the sideshift,
requiring them to be installed in appropriate lengths.

2.3 General hazard notes

Serious injury to persons or damage to equipment and property may be

caused as a result of

- improper use of the equipment

- incorrect operation of the equipment
- inadequate maintenance and servicing

Failure to observe the safety notes contained in the operating manual can
lead to injury or even death. This applies particularly to improper use of the
equipment.

Persons under the influence of drugs, alcohol or medications affecting nor-

mal responses must not be allowed to perform any work with or on the
machine or equipment.

The machine and equipment must not be operated in explosion-hazard areas

unless expressively designed and authorized for use in such areas.

Safety 9
 Operating Manual

Sideshifter T 151 P2

3. Design

The sideshifter is constructed of a high-visibility fork carriage, the upper beam

of which is bolted to cast iron housings containing the pistons for hydraulic
sideshift motions and sliders made of plastic.

These sliders move on a steel rail fastened to and assembled on the center
lock of the lift truck fork carriage. A metal guard is fitted over the pistons to
prevent twisting of the hydraulic connections and damage to the pistons due
to falling objects.

Hooks fitted with integral rollers are bolted to the lower fork carriage beam.
Speed of sideshifting is decelerated just before end position is reached by
cushioning of the pistons.

Options:

Sideshifting to ISO Class 2 ± 80 mm or ± 100 mm

Sideshifting to ISO Class 3 ± 100 mm or ± 125 mm
Sideshifting to ISO Class 4 ± 100 mm or ± 160 mm

3.1 Application

The sideshifter is designed to provide sideways shifting of lifted loads.

This enables the fitted load forks to be positioned precisely for picking up
or putting down loads in racks, on truck platforms and so on without having
to maneuver the lift truck.

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 Operating Manual

4. Installation and checking out

4.1 Installation

Lift the attachment by crane and remove the bottom hooks by undoing
the holding bolts.

- Locate the guide beam with center lock to ISO 2328 in the center groove
of the lift truck fork carriage.
If required, remachine the groove to the required width and depth.

Locate the attachment on the guide beam, making sure the sliders are correctly
seated in the housings.

Pull the unit at the bottom forward for the purpose of fitting the bottom hook with
roller or slide plate.

Connect the hose lines directly to the hydraulic service supply or screw on/
plug in the coupling.

The righthand hydraulic service is the sideshift function.

The lefthand hydraulic service is the clamping or other function.

When a third hydraulic service is provided, its function must be defined

individually (VDI 3642).

4.2 Checking out

Lubricate the sideshifter at the specified lubrication points. Start the lift truck
and operate the hydraulic service supply to move the sideshift to both sides.

Move the sideshifter to both end positions several times.

This repeated actuation vents the plunger cylinders.

Inspect the hydraulic connections for any leaks and retighten them if and as
necessary.

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 Operating Manual

Provided the sideshifter is found to be working properly, attach the forks and
secure them on the fork carriage with the retainer screws.

After mounting the load backrest, if supplied, the sideshifter is ready for use.

5. Operation

Start the lift truck.

Drive the forks under the load as far as they go.
The forks should be set to the widest possible spacing.
If necessary, back off the truck and adjust fork spacing.
Lift the load clear and transport it to its destination.

Load should be centered on forks as closely as possible.

Only operate the sideshifter with the load lifted.

6. Maintenance

Regular maintenance is essential to ensure reliable working and long life of

the sideshifter.
Check tightening torque of fastening screws after the first 10 hours in
operation and every 200 operating hours after that. Retighten to the torques
specified on page 8 of this Operating Manual.

Lubricate the sliders on the guide rail via the grease nipples fitted.

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 Operating Manual

7. Trouble ® Cause
¯
Correction

Shift position ® Hydraulic couplings

- to one side only - not engaged correctly
- not fastened correctly
¯
Correctly engage or fasten couplings.

Shift motion ® Hydraulic couplings

- difficult - defective
- none at all - support roller defective

¯
Replace defective component.
Replace support roller.

Cylinder leak ® Seals worn

¯
Strip leaking cylinders as shown in illustration T 151 P2 of Spare Parts List. This
requires the sideshifter to be dismantled from the lift truck fork carriage. (Reverse
order to that described for installation.)
Remove each cylinder housing after removing the fixing screws. Extract piston
rod and check it for longitudinal grooves resp. pressure marks, replace if necessary.
Dismantle seal kit as shown in illustration and check seal face in housing for
damage. Mount new seal kit and insert piston rod. Fix cylinder housing at carriage.
Continue as instructed under 4.1 Installation.

Excessive clearance between ® Check lift truck fork carriage

sideshifter and lift truck for correct dimensions to
fork carriage ISO 2328

® Plastic sliders worn

¯
Replace plastic sliders if heavily worn and scored.
This requires the sideshifter to be dismantled from the lift truck.

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