ROTATOR ORS-25/360 USER’S MANUAL

USER’S MANUAL AND MAINTENANCE

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Contents
Page

1. Introduction
1.1 How to read the manual
1.2 Precautions and Hazard symbols
1.3 Copyright
1.4 Conformity Mark CE
1.5 Qualified and Authorized Personnel
1.6 Warranty claims
1.7 Usage restrictions
2. Health and Safety
3. Rotator construction
4. Equipment proper handling
5. False handling
6. Mounting to the forklift and checking activities
6.1 Mounting to the forklift
4.1.2 Model ORS 25/360
4.1.3 Forklift carriage
4.2 Checking activities
4.2.1 Hydraulic system start-up
4.2.2 Hydraulic system interference after start-up
5. Usage
5.1 General information
5.2. Load transport
5.3. Drive/Operating
5.4. Rotation
6. Maintenance and repair
6.1 General Information
6.2 Key modifications
6.3 Maintenance and oiling/greasing scheme/outline
6.3.1 Rotator
6.3.2 Installation of the rotator
6.3.3 Forklift carriage
6.3.4 Nameplate and Warning plate
7. Troubleshooting
8. Used components and other waste

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9. Transport
10. Dismounting and storage
11. Specification and capacity

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1. Introduction

1.1 How to read the user’s manual

The manual contains information essential for proper, safe, and effective usage of the
machine.

All persons operating and/or maintaining the machine are obliged to acknowledge the user’s
manual and act accordingly particularly with:

Mounting and operating the equipment

Inspections and repairs
Transport and disposal

At all times, the manual must be available in the place of operating the equipment.
The drawings may differ from the particular version of the equipment.

1.2 Precautions and hazard symbols.

The hazard symbols are used in the manual in order to mark particularly important issues like:

Prohibitions, precepts, and recommendations to abide by in order to avert damages to health

and possessions.
Marking the particular points from the list
Showing subsequent steps that the operator of the machine should take.

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1.5. Qualified and authorized personnel

The qualified and authorized personnel mean persons with an appropriate education, knowledge,
and training to fulfill the given tasks according to common practice and health and safety
regulations.

1.6. Warranty claims

The producer does not take any responsibility for the equipment if:

False handling
User’s own components modification
False or lack of installation, maintenance, inspections, service
Unqualified and/or unauthorized personnel assigned to maintaining, service, reparation or
inspect the equipment.
Third party claim

1.7. Restriction on use

The equipment may be used in the following climate conditions:

Average environment temperature at constant work +25C

Maximum environment temperature at short run (up to 1 hour) +40C
Minimum temperature for the equipment operating inside buildings +5, C
Minimum temperature for the equipment operating outside buildings -20 C

Standard equipment is NOT appropriate for:

Operating in frost
Operating in the explosion risk zone
Operating with the hydraulic system working on bio oils
Operating in aggressive environmental conditions (e.g. sea water contact)
Transporting aggressive/corrosive liquids

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2. Health and Safety.

Besides the given in this manual health and safety notes it is advisable to act according to any
health and safety regulations ensure safe and environmental-friendly use of the equipment.

One should abide to all safety and hazard symbols in this user’s manual and on the
equipment. Neglecting the above may result in serious injuries or death.

One should abide strictly to the user’s manual attached by the forklift producer.

One should maintain a safe distance from the moving parts of the equipment in order
to prevent being crushed, pulled into, or jammed in the mechanism.

A person responsible for the equipment should be informed about any irregularities
which may have influence on work safety immediately.

In case of transporting loads that limit visibility, appropriate means of its improvement
should be used (e.g. mirrors, cameras, etc.)

Only qualified and authorized personnel may use the equipment. It is advisable to
abide to workers minimum age regulations.

Compatible with the intended use only

It is strictly forbidden to operate the equipment under the influence of drugs and
alcohol and medications that may cause the delay in reaction time.

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3. Rotator construction

The rotator is built of faceplate (1) and the baseplate (2) with hydraulic system driven by gearbox (3)
and hydraulic motor (4). The bearing (5) is attached to the faceplate and forks carriage (6) with screws.
Forks carriage (6) is equipped with securing bolts (7) and plates (8) that prevent forks from sliding off
from the carriage while rotating. Whole equipment is suspended and secured on the forklift carriage
with upper (9) and lower (10) hooks.

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4. Equipment propper handling
Rotators are intended to rotate loads such as cases, containers, etc. lifting on forks.
Attention!!! The equipment is not intended to side push of loads. Operating like this is against
equipment intended purpose. Proper handling particularly means:

Abiding to the user’s manual in any case.

Abiding to the restrictions given on a nameplate.
Abiding to the recommendations of current inspection and maintenance

5. False handling

Exceeding the maximum load and the load center (balance point)
Exceeding maximum
Transport of people with load or transporting other equipment also used to transport
Additional equipment use that may cause changes in the producer’s intended purpose
of the rotator (e.g. forks extension) without producer’s authorization.

6. Forklift mounting and inspection

6.1 Mounting onto the forklift
Equipment mounting and dismounting by authorized personnel only. It is only
permissible to use the elements intended to transport and hoisting equipment of
sufficient capacity like examples given below:

Capacity: 350 kg/M16 1200 kg/M16 2000 kg/M16

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4.1.2 ORS -25/360 model

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Forks carriage

Lift the equipment in the given position (1)

Dismount the lower hooks/clamps (2)
Put the equipment onto the forklift carriage
Make sure that the equipment is blocked in the central position
Mount the lower hooks/clamps (2) by tightening screw (5) with the force of 190 Nm
Connect the hydraulic system (7) with the appropriate connections of the forklift
Dismount the securing bolts/screws (8) and plates (9) and slide forks onto the carriage
from its side.
Make sure that the securing bolts (8) and plates (9) were mounted back correctly
Before first using the equipment must be checked and compatible with operating
elements (levers, joysticks).
The residual capacity plate should be placed in a noticeable place together with forklift
combination parameters and the equipment (if there is no such).

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Inspection

The equipment are delivered upon greasing. If the equipment was stored longer period of
time, it is advisible to grease it again before usage. See part 6- Maintenance and next.

The incorrect connection of the controling elements with the drive may cause false
operation and/or equipment damage. After installing the equipment and before its first
use it is necessary to check its operation and compatibility with controlling elements.

Hydraulic system start-up

Start the forklift

Make a side-sliding movement in both directions to the maximum several times
Turn the rotator left and right several times
Check, if there are no leakages on hydraulic connections. Hydraulic system
interference after start-up
The hydraulic system is under constant pressure. If interfered while working, it may cause
injuries. That is why it is necessary to reduce oil pressure before interfering in the system
in accordance to the notes and tips in the forklift’s manual. If there are any injuries one
must immediately inform medical supervisor and contact specialized doctor.

Usage

General information
At least once in a working shift the equipment should be checked if there are no visible
damages and defects. About such, the supervisor should be immediately informed and the
damages ought to be removed.
Mind people that are in the working area of the machine and make sure that they are not
subject to any risk.
It is not allowed to exceed the maximum capacity stated on the residual capacity plate for a
combination of a forklift plus equipment

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Load transport

Set up the forks as wide as possible for the load transported

Put the mast upright and lift the load parallel to the ground
Get the forklift with the rotator possibly nearest to the load
Lift the load to a height of about 300mm and lean the mast backwards
Try to lift the load possibly centered.

Drive/Operating

Make sure that the pallets, baskets of other containers are in a good condition.
Do not drive with the mas leaned towards
Make sure that neither load nor the equipment touches the ground while driving.

Rotating

Rotating may cause damages to the load and/or equipment. Make sure that a safe
distance between the load and the ground, ceiling or other objects in the area is
kept. If the load causes higher torque than the one that the equipment is intended
to, rotation may be uncontrolled or there might be no rotation. The torque given on
the nameplate of the equipment should be kept.
The torque of 160 bars given on the nameplate refers to pressure differential in a hydraulic
motor
Rotate loads only perpendicularly to the ground
Do not rotate loads if there are people near
Rotate lifted load slowly. Quick rotation may cause the instability of the forklift.

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Service and Maintenance

General information

Correct and regular maintenance and service are necessary to provide long living and problem-free usage.

Maintenance and service must be run by qualified and authorized personnel only
Equipment greasing and cleaning may be also done by the operator of the forklift
Maintenance and service activities should be run only when the equipment is safely
stabilized on a flat surface. When mounting and dismounting the equipment it is
recommended to use the pallet so that it may be safely transported and/or put away.
It is only permissible to use hoisting equipment of sufficient capacity.
Damaged and/or illegible symbols and signs should be replaced.

Only producer’s original spare parts may be used with the rotator. Not original parts
may cause a risk of accident. In case of using not original parts, the Declaration of
Conformity CE becomes null and void and thus the user takes all responsibility for any
accident.

The hydraulic system is under constant pressure. If interfered while working, it may
cause injuries. That is why it is necessary to reduce oil pressure before interfering in
the system in accordance to the notes and tips in the forklift’s manual. If there are any
injuries one must immediately inform medical supervisor and contact specialized
doctor.

The securing bolts may loosen because of vibrations. During routine maintenance
it is necessary to check if the screws and bolts are tighten with an appropriate
torque and change the damaged ones.

The values described below refer to the screws with connection surfaces according to ISO 4762, ISO
4014, ISO 4032 etc.:

Thread type 8.8 10.9 12.9

M6 9,3 Nm 14 Nm 16 Nm
M8 23 Nm 33 Nm 39 Nm
M10 45 Nm 66 Nm 77 Nm
M12 77 Nm 115 Nm 135 Nm
M16 190 Nm 280 Nm 330 Nm
M20 385 Nm 550 Nm 640 Nm
M24 660 Nm 950 Nm 1100 Nm

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Securing elements faultiness (e.g. pressure valve) and incorrect drive control elements
connection may cause damage and incorrect work of the equipment. After installing the
equipment and before its first use it is necessary to check its operation and compatibility
with controlling elements.

6.2 Key modifications

The key modifications are these which have influence on working and operating of the equipment,
stability, speed and/or durability of the components.

Any key modification makes the Declaration of Conformity null and void.

Any modification requires prior consent of the producer.

6.3 Maintenance and greasing scheme.

Reccomended and accepted grease

Grease
Grease with lithium Symbol:
e.g. Avialith 2
thickener NLGI grade 2 DIN51825: K 2 1<-30
Grease with thickener
np. urmogrease Gel M 5 Casting application only
complex LGI grade 2

Teflon spray np. Wieds or Rivolta Only for plasic elements

The given maintenance schemes may change under special working conditions
like extreme temperatures, dust or rough terrain. All factors must be considered
by a user. For special loads e.g. where extra-long forks over 2400mm must be
implemented or balance points are higher, it is necessary to contact the
producer in order to shorten inspection periods.

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6.3.1 Rotator

6.3.2 Installation of the rotator

Upper clamp

Lower clamp

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Everyday

Check hoses and connections if there are no leakages or damages

After first 50 and then every 500mth of working

Check:
rotating connection
Nut on a rotating connection/faceplate
Gear
Hydraulic engine
Lower and upper clamps

Change all the loose elements. Retighten screws in accordance with tips from chapter 5.1

Every week

Rotating elements

After every 200mth

Greasing

Rotating connection through the oiler

Secure the rotating connection against dust, dampness, and water

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Every 500mth of working

After first 2500mth and every next 2000mth of working

Check:
rotating connection
Nut on a rotating connection/faceplate
Gear
Hydraulic engine
Lower and upper clamps

Once a year

Check the clearance in the rotator connection

If necessary

Dismount whole rotator as follows in chapter 4.1

Install the rotator according to the description from chapter 4.1

Change damaged lower rolls dismounting screws. Lean the rotator forwards (from
the forklift carriage) with lifting equipment intended to. Dismount the bolts from
the clamps and change the damaged ones. Install the rotator proceeding
backwards.

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6.3.3 Forks carriage

After first 50 and then every next 500mth

Check:

On the forks carriage

Rotating connection
Washers on the forks carriage
Safety plates on the forks carriage.

Change all the loose elements. Retighten screws in accordance with tips from chapter 5.1

Once a year
Check the safety bolts wear level. Change used bolts and washers.
Check screws and safety plates wear level. Change damaged/used parts.
Make sure that all safety bolts were mounted after each forks
dismounting and mounting.

Lubrication and Mounting Bolts

There are three places which need to be lubricated, they are slewing
ring raceway, worm thread and
taper roller bearings. Slewing drives are supplied fully lubricated.
A suitable grease type for normal cases is shown on table 4

Tabele 4
Roller Bearing
Parts needed to be lubricated Ring raceway
Worm Gear Thread
Recommended Grease ISOFLEX
Product name NBU15 DOW CORRING-44、MOBILITMP SHC 100、
MOBILITMP SHC 32 、 CALTEX UNITEMP
GREASE 550
Applicable temp. range in ºC -40 ~+200

Color White

Four-ball test 3500 N welding load

Viscosity (-40 °C, 10 s-1) Pas 653

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Dropping Point °C 316

Penetration, Worked 0.1 mm 67

NOTE: This kind of ecological friendly grease is harmless to human and
circumstan
Parts needed to be Quantity of grease-filled（unit：g）
lubricated
14＂

Ring raceway 55-60

Worm Gear Thread 100-110

Taper Bearing 10±0.5

Manufacturer provisions about handling the respective lubricants must

be observed.
 While rotating the slewing drive, inject grease into all the cleaned
grease nipples consecutively ,the
quantity of grease-filled need to according to Table 5

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Number Description

1 Nameplate

Read this user’s manual and

2 health and safety tips carefully
before commission.

On no condition must you reach

3 into the machine. Reaching may
cause serious injuries.

4 Hook

7. Troubleshooting

Problems concerning the equipment ought to be solved by authorized and qualified personnel
only.

Problem Probable cause Solution

Rotator
When rotating
Too low oil flow value
Rotation too slow Increase oil flow
from forklift
Vibrations while Loose screws in the
Retighten screws
rotating equipment
Loose screws in hydraulic
Retighten screws
motor

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Rough rotation Oil lock Increase oil flow

No rotation Connectors unplugged Plug the connectors
Hydraulic
motor Change the hydraulic motor
malfunction
Equipment overloaded Check load and torque

Rotation slips Equipment overloaded Check load and torque

Too significant Cogwheel damaged Change cogwheel

clearance
Rotating connection Change the connection
malfunction
Collar/neck leans Retighten screws or change
Loose screws
forwards if necessary
Oil leakage
From the hydraulic Hydraulic motor leaks Change the motor
motor
Loose screws Retighten screws

Seal damage change

8. Used components and elements

Prevent environment contamination by correct and lawful utilization of:
Oils, grease, lubricants and other waste (cleaning cloth)
Transport materials (pallets, cardboard, tapes, etc.)
After final use of the equipment, it should be utilized according to the rules of
law.

9. Transport

Always use special precautions and means to transport the equipment (e.g. pallets). They cannot
be damaged. The equipment must be secured against sliding from the pallet.

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Dismounting and storage

If the equipment is to be stored for a longer period of time, all the hydraulic connections must be secured
against dust and damages. Keep dry and clean.

Specification and capacity

Nr Details Unit Value

1.
2. Capacity max. (pallet + load) kg 2500
3. Maximum height B1 mm 630
4. Height to hydraulic connections/ hook-up mm 530
5. Width of the faceplate G mm 1000
6. Balance center E / M mm 105
7. Reinforcement in front of the carriage C mm 168
8. Distance of the forks clamp canals N mm 70
9. Mounting class ISO 2A
10. Width of the assembly board/mounting plate A mm 530
11. ROTATOR weight/mass kg 245
12. Turning angle degrees 360
13. Arm load force kg 800 kg
14. Hydraulic system specification 1 double hook-up (connection)
15. Operating pressure bar 160

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