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Electric Fitting Set T026: Operating Manual
Electric Fitting Set T026: Operating Manual
Operating Manual
Contents
Page
1. Introduction ............................................................................................................................................. 4
1.1 Working with this manual............................................................................................. 4
1.2 Warning notes and symbols ........................................................................................ 4
1.3 Copyright ..................................................................................................................... 4
1.4 Qualified and authorised personnel............................................................................. 5
1.5 Warranty claims based on defects .............................................................................. 5
1.6 Limits of applicable use ............................................................................................... 5
2. Safety aspects ......................................................................................................................................... 6
3. Design ...................................................................................................................................................... 7
3.1 Proper use of the equipment ....................................................................................... 8
3.2 Improper use................................................................................................................ 8
4. Installation and checking out ................................................................................................................ 8
4.1 Installation.................................................................................................................... 8
4.1.1 Installing the controls (Set #1) ..................................................................................... 9
4.1.1.1 Pressure Button 0260080001 ................................................................................................... 9
4.1.1.2 Rocker Switch / Seesaw Switch , vehicle internally usable switch (0260080002)................... 10
4.1.1.2.1 Seesaw Switch 0260947901 (0260080002)............................................................................ 10
4.1.1.2.2 Rocker Switch 0260894601 – (0260080002).......................................................................... 11
4.1.1.2.3 Direct connection 0260844701 – (0260080002)..................................................................... 12
4.1.1.3 Connecting / disconnecting the in-line socket and in-line plug ................................................ 13
4.1.2 Circuit diagram........................................................................................................... 14
4.1.2.1 Pressure Button 0260080001 ................................................................................................. 14
4.1.2.2 Seesaw Switch 0260080002................................................................................................... 15
4.1.2.3 Rocker Switch 0260080002 .................................................................................................... 16
4.1.2.4 Direct connection 0260080002 ............................................................................................... 17
4.1.3 Installing the cable routing to the lifting frame (Set # 2) ............................................ 18
4.1.3.1 Installation on the lifting frame of the lift truck / helical cable 0260081001 / 0260081002....... 18
4.1.3.2 Installation on the fork carriage base of the lift truck / helical cable 0260081001 / 0260081002
19
4.1.3.3 Installation on the lifting frame of the lift truck / Deviating roller 0260081003 / 0260081004... 20
4.1.3.4 Installation on the fork carriage base of the lift truck / Deviating roller 0260081003 / 0260081004
21
4.1.3.5 Installation on the lifting frame of the lift truck / Cable drum 0260081005 ............................... 22
4.1.3.6 Installation on the fork carriage base of the lift truck / cable drum 0260081005...................... 23
4.1.4 Wiring diagram........................................................................................................... 24
4.1.4.1 Fitting set helical cable 0260081001 / 0260081002 ................................................................ 24
4.1.4.2 Fitting set deviating roller 0260081003 / 0260081004............................................................. 25
4.1.4.3 Fitting set cable drum 0260081005......................................................................................... 26
4.1.5 Connecting the valve to the unit ................................................................................ 27
4.1.6 Connecting single solenoid valve 0260082001 ......................................................... 28
4.1.7 Connecting Dual solenoid valve 0260082002 ........................................................... 29
5. Operation ............................................................................................................................................... 30
5.1 General ...................................................................................................................... 30
6. Maintenance and servicing .................................................................................................................. 30
6.1 General ...................................................................................................................... 30
6.2 Significant modification .............................................................................................. 30
6.3 Schedule for routine maintenance and lubricants ..................................................... 30
6.3.1 General ...................................................................................................................... 31
6.3.2 Fitting set / Fork carriage base .................................................................................. 32
6.3.3 Fitting set helical cable 0260081001 / 0260081002 / Lift mast ................................. 33
6.3.4 Fitting set idle pulley 0260081003 / 0260081004 / Lift mast ..................................... 34
6.3.5 Fitting set cable drum 0260081005 / Lift mast........................................................... 35
7. Troubleshooting.................................................................................................................................... 36
8. Disposal ................................................................................................................................................. 36
Our service department in Aschaffenburg will be happy to answer your technical questions and to provide additional support.
Technical Support:
0049 (0)6021 865 395
0049 (0)6021 865 284
0049 (0)6021 865 352
Outside of normal business hours the Kaup – Service Hotline is available to you 365 days a year:
1. Introduction
This operating manual contains important information on how to operate the electric fitting set
properly, safely and efficiently.
The operating manual shall be read, understood and applied by all personnel working on or with the
equipment, for example:
The manual must be kept available for ready reference at the electric fitting’s place of use.
The illustrations in this operating manual may deviate from the actual version of
the equipment.
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.
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 is forbidden and liable to prosecution.
This applies, in particular, to reproduction, translation, microfilming as well as storage and
processing in electronic systems.
Qualified and authorised 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.
KAUP shall not be liable for any damage to the electric fitting set resulting from:
Modifications to components.
KAUP-Electric fitting sets are intended for use under the following climatic
conditions:
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 electric
fitting set.
Pay close attention to the operating manual provided by the manufacturer of the fork lift
truck.
Only allow work on the electric fitting set to be carried out by qualified and authorised
persons. Adhere to the legal minimum age in the country of operation!
The electric fitting set should only be used for the purpose intended.
Never work on or with electric fitting sets while under the influence of drugs, alcohol or
medicines which affect reaction time.
Keep a safe distance away from moving, reciprocating or rotating parts of the
attachment to avoid danger of crushing, pinching or entanglement
3. Design
Electrical kits are designed to establish power supply between the solenoid valve on the attachment
and the lift truck.
The electrical kits are allowed to be used for the voltage range from 12V to 80V.
Exception: KAUP push button 0260080001 / approved von 12 Volt to 24 Volt.
Improper installation of the cable routing equipment to the lifting frame of the lift truck.
4.1 Installation
Basically, electrical kits are to be connected such that the circuit is disconnected when
the key is removed from a latch or starter switch.
When the electrical kit including solenoid valve needs to be powered with the main
circuit switched OFF, the following rules are to be observed:
The electrical kit is to be connected to the system at a position located between the
latch or starter switch and the battery.
For electrical kits using toggle switches, there is the risk of discharging the lift truck
battery (positions 1 and 2). To prevent this from happening, the handle of the switch for
disconnecting the circuit has to be placed in position 3 after having operated the
solenoid valve.
Use the cap nut (4) to install the control (2) to an appropriate position on the lift truck
•
dashboard.
Attach the cable (1) to the control (2). Connect the cable (1) to the control (2) as per pin
•
assignment (3) of the switch.
• Connect all cables according to the wiring diagram (refer to section 4.1.6.1).
4.1.1.2 Rocker Switch / Seesaw Switch , vehicle internally usable switch (0260080002)
Use the cap nut (4) to install the control (2) to an appropriate position on the lift truck
•
dashboard.
Attach the cable (1) to the control (2). Connect the cable (1) to the control (2) as per pin
•
assignment (3) of the switch.
• Connect all cables according to the wiring diagram (refer to section 4.1.6.2).
• Connect the cable (1) to the control (2) as per pin assignment (3).
• Connect all cables according to the wiring diagram (refer to section 4.1.6.3).
• Connect all cables according to the wiring diagram (refer to section 4.1.6.4).
Connect the in-line plug (1) to the in-line socket (2) and secure both parts using the
•
retaining clip (3).
Disconnect the in-line plug (1) from the in-line socket (2) by disengaging the retaining
•
clip (3).
Select the appropriate cable routing for your lift truck / Select the cable guide /
cable length that is appropriate for your lift truck (items 22 + 24 or items 22 + 23
+ 24).
4.1.3.1 Installation on the lifting frame of the lift truck / helical cable 0260081001 / 0260081002
• Assemble the pipe ends at items (22, 23, 24) and use the bolt (25) to secure them.
Identify the adhesive areas (1) on the lifting frame (2) of the lift truck by holding the
• entire cable routing (3) onto the lifting frame with the bonding areas of the knurled
nut (4) facing to the lifting frame.
Clean the bonding areas of the knurled nut (4) at the cable routing (3) and at the
•
lifting frame (1). The contact areas must be free of paint, grease, or oil.
Remove the knurled nut (4) from the cable routing (3), apply Loctite 3090 adhesive
• onto the contact surface, and fix it to the lifting frame (2) for approximately 5 minutes
using C-clamps. Observe the adhesive setting time of 90 to 180 seconds.
The cable routing may be installed only after the final strength has been reached
after 24 hours.
• Remove the set screws (5) and the pipe clamp (6) from the cable routing (3).
Install the set screws (5) and the pipe clamp (6) into the bonded knurled nuts (4) at
•
the lifting frame (2).
• Install the cable routing (7) onto the pipe clamps (6).
Other fixing options have to clarify by the manufacturers of the lift trucks.
4.1.3.2 Installation on the fork carriage base of the lift truck / helical cable 0260081001 / 0260081002
At an appropriate location, drill two M8 (21) tapped holes into the fork carriage base (8)
• of the lift truck. Observe the routing of the helical cable. Several optional M8 tapped
holes (10) are available at the holder (9).
Using the bolt M8 (11), install the holder (9) to the M8 tapped hole (21) at the fork
•
carriage base (8). Observe the routing of the helical cable.
Route the free end of the helical cable (12) around the cable routing (13) and install the
•
routing to the holder (9) using the bolts (14).
Using the bolt (16), install the strain relief (15) to the holder (9). Fix the helical cable
•
(12) in the strain relief (15) using the bolts (17).
Secure the plug (18) of the helical cable (12) to the holes (20) of the holder (9) using
•
wire straps.
4.1.3.3 Installation on the lifting frame of the lift truck / Deviating roller 0260081003 / 0260081004
At an appropriate location of the upper moving side of the lifting frame (2) of the lift
•
truck, drill an M16 tapped hole (1). Observe the routing of the cable.
Using the bolt (4), install the idle pulley (3) to the M16 tapped hole (1) at the lifting
•
frame (2).
At an appropriate location of the upper moving side of the lifting frame (2), weld a weld-
•
on nut M16 (24) (not included). Observe the routing of the cable.
Using the bolt (4), install the idle pulley (3) to the M16 weld-on nut (24) in position (1) at
•
the lifting frame (2).
At the lower rigid side of the lifting frame (2), weld the holder (5) to an appropriate
•
position (6). Observe the routing of the cable.
Install the strain relief (7) to an appropriate position of the cable (8). Observe the
• preload of the cable (8) created by the spring (9) that will be engaged into the holder (5)
and into the strain relief (7).
Other fixing options have to clarify by the manufacturers of the lift trucks.
4.1.3.4 Installation on the fork carriage base of the lift truck / Deviating roller 0260081003 / 0260081004
At an appropriate location, drill two M8 tapped holes (23) into the fork carriage base
• (10) of the lift truck. Observe the routing of the cable. Several optional M8 tapped holes
(12) are available at the holder (11).
Using the bolt M8 (14), install the holder (11) to the M8 tapped hole (23) at the fork
•
carriage base (10). Observe the routing of the cable.
Route the free end of the cable (15) around the cable routing (16) and install the routing
•
to the holder (11) using the bolts (17).
Using the bolt (13), install the strain relief (18) to the holder (11). Fix the cable (15) in
•
the strain relief (18) using the bolts (19).
Secure the plug (20) of the cable (15) to the holes (22) of the holder (11) using wire
•
straps (21).
4.1.3.5 Installation on the lifting frame of the lift truck / Cable drum 0260081005
At an appropriate location of the upper rigid side of the lifting frame (2) of the lift truck,
•
drill two M12 tapped holes (1). Observe the routing of the cable.
Using the bolt M12 (not supplied), install the holder (3) of the cable drum (4) to the M12
•
tapped hole (1) at the lift mast (2).
• Using the bolt (5) and nut (6), install the cable drum (4) to the holder (3).
Other fixing options have to clarify by the manufacturers of the lift trucks.
4.1.3.6 Installation on the fork carriage base of the lift truck / cable drum 0260081005
At an appropriate location, drill two M8 (20) tapped holes into the fork carriage base (7)
• of the lift truck. Observe the routing of the cable. Several optional M8 tapped holes (9)
are available at the holder (8).
Using the bolt (10), install the holder (8) to the M8 tapped hole (20) at the fork carriage
•
base (7). Observe the routing of the cable.
Route the free end of the cable (11) around the cable routing (12) and install the routing
•
to the holder (8) using the bolts (13).
Using the bolt (15), install the strain relief (14) to the holder (8). Fix the cable (11) in the
•
strain relief (14) using the bolts (16).
Secure the plug (17) of the cable (11) to the holes (19) of the holder (8) using wire
•
straps (18).
5. Operation
5.1 General
At least once per working shift, the electric fitting set must be inspected for visible
damage and defects.
Repeat faults to your superior and have them rectified without delay.
6.1 General
Regular maintenance is essential to ensure reliable operation and long service life of the KAUP
Electric fitting set.
Ensure that maintenance and servicing are performed by qualified and authorised
personnel only.
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, ISO 4032 etc.:
Significant modifications are, for example, those which affect the stability, performance, speed and
strength of components.
Modifications to the attachment may only be made with prior approval by the manufacturer.
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.
6.3.1 General
Ensure that power is not supplied to the electrical kit during service operations
(e.g. remove the ignition key, disconnect the battery).
Alle 2000h
Check:
the cable insulation
Replace defective cables.
As necessary
Check screws
(1) at the holder (2) of the cable routing.
(3) at the cable routing (4).
(5, 7) at the strain relief (6).
Replace loose or damaged screws. Torque the screws as specified in Chapter 6.1
General.
Daily
Check
the joint (6) of knurled nut (1) and lifting frame (2).
Check the
set screws (3).
bolts (4) at the pipe clamps (5).
Replace loose or damaged screws. Torque the screws as specified in Chapter 6.1
General.
Check the
Replace loose or damaged screws. Torque the screws as specified in Chapter 6.1
General.
Every 200h
on the pull spring (4) at the strain relief (5) / holder (6).
Replace worn parts.
Annually
Check the welded seam (7) between the holder (6) and the lifting frame (3).
Check the welded seam (8) between the M16 weld-on nut (9) (not supplied) and
the lifting frame (3).
Check the
bolts (not supplied) at the holder (1) and the lifting frame (2).
bolts (3) and nut (4) at the holder (1) and cable drum (5).
Replace loose or damaged screws. Torque the screws as specified in Chapter 6.1
General.
7. Troubleshooting
Solenoid valve
8. Disposal
Teile-Nr. Anzahl
Pos. Part-no. Quant. Bezeichnung Designation Désignation
Piece-no. Quant.
1 0260032002 1 Sicherung fuse fusible
2 0260845601 3 Ader-Endhülse end splice embout de cable électrique
3 0260845701 1 Kabel cable câble
4 0260845801 1 Kabel cable câble
5 0260847801 1 Sicherungshalter lock holder support de cable
6 0260905601 1 Stromkabel electrical cable câble
7 0260991301 1 Druckschalter pressure switch interrrupteur
8 0260995501 1 Klemme fastener borne
9 0260995601 1 Klemme fastener borne
10 0260945201 2 Kabelbinder cable ties attaches de câble
9.2 Fitting set Rocker Switch / Seesaw Switch , vehicle internally usable switch (0260080002)
Teile-Nr. Anzahl
Pos. Part-no. Quant. Bezeichnung Designation Désignation
Piece-no. Quant.
1 0260947901 1 Kippschalter tilt switch interrupteur
2 0260894601 1 Schalter switch interrupteur
3 0260844701 3 Ader-Endhülse end splice embout de cable électrique
4 0260032002 1 Sicherung fuse fusible
5 0260845601 3 Ader-Endhülse end splice embout de cable électrique
6 0260845701 1 Kabel cable câble
7 0260845801 1 Kabel cable câble
8 0260847801 1 Sicherungshalter lock holder support de cable
9 0260905601 1 Stromkabel electrical cable cable
10 0260995501 1 Klemme fastener borne
11 0260995601 1 Klemme fastener borne
12 0260945201 2 Kabelbinder cable ties attaches de câble
Type: T026
meets the requirements of the 2006/42/EC machine directive as delivered and is intended for
installation in a machine.
The following fundamental health and safety requirements of Appendix 1 of the above-mentioned
directive have been applied and adhered to:
The special technical documentation according to Appendix VII B has been produced.
The manufacturer commits itself to electronically transfer spezial documents for partly completed
machinery to Community & National authorities upon request.
Initial startup is not permitted until it has been determined that the machine into which the incomplete
machine will be installed meets the requirements of EU machine directive 2006/42/EG.
Aschaffenburg,