Service Manual
Contents
1. e Lubricate and grease all parts that require lubrication see Chapter 5 for instructions e Protect all parts that might corrode with a suitable corrosion inhibitor or grease e Move arms to a totally closed position so that the piston rods are completely inside the cylinders e Protect the clamp from the effects of the weather Store it inside or under a proper cover e Check the condition of the clamp during storage and if possible regularly run all hydraulic functions of the clamp several times 3 3 Installation Before installation carry out the following checks e Make sure that the lift truck fulfills all clamp requirements Section 3 1 e Check that the clamp mounting type is the same as the one used on the truck e Check that the lift truck hydraulic oil level is correct e Check that the lift truck auxiliary hosing and fittings are in good condition 960029E User Manual Series AM Bolzoni Auramo Group Auramo Oy 2003 All Rights Reserved YOJLZIOINE du 4 AUPFAIVIO Wrz e Clean the fork carriage Make sure that it has no defects or wear that could prevent the installation or use of the clamp attachment 3 3 1 Installation Standard Carriages Installation to the most common standard fork carriages types ISO 2328 2 is as follows e Remove the lower mounting hooks e Lift the clamp to the carriage so that it hangs from the upper mounting hooks Ensure that the center locator tooth is well p2. OLZON gy Safety Instructions DOE WARNING Know the capacity and limitations of your machine Do not overload the lift truck or the attachment Please note that the rated capacity of the truck attachment combination may be less than the capacity shown on the attachment nameplate The lift truck manufacturer is responsible for calculating the rated capacity for the combination See the lift truck nameplate WARNING Never stand on the forks or on the load WARNING Never stand under a load or attachment WARNING Never stand in the attachment operating area or between the forks WARNING Limit driving with a raised load to the minimum Never accelerate or brake powerfully with a raised load WARNING Handle only those products which the attachment has been designed for It is unsafe to lift any other objects WARNING Do not risk the lift truck stability by sideshifting Sideshift only when the load is lowered down or near its seat Use extreme caution when handling off centered loads WARNING Always check the operating condition of the attachment before use Never use a defective or damaged attachment Repairs may be done by authorized personnel only 960029E User Manual Series AM Bolzoni Auramo Group Auramo Oy 2003 All Rights Reserved EXO LAON du 4 ALJIRAIVIO Yz Contents 1 Gener
3. Make sure that hoses do not twist when tightening the fittings WARNING Never remove or tighten pressurized parts or hoses 7 3 2 Seal Change Clamp Cylinders Remove hoses protect open fittings with proper caps WARNING Never remove pressurized parts or hoses Figure Clamp Cylinder Open the housing 51 Pull the piston assembly and housing 20 51 50 out of the cylinder shell 10 960029E User Manual Series AM Bolzoni Auramo Group Auramo Oy 2003 All Rights Reserved 30 YOJLZIOINE Ky 4 AUPFAIVIO Waa e Use a blunt screwdriver to take old seals away from the piston If necessary cut the seals to remove them CAUTION Do not scratch piston surfaces with sharp tools Note the direction of the seals e Open the grub screw 53 If necessary heat the screw before opening e Unscrew the piston 50 from the piston rod 20 e Slide the housing 51 off the piston end of the rod e Remove old seals from housing CAUTION Do not scratch housing surfaces with sharp tools Note the direction of the seals e Clean and check piston piston rod cylinder shell and housing See if there are any scratches wear corrosion cracks or other similar defects that could prevent normal operation of the cylinder e Replace all damaged or worn parts e Install new seals to the housing e Lubricate seals and piston rod e Slide housi
4. Possible cause Pressure relief valve defective or wrongly set e Replace valve or correct the setting Possible cause Leak in pressure cylinders e Check and replace seals if needed Problem Clamping force too small Possible cause Hydraulic pressure is too low e Check truck pressure settings Measure pressure coming from the truck Pressure must be the same as or higher than what is required for the clamp e Check the oil level e Check for external leaks If needed clean components before examination e Blocked hose or fitting Repair or replace Possible cause Wrong setting in the main pressure relief valve e Check clamping pressure with the Bolzoni Auramo test cylinder The pressure can be adjusted by turning the adjustment screw clockwise pressure increases counterclockwise pressure decreases Never exceed the maximum operating pressure of the clamp Possible cause Leak in check valve e Clean or replace check valves or short arm pressure relief valve Possible cause Leak in cylinder seals e Replace seals 960029E User Manual Series AM Bolzoni Auramo Group Auramo Oy 2003 All Rights Reserved 26 aT meas CN A Possible cause Too much pressure in tank line e Check hoses and repair if needed Problem Clamping force OK load falls Possible cause Worn or dirty contact pad friction surfaces e Clean or replace the contact pads Possible cause Operator error e Check that the load is clamp
5. loads and working conditions Net Capacity The lift truck dealer or manufacturer must calculate the net working capacity for the lift truck clamp combination WARNING Clamp attachment decreases the lift truck rated capacity WARNING The truck is dangerous to the driver and to persons working near the truck if the driver does not know the net working capacity Net capacity information must always be visible from the driver s seat WARNING The lift truck manufacturer is responsible for giving the final capacity rating to the forklift attachment combination 960029E User Manual Series AM Bolzoni Auramo Group Auramo Oy 2003 All Rights Reserved EXOJLAIOINT fy j AURAIVIO Ga 3 1 2 Hydraulic Pressure and Oil Flow Recommendations Hydraulic pressure recommendations Clamping Pressure Clamping Rotation Pressure Rotation Connection Connection Pressure Pressure Max A Eve MPa MPa AM 13RF RH AM 18RF RH Clamping Pressure Clamping Rotation Pressure Rotation Connection Connection Pressure Pressure Max in a Eve psi AM 13REF RH AM 18RF RH 2 320 Oil flow rate recommendations Oil flow rate recommendations Model Oil Flow Rate Clamp Oil Flow Rate Rotator Min Recomm A Min Recomm l min I min I min l min AM 13RF RH AM 18RF RH 20 35 25 35 Oil flow rate recommendations Model Oil Flow Rate Clamp Oil Flow Rate Rotator Min Recomm A Min Reco
6. help you 7 2 Notes on Service Actions Clean the clamp carefully before removing or replacing any parts Protect the environment Always put used oil into a proper tank Do not let dirt or debris enter into the hydraulic system Always protect open fittings with a proper cap Clean all parts carefully before installing them onto the clamp 7 3 Service Instructions In the following pages you will find instructions on how to perform such service actions and repairs that are outside the normal maintenance schedule WARNING Read instructions carefully before you do anything Repairs done incorrectly are safety hazards Follow all safety instructions given in previous chapters 960029E User Manual Series AM Bolzoni Auramo Group Auramo Oy 2003 All Rights Reserved 29 pee SYOJLZOIN Ce M p 7 3 1 Hose Change Clean the clamp carefully before removing or replacing any parts If the hose leaks from the fitting first try to tighten the fitting Change the hose only if this does not help Label all hoses before removing them This makes re assembly significantly easier Protect all open fittings with a proper cap Make sure that hose length is correct before installing it Always compare the length of new and old hoses Make sure that enough play length is left on the hose before fastening Do not over tighten hose fittings Over tightening will easily cause damage to valve blocks or fittings
7. sideshift several times between respective end positions WARNING Clamp arms can move unpredictably if there is air in the system 3 9 Checks Before Operating the Clamp Check the mounting and all functions of the clamp before using it for the first time 3 9 1 Mounting and Clamp Mechanics e Check all parts of the clamp to see that no damage occurred during the transportation e Check that there are no loose bolts or joints e Check that installation on the truck is correct e Check that the clamp is centered on the truck 3 9 2 Hydraulic Parts e Wipe clean all hydraulic parts e Check truck oil level e Run all movements clamping and rotation several times between respective end positions e Check all cylinders valves hoses and fittings for any leaks e Check that hosing is correct also when pressurized 3 9 3 Clamping Force Test It is recommended that regular clamping force tests are carried out in order to minimize the possibility of load damage This is especially important with paper roll clamps and other clamps handling sensitive loads 960029E User Manual Series AM Bolzoni Auramo Group Auramo Oy 2003 All Rights Reserved 13 ST ens SYOJLZOIN Ce M a 14 e Check clamping force by using the Bolzoni Auramo Test Pad Test Stand Test Cylinder or any other suitable device e Check that the clamping force is maintained when clamping for an extended time period Leave the p
8. upwards both arms are stopped 135 Figure Rotation positions for moving the short arm 4 3 Paper Roll Handling 4 3 1 Clamping a Vertical Roll Center the clamp in relation to the paper roll Big rolls Open both arms fully Drive the truck near the roll into a _ position where the short arm just touches the roll and the roll leans against the clamp body Small rolls Close the short arm fully open the long arms sufficiently Drive the truck near the roll into a position where the short arm just touches the roll Clamp the roll by closing the long arm Hold on closing for a couple of seconds to ensure necessary clamping force Do not pump the valve Clamp big rolls max diameter to max diameter 10 in such a way that the roll touches the clamp body and contact pads Smaller rolls must be clamped so the center of the roll would be ona line that goes through the contact pad center points Do not clamp the roll too much behind its centerline as the roll can easily slip off the clamp Furthermore do not clamp any roll too far in front of its centerline as this can lead to the clamp frame and the contact pad corners damaging the roll Always clamp the roll so that the clamp attachment is aligned to the roll Misalignment easily leads to roll damage When handling singular rolls 960029E User Manual Series AM Bolzoni Auramo Group Auramo Oy 2003 All Rights Reserved
9. 16 rT meas 2 always grip the roll so that the arms are centered between the ends of the roll 4 3 2 Clamping a Horizontal Roll Adjust the opening of the short arm to suit the diameter of the roll Open long arm sufficiently Turn short arm down long arm up Tilt the mast completely forward ca 5 6 degrees Carefully adjust the truck so that the clamp is centered to the roll Slowly lower the clamp until the short arm just touches the floor Slowly approach the roll and stop when the lower contact pad touches the roll Clamp the roll with the long arm Tilt the mast back to the vertical position Lift the roll and then rotate it to the vertical position Take care not to damage the roll edges during rotation WARNING Never drive with roll in horizontal position Lift the roll high enough before rotating Keep roll ca 30 cm 1 ft above the floor when driving Do not rotate off centered rolls Always clamp from the middle of the roll 4 4 Tips for Safe Operation Clamp the roll correctly Drive carefully and safely Avoid strong acceleration and braking Always drive with the load lowered down and the mast in a vertical or backward tilt position Note that too much tilt backward or forward increases the risk of roll edge damage 960029E User Manual Series AM Bolzoni Auramo Group Auramo Oy 2003 All Rights Reserved 17 ST ens SYOJLZOIN Ce M
10. 2 Inspection and Service WARNING In the following service actions the clamp is to be moved hydraulically Do not leave any body parts between moving clamp attachment parts Do not remove pressurized parts Beware of part movements when removing hoses or pipes Do not climb on the clamp Carry out the following checks and services twice a year or every 200 hours whichever comes first e Clean the clamp e Carry out all routine tasks mentioned in Section 5 1 e Inspect the oil level in the primary reduction gear unit Top up if necessary 960029E User Manual Series AM Bolzoni Auramo Group Auramo Oy 2003 All Rights Reserved 19 ST ens SYOJLZOIN Ce M p e Apply grease to the rotation bearing Remember to rotate the clamp during this operation Wipe off all excessive grease e Protect all such moving parts that are susceptible to rust such as springs and pull rods Apply grease to arm pivot pin bearings and cylinder pivot pin bearings Wipe off all excessive grease e Check contact pads contact pad pull rods contact pad springs and wear plates e Check the clamp for parts that might become defective or cause other trouble during the next service interval Especially check arm pivot pins and their bushings contact pads and wear plates Check rotation bearing screws and mounting components Replace or repair all parts showing signs of excessive wear or defects Arm pivots pins bushings a
11. Grease leaking out from the rotator Possible cause Worn out felt strip or excessive lubrication e Wipe off all excessive grease If necessary replace the felt strip Use Bostik 524 2C glue for fastening the strip or other similar good quality glue Problem Oil leaking from the swivel joint Possible cause Worn out packing seals e Check and replace Possible cause Worn or loose hydraulic fittings e Tighten and replace if necessary Problem Noisy or vibrating operation of the rotation unit Possible cause Worn gear or gear bearings e Verify that the play between the pinion and the toothed crown does not exceed 0 3 mm 0 012 Verify that the play between the worm screw and the bronze gear does not exceed 0 1 mm 0 004 960029E User Manual Series AM Bolzoni Auramo Group Auramo Oy 2003 All Rights Reserved gem 2 7 Service and Repairs 7 1 General Bolzoni Auramo and its authorized representatives are anxious to answer all customer questions concerning Bolzoni Auramo service and products To help us resolve any problem you may be having as fast and accurately as possible please check the following information before contacting us Clamp attachment type serial number and production year This information can be found on the clamp nameplate How and under which operating conditions the trouble occurs Type of operation estimated work hours of the clamp Any other information you think will help us to
12. al snonrrcsr a 4 1 1 Notices 1 2 Safety Instructions 2 General Information csccceeesseeeeees 5 3 Installation Instructions eeeeeeeeeeees 6 3 1 Lift Truck Requirements 3 2 Handling and Storage 3 3 Installation 3 4 Hose Flush 3 5 Connecting the Hoses 3 6 Hydraulic Connections 3 7 Hydraulic Connection Options Opening Relief Valve 3 8 Air Removal 3 9 Checks Before Operating the Clamp 4 User Instructions ccessseeeeeeseeseeeeees 15 4 1 General Instructions 4 2 Short Arm Operation Model AM RH Only 4 3 Paper Roll Handling 4 4 Tips for Safe Operation 5 Periodic Maintenance _ ceessesee 19 5 1 Daily Checks 5 2 Inspection and Service 5 3 Tightening the Bolts 5 4 Lubricants 6 Hydraulic System amp Trouble Shooting 22 6 1 General 6 2 Safety Warnings 6 3 Hydraulic System B Series 6 5 Trouble Shooting 7 Service and Repairs ccccssccceseeeesseeneeees 29 7 1 General 7 2 Notes on Service Actions 7 3 Service Instructions 8 Spare Parts ccs steccesceetccsecec cece iain akanai 32 8 1 Spare Parts Book 8 2 Ordering Spare Parts 960029E User Manual Series AM Bolzoni Auramo Group Auramo Oy 2003 All Rights Reserved OLZON yp 1 General This manual contains installation maintenance and service instructions for standard Bolzoni Auramo AM Series clamp attachments Please read this manual carefully before using or servicing this equipment In this way yo
13. and have their own spare parts lists These lists are referenced in the sub construction spare parts list Make sure that correct part numbers are quoted especially where a part number is dependent on part dimensions or pressure used in the system such as clamp cylinders and valves Quality Control Report Includes results from tests and inspections carried out during the final check 8 2 Ordering Spare Parts In order to ensure a fast and error free ordering of spare parts always include at least the following data with your order e Name e Delivery address e Possible order number 960029E User Manual Series AM Bolzoni Auramo Group Auramo Oy 2003 All Rights Reserved 32 aT meas CA A e Clamp type and serial number e Spare parts number e Quantity e Delivery type Unless otherwise specified in the order Bolzoni Auramo will deliver spare parts in such a way as it finds suitable NOTE Spare Parts Books are unique for each clamp attachment Always use the correct book when ordering spare parts Make sure that the serial number in the Spare Parts Book is the same as the one on the attachment nameplate 960029E User Manual Series AM Bolzoni Auramo Group Auramo Oy 2003 All Rights Reserved 33
14. d down and if possible the mast tilted backwards No speeding No overloading consult the lift truck nameplate for available lifting capacity Parking Always lower the load and attachment down when parking Shut the power off and set the brakes on when leaving the truck unattended Loading When taking a load or pallet from a stack back away only so far as to be able to lower the load safely Never accelerate or brake powerfully when the load is up as this can lead to loss of balance Use extreme care when sideshifting rotating or tilting raised loads Do not overload the lift truck clamp combination Rotating Do not risk the lift truck stability with rotation Rotate only when the load is lowered down or near its seat Use extreme caution when handling off centered loads 4 2 Short Arm Operation Model AM RH only Model AM RH has a hydraulically positionable short arm The short arm opening can be changed when the clamp is rotated to a 45 degree angle with the short arm facing downwards In this position the oil flow to the long arm cylinder is closed and the short arm can be moved using the clamping lever When the clamp is rotated to vertical or horizontal handling position only the long arm can be moved 960029E User Manual Series AM Bolzoni Auramo Group Auramo Oy 2003 All Rights Reserved 15 pee SYOJLZOIN Ce M p If the clamp is rotated to a 45 degree angle with short arm facing
15. draulic connections Optional connection points are as follows e Clamping amp opening on the right side as seen from the driver s seat e Rotation on the right side HYDRAULIC CONNECTIONS CLAMPING G a OPENING Me ROTATION Clamping pressure relief valve Figure Optional hydraulic connections 960029E User Manual Series AM Bolzoni Auramo Group Auramo Oy 2003 All Rights Reserved 11 SYOJLZOINT di p AURAIVIO Nz 3 7 Hydraulic Connection Options Opening Pressure Relief Valve An optional pressure relief valve for arm opening is available on request This option must be selected if the lift truck pressure exceeds the maximum connection pressure of 18 0 MPa 180 bar 2 600 psi The valve is available for both left and right side assembly HYUDHAULIG GUNNEG I IONS ffi CLAMPING i gt OPENING n S ROTATION Clamping pressure relief valve l Opening pressure relief valve Figure Optional opening pressure relief valve connections left HYDRAULIC CONNECTIONS CLAMPING gt OPENING f ROTATION Opening pressure relief valve Clamping pressure relief valve Figure Optional opening pressure relief valve connections right 960029E User Manual Series AM Bolzoni Auramo Group Auramo Oy 2003 All Rights Reserved 12 aT meas 2 3 8 Air Removal Air in the hydraulic system can cause extra flex or movements in clamp functions e Remove air by carrying out all movements clamping and
16. ed correctly and that there is no overloading Possible cause Wrong clamp for the load e Check if clamp capacity arm opening range and arm models are suitable for the load Problem Loss of clamping force Possible cause Leaks in hoses or fittings e Check for external leaks If needed clean components before check Possible cause Leak in check valve e Clean or replace check valves Possible cause Leak in cylinder seals e Replace seals Problem Clamp arms close or open too slowly Possible cause Oil flow from the pump is too small or much too high e Check the pump and replace repair it if needed Note flow rate recommendation see Section 3 1 3 Possible cause Defect in hoses or hoses are too small e Repair or replace with correct sizes Problem Arms move jerking shaking Possible cause Air in the system e Remove air by totally opening and closing arms several times Possible cause Dirt in hydraulic system e Clean system and change oil and oil filter Problem Jerking shaking rotation Possible cause Too heavy load or load too far out of the center e Reduce the load weight or clamp the load from the center 960029E User Manual Series AM Bolzoni Auramo Group Auramo Oy 2003 All Rights Reserved 27 ST ens SYOJLZOIN ans M a 28 Possible cause Excessive play in the gear unit e Check the play between the pinion and the reduction unit Repair or replace worn components Problem
17. igned for vertical and horizontal handling of single paper rolls All series AM clamps have the following properties in common e Pivoting arm movement e Short and long arm e 360 degree rotation Models AM RF have fixed short arm This makes the clamp design simple and cost effective Models AM RH have hydraulically positionable short arm Positionable short arm enables smaller minimum roll diameters Short arm positioning is possible in a 45 degree rotation angle Model AM RF Model AM RH 960029E User Manual Series AM Bolzoni Auramo Group Auramo Oy 2003 All Rights Reserved pee SYOJLZOIN a p 3 Installation Instructions 3 1 Lift Truck Requirements Attachments reduce the lift truck rated capacity The lift truck capacity must be re rated when an attachment is selected WARNING Never use the lift truck amp attachment combination to lift more than its rated capacity as stability factors will be changed The lift truck may become unsafe 3 1 1 Clamp Attachment Rated Capacity Rated Capacity The rated capacity given for each clamp is a nominal value defined by the clamp construction and clamping force Rated capacity does not take into consideration properties of the load or working conditions Therefore the net working capacity of a truck clamp combination is not a fixed value It is defined by the clamp rated capacity and the truck rated capacity at certain heights
18. mm GPM GPM GPM GPM If the lift truck produces more hydraulic pressure than what is allowed to any of the unprotected functions of the attachment separate pressure relief valves must be installed into the lift truck or attachment hydraulic system WARNING Never exceed the maximum connection and operating pressures 3 1 3 Hydraulic Oils Use petroleum based hydraulic oil as recommended by the truck manufacturer If you wish to use aqueous based or biohydraulic oils please contact Bolzoni Auramo 3 1 4 Hydraulic Functions Standard Bolzoni Auramo AM Series clamps require two 2 hydraulic functions from the lift truck hydraulic system in order to enable clamping and rotation 960029E User Manual Series AM Bolzoni Auramo Group Auramo Oy 2003 All Rights Reserved pee SYOJLZOIN ans M p 3 2 Handling and Storage of the Clamp Attachment Prior to installation check the clamp carefully to ensure that no damage occurred during transportation 3 2 1 Lifting the clamp If you have to lift the clamp during installation make sure that the capacity of your lifting device is adequate for the load WARNING Never go under a hanging load Beware of load swing when lifting 3 2 2 Long Period Storage If for any reason the clamp has to be stored for an extended period follow the instructions given below in order to prevent damage caused by corrosion e Clean the clamp carefully
19. mp Trouble Shooting 6 1 General It is estimated that up to 80 of all problems and defects in hydraulic systems originate from dirty hydraulic oils In most cases dirty oil is the reason for various valve problems and excessive wear in seals and o rings Because all clamp attachment hydraulic functions move back and forth it is possible that the same debris might be moving in the oil for a very long time unless special attention is paid to cleanliness Bolzoni Auramo strongly recommends that the hydraulic oil and oil filters be changed regularly 6 2 Safety Warnings During all troubleshooting operations work will be carried out near the clamp Always work safely WARNING Do not open pressurized components Hydraulic components can be hot Use suitable protection Beware of leaks High pressure oil can damage the eyes and skin Always wear protection goggles having side protection Do not remove cartridge valves when pressure is on Do not put your body parts between or near moving clamp parts Do not climb on the clamp 6 3 Hydraulic System The standard hydraulic system consists of two separate parts e clamping hydraulics e rotation hydraulics A pressure relief valve for clamping is included into the standard delivery Optional pressure relief valve is available for arm opening Modifications to the standard hydraulic system are possible therefore always check the spare parts documentation s
20. nd their seats e When moving arms up and down by hand the play in the arm bearing bushings should be less than 5 mm 0 2 inch measured from 1000 mm 40 inch arm length If the play is greater than this and disturbs normal operations replace the bushings 5 3 Tightening the Bolts Most bolts on Bolzoni Auramo AM Series clamps are secured using LOCTITE 270 Bolts under high stresses are also tightened to a certain fastening torque Normally retightening of the bolts is unnecessary Should loose bolts be found during daily checks open them apply some LOCTITE 270 to the bolt threads and retighten them Also remember to check the tightness of bolts within the immediate area Please refer to the spare parts book for correct fastening torques 5 4 Lubricants Greases The following lubricants are to be used on lubrication points on Bolzoni Auramo AM Series clamps Arm pivot bearings cylinder pivot bearings e Mobil Mobilux EP2 AGIP GR MU EP2 or other equivalent good quality grease Rotation bearing e Mobil Mobilux EP2 ESSO Beacon EP2 Shell Calithia EP Fett T2 AGIP GR MU EP2 or other equivalent good quality grease Primary reduction gear e AGIP BLASIA 307 or other equivalent good quality oil Secondary gear e Mobilux EP2 AGIP GR MU EP2 or equivalent good quality grease 960029E User Manual Series AM Bolzoni Auramo Group Auramo Oy 2003 All Rights Reserved 20 aT mene 2 6 Hydraulic System a
21. ng onto the rod from the piston end of the rod e Install the piston back onto the piston rod Use LOCTITE 542 to secure the joint e Screw the grub screw back into the piston Use LOCTITE 270 to lock the screw e Install new seals on the piston e Oil the cylinder shell e Slide piston assembly into the cylinder shell e Screw the housing into the cylinder shell e f possible test run the cylinder before re assembling it to the clamp Max test pressure is 22 MPa 220 bar 3 200 psi e Re install the cylinder to the clamp e Connect hoses e Test run all cylinder functions Check for leaks 960029E User Manual Series AM Bolzoni Auramo Group Auramo Oy 2003 All Rights Reserved 31 pee SYOJLZAOIN Ce M p 8 Spare Parts Bolzoni Auramo and its authorized dealers supply spare parts for all products manufactured by Bolzoni Auramo 8 1 Spare Parts Book A unique Spare Parts Book comes with each clamp attachment This book consists of four main parts Machine Card Includes attachment definitions as mentioned in the order The Machine Card also contains the same information as the attachment nameplate Construction List The Construction is a list of the main parts of the clamp attachment It contains part numbers for sub construction spare parts Spare Parts List Contains part numbers and part quantities in sub constructions Some parts contain other parts for example clamp cylinders and valves
22. on Standard rotator unit does not have a pressure relief valve If the lift truck pressure exceeds the maximum connection pressure a separate pressure relief valve must be used 6 Motor 5 G Rotation hydraulics AM 13RF AM 13RH AM 18RF AM 18RH 960029E User Manual Series AM Bolzoni Auramo Group Auramo Oy 2003 All Rights Reserved 23 SYOILZIOINY fy 2 AURAIVIO 24 aa 6 3 6 Swivel joint Photo Swivel joint 6 3 7 Clamping pressure relief valve with connection tubes eie file 960029E User Manual Series AM Bolzoni Auramo Group Auramo Oy 2003 All Rights Reserved SYOJLZIOINI du b ALJRAIVIO Yz 6 3 8 Clamping cylinder Clamping cylinder incorporates a check valve and a pressure check point gt Photo Clamping cylinder 960029E User Manual Series AM Bolzoni Auramo Group Auramo Oy 2003 All Rights Reserved 25 ST ens SYOJLZOIN Ce M p 6 4 Trouble Shooting Problem No pressure in the clamp Possible cause Hose connection between the clamp and truck is defective e Check all connections If needed replace them Possible cause Failure in the truck hydraulic system e Check that oil is coming from truck hydraulic system Problem Pressure is on arms do not move Possible cause Incorrect hose connection e Check the hoses Rectify connections if needed Possible cause Dirt in check valve e Clean or replace check valves
23. opening function by pushing the clamping lever rotation clockwise by pulling the rotation lever rotation counterclockwise by pushing the rotation lever Standard connection fitting sizes AM Series clamps e All models JIC 8 e Special connection fittings are available on request e Attach connection hoses to fittings as shown in the chapter 3 6 Make sure that hoses do not twist when tightening the fittings e Motor connections are conical and fitted with teflon rings recommend not to use tightening torques exceeding 60 Nm e Check that the hose lengths are correct Check that the hoses are not pressed or chafed by any of the lift mast or attachment components e Do not use a smaller hose bending radius than recommended by the hose manufacturer CAUTION Do not over tighten the hose fittings 3 6 Hydraulic Connections Hydraulic connection points for the clamping and opening functions can be mounted on the left side standard or right side optional Rotator hydraulic connections are always on the right side Standard connection points are as follows e Clamping amp opening on the left side as seen from the driver s seat e Rotation on the right side 960029E User Manual Series AM Bolzoni Auramo Group Auramo Oy 2003 All Rights Reserved 10 BOILZIOIN g AURAIVIO Ga HYDRAULIC CONNEC I IONS gt be CLAMPING eRe oPenine ROTATION Clamping pressure relief valve Figure Standard hy
24. ositioned into the center notch of the lift truck carriage e Install the lower mounting hooks Tighten the screws with a torque of 80 to 120 Nm WARNING Upper mounting hooks must be properly engaged on the upper carriage bar before fastening lower mounting hooks If not properly engaged the clamp can drop 3 4 Hose Flush Flush the truck mast hosing before you connect it to the clamp attachment It is estimated that up to 80 of all defects in hydraulic systems are caused by dirty hydraulic oil Oil from the mast hoses should be run through the oil filter during the flushing to minimize the amount of debris and dirt in the hoses e Connect each hose pair with suitable fittings If needed use an extra hose e Turn the truck on and actuate control valves in both directions for about 40 seconds NOTE Hose flushing reduces the service costs in the long run 960029E User Manual Series AM Bolzoni Auramo Group Auramo Oy 2003 All Rights Reserved pee SYOJLZOIN ans Ce p 3 5 Connecting the Hoses Dimensions of the lift truck mast hoses and other hydraulic components must be adequate to meet the needs of a clamp attachment In this way there is no excessive power loss or damage caused by oil overheating Whenever possible avoid 90 degree fittings as these cause large pressure loss Connect the hoses as required by the safety rules clamping function by pulling the clamping lever
25. p When taking a roll from the stack back away only so far as to be able to lower the roll safely Never accelerate or brake powerfully when the roll is up as this can lead to loss of balance Do not release the roll before it is in its place Never allow the roll to fall down Beware of slackness in the mast chains when lowering the load WARNING Always work safely Do not stand in the lift truck operating area or in front of the moving direction Never stand under a load or clamp attachment Do not lift more than one paper roll at a time 960029E User Manual Series AM Bolzoni Auramo Group Auramo Oy 2003 All Rights Reserved 18 gem 2 5 Periodic Maintenance 5 1 Daily Checks Check that there are no leaks worn hoses or loosened parts in the clamp Check the clamp frame and arms for defects or cracks Check that there are no sharp edges on such parts that come into contact with the load Remove any such edges for example by grinding them Check all arms and contact pads and clean them if necessary Contact pads should move easily when tested by hand Check that the clamping force is correct for your load If needed adjust clamping pressure to suit your needs Never exceed a clamp s maximum operating pressure WARNING Always check the clamp operating condition before you use it Never use a defective or damaged clamp Never exceed the maximum operating pressure 5
26. ressure on for 5 10 minutes and check for the loss of pressure Clamping force may decrease up to 10 in ten minutes maximum 3 9 4 Action Test e f possible test all clamp attachment functions with an actual load e Check the hydraulic system for any leaks or other problems e Check that the clamping force is correct for the load 3 9 5 Operation Times It is difficult to give exact values for clamping and sideshift times because the available pump flow volume affects movement speeds Thus the values given below should be considered as guidelines only Clamping max min 4 10 seconds depending on the clamp size Opening min max 4 10 seconds depending on the clamp size Rotation 15 30 seconds depending on the clamp size If measured operation times are much slower than given values check all hydraulic system connections and the pump flow volume If necessary contact your Bolzoni Auramo representative 960029E User Manual Series AM Bolzoni Auramo Group Auramo Oy 2003 All Rights Reserved gem 2 4 User Instructions This section gives some basic instructions on how to handle loads with AM Series clamp attachment models 4 1 General Instructions 50 100 mm 2 4 Using the lift truck Only trained and authorized operators may use the lift truck and the clamp attachment Driving with the load Drive carefully and safely Avoid strong acceleration and braking Always drive with the load lowere
27. u will ensure safe and error free operation of the clamp attachment right from the start Make sure that you know how the clamp works before you attempt to use it Every country has its own safety regulations concerning lift trucks and lift truck attachments It is the responsibility of the user to know and follow these regulations If safety recommendations given in this manual should differ from your local regulations you should always follow the local regulations 1 1 Notices You will find three different levels of notices in this manual WARNING These paragraphs contain information that will help you prevent injuries CAUTION These paragraphs contain information that will help you prevent damage to the equipment NOTE These paragraphs contain information that will help you service the equipment 1 2 Safety Instructions Always check the operating condition of the clamp attachment before use Never use a defective or damaged attachment Never stand under a load or clamp attachment Never stand in the clamp operating area or between the clamping surfaces Handle only those products which the clamp attachment has been designed for It is unsafe to lift any other objects Know the capacity and limitations of your machine 960029E User Manual Series AM Bolzoni Auramo Group Auramo Oy 2003 All Rights Reserved gem ane 2 General Information Series AM paper roll clamps are des
28. upplied with the clamp 960029E User Manual Series AM Bolzoni Auramo Group Auramo Oy 2003 All Rights Reserved 21 SYOJLZOINT di p AURAIVIO Nz ai 6 3 1 Clamping Hydraulics Model AM RF standard 1 Long arm cylinder 3 Swivel joint 4 Clamping pressure relief valve Clamping hydraulics AM 13RF AM 18RF 6 3 2 Clamping Hydraulics Model AM RH standard 1 Long arm cylinder 2 Short arm cylinder 3 Swivel joint 4 Clamping pressure relief valve Clamping hydraulics AM 13RH AM 18RH 6 3 3 Clamping Hydraulics Model AM RF with optional opening pressure relief valve 1 Long arm cylinder 3 Swivel joint 4 Clamping pressure relief valve X gt 8 BO 5 Opening pressure relief valve N a AO A B1 4 3 5 B AT Ok D A B B Clamping hydraulics AM 13RF AM 18RF 960029E User Manual Series AM Bolzoni Auramo Group Auramo Oy 2003 All Rights Reserved 22 aT meas CA A 6 3 4 Clamping Hydraulics Model AM RH with optional opening pressure relief valve 1 Long arm cylinder 2 Short arm cylinder 3 Swivel joint 4 Clamping pressure relief valve BO 5 Opening pressure relief valve AO _ a Clamping hydraulics AM 13RH AM 18RH 6 3 5 Rotation Hydraulics Model AM RF AM RH standard rotati
Download Pdf Manuals
Related Search