960041E, AR User Manual, English
Contents
1. 5705 DN Helmond Industrieterrein nr 8955 The Netherlands Tel 31 492 50 97 77 Fax 31 492 38 28 44 E mail sales benelux bolzoni auramo com BRUDI BOLZONI AURAMO INC 17635 Hoffman Way Homewood Illinois 60430 U S A Tel 1 800 358 54 38 USA only Tel 1 708 957 88 09 Fax 1 708 957 88 32 E mail sales us bolzoni auramo com BRUDI BOLZONI AURAMO Ltd 90C Brunswick Blvd Dollard des Ormeaux Quebec H9B 2C5 Canada Tel 1 800 685 78 71 Canada only Tel 1 514 685 78 71 Fax 1 514 685 52 38 E mail sales ca bolzoni auramo com BOLZONI AURAMO S A Av sidora Goyenechea 2925 Office 103 Las Condes Santiago Chile Tel 56 2 374 09 99 Fax 56 2 374 03 68 E mail sales cl bolzoni auramo com BOLZONI AURAMO Pty Ltd P O Box 7198 Baulkham Hills DC NSW 2158 Australia Tel 61 2 9659 22 24 Fax 61 2 9659 22 25 E mail sales au bolzoni auramo com BOLZONI AURAMO NEW ZEALAND Ltd P O Box 34941 Birkenhead Auckland New Zealand Tel 64 9 570 40 29 Fax 64 9 570 40 23 E mail sales nz bolzoni auramo com BOLZONI AURAMO SOUTH AFRICA Pty Ltd P O Box 915 Benoni 1500 South Africa Tel 27 11 421 07 38 Fax 27 11 421 52 08 E mail sales za bolzoni auramo com AURAMO BALTIC OU Suur Sdjamae 10 Tallinn 11415 Estonia Tel 372 6 10 11 14 Fax 372 6 10 11 58 E mail sales ee bolzoni auramo com MCGOWAN ENGINEERING LTD Lightoburn Road Cambuslang Glasg2. which are located at the end of the rotation cylinders See Section 6 3 3 for instructions 960041E User Manual Series AR Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 28 SCT Ed be P ALUIFAIVIO Ws 6 Service and Repairs Perform all maintenance actions with the lift truck turned off and only after relieving pressure in the hydraulic circuit by actuating all control levers in both directions 6 1 Service Instructions In the following pages you will find instructions on how to perform service actions and repairs that are outside the normal maintenance schedule WARNING Read the instructions carefully before you do anything Repairs done incorrectly are safety hazards Follow all the safety instructions given in previous chapters Never remove pressurised parts or hoses 6 1 1 Changing the Rotation Hoses Series AR clamps have four hoses routed through the rotation system These hoses require a special procedure for easy replacement 1 Remove the clamp from the lift truck and leave it on the ground or on a working table in a normal vertical position To remove the clamp follow the instructions given in chapter 2 3 in reverse order 2 Open the front cover plate open the two back cover plates 960041E User Manual Series AR Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 29 SYOILALGINT d A ALJIRAIVIO Yz 3 Loosen the clamping valve block from the clamp bod
3. 21 Check valve prevents long arm from closing under its own weight 22 Control valve for stopping the free split arm 23 Flow divider valve for high flows for simultaneous opening of check valves in the cylinders 24 Flow divider valve for moderate flows for simultaneous opening of load check valves 25 Pressure relief valve for opening pressure 26 Pressure relief valve for clamping pressure 27 Short arm pressure relief valve for positioning the short arm 28 Sequence valve controls flow path when opening with high flows 29 Throttle valve for adjusting the balancing speed of the arms 30 Throttle valve compensates pressure difference 31 Throttle valve decreases flow 960041E User Manual Series AR Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 24 SYOJLZAIOING A ALJIRAIVIC as Split long arm with 1 flow divider valve diagram 690064 101 Sc lt 90 gt 102 IZ lt 901 gt 22 lt 900 gt 1 Valve block 19 Check valve prevents short arm from shifting when operating clamp 20 Check valves are used to control the flow path when opening with a low flow 21 Check valve prevents long arm from closing under its own weight 22 Control valve for stopping the free split arm 23 Plug replaces flow divider valve 24 Flow divider valve for moderate flows for simultaneous opening of load check valves 25 P
4. cause flow control valve in cylinders is blocked e Clean or replace dirty or blocked flow control valves Possible cause bleed valve in cylinders is defective e Clean or replace dirty or blocked bleed valves Possible cause pressure relief valve 2 is defective or incorrectly adjusted e Replace the pressure relief valve or readjust the valve Problem clamping force too low 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 oil level and add oil if necessary e Check for external leaks If necessary clean components before checking 960041E User Manual Series AR Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 26 SCT Ed be A ALUIFAIVIO We e Blocked hose or fitting Repair or replace Possible cause wrong setting in the main pressure relief valve 26 e Check clamping pressure The pressure can be adjusted by turning the adjustment screw clockwise pressure increases anticlockwise pressure decreases Never exceed the maximum operating pressure of the clamp Possible cause defective check valve 1 amp 2 e Clean or replace check valves Possible cause leak in cylinder seals e Replace seals Possible cause too much pressure in tank line e Check hoses and repair if necessary Problem clamping force OK load falls Po
5. cylinder shell and guide parts See if there are scratches wear corrosion cracks or other similar damage that could affect the normal operation of the cylinder Replace all damaged or worn parts 10 Check and clean the cushion bushing in the other end of the rack Clean the cushion channel from the other end of the cylinder shell 11 Install new seals onto the end of the rack Oil the seals 12 Slide guide parts onto the cylinder shells 13 Slide the cylinder shell onto the rack 14 If necessary repeat the operation with the other cylinder shells 15 Check the condition of hoses located under the rotation cylinder assembly Replace hoses if necessary Clean and re lubricate these hoses if necessary 16 Apply a thick layer of grease to the rack and pinion gear teeth 17 Lift the rotation cylinder assembly back onto the clamp Note that cylinders must be in the same position as they were previously Make sure that centring marks found on rack and pinion teething are in the correct positions otherwise full 180 degree motion will not be attainable 18 Make sure that holes in cylinder shell ends settle correctly into the centring pins that are located in the clamp frame 19 Adjust and fasten guide parts Make sure that guides settle properly into their seats 20 Screw cylinder shell end adjustment nuts back to their original positions Use previously made marks to determine the correct position 21 Assemble hoses and
6. models e JIC 8 Standard hose connections are located as follows clamp functions on the right hand side rotation functions on the left hand side Figure Hose connections of the AR series clamp e Attach connection hoses to fittings as shown in the figure Make sure that hoses do not twist when attaching the fittings e Check that hose lengths are correct Check that the hoses will not be pressed or chafe against the mast when lifting or tilting e Do not use a smaller hose bending radius than recommended by the hose manufacturer CAUTION Do not over tighten the hose fittings 960041E User Manual Series AR Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved SYOJLZAIOING 4u P ALIrFeAIViO as 2 6 Checks Before Operating the Clamp Check the correct operation of all functions of the clamp before using it for the first time with the load e Run all movements clamping and rotation several times between the respective end positions e Check the operation of the split long clamping arm Close all clamps fully by pressing wait a moment and then open them by using a low flow which causes both long arms to open simultaneously Close and open the long arms The arms should move almost at the same pace The synchronisation speed of the separated long arms should be set to a suitable level Appropriate instructions for adjustment are given in sec
7. pipes 22 Attach the clamp back onto the truck Test all rotation functions Check for leaks Check that the clamp rotates a full 180 degrees Check that the rotation end cushioning works Fasten the cover plate 960041E User Manual Series AR Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 33 STE A ALJIRAIVIC as 6 1 4 Replacement of Wear Plates The short arms of the AR series clamp have wear plates made of special wear resistant steel The purpose of these plates is to protect the short arms from wearing during normal operation Plates should be replaced before they become totally worn out e Remove the remnants of an old plate by for example grinding Weld a new plate at the same location e Also check whether there is excessive wear to other parts of the clamp and repair if necessary Figure Wear plates and other typically wearing parts 6 1 5 Split Arm Synchronisation Adjustments Only models AR RJ ARC S with 2 flow dividers Using the pressure relief valve 28 ensures that even with low flow rates all of the oil runs through the flow divider valve 24 when clamps are opened Before starting the synchronising of split arms check the adjustment of the pressure relief valve 28 The recommended adjustment is 80 bar 8 0 MPa 1 160 psi when the head of the adjustment screw is 12 5 mm from the surface of the tightening nut 12 5 mm H 960041E User
8. 007 All Rights Reserved 13 SYOJLZAIOING 4u P ALJIRAIVIC as e Slowly lower the clamp until the short arm just touches the floor Avoid unnecessary rubbing of the arm on the floor e Slowly approach the roll and stop when the lower contact pad touches the roll e Grip the roll with the long arm Tilt the mast back to the vertical position e 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 the roll in a horizontal position Lift the roll high enough before rotating Keep the roll approx 30 cm 12 above the floor when driving 960041E User Manual Series AR Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved SCT Ed be A ALJIRAIVIC Wrz 3 2 Rotating the Roll AR clamps have a hydraulic cushioning in the vertical positions of the rotation mechanism This reduces forces on the roll during rotation e Grip the roll and lift it high enough before rotating Avoid rotating when the roll is lifted high 3 3 Tips for Safe Operation e Grip the roll correctly e Drive carefully and safely Avoid strong acceleration and braking e Always drive with the load lowered down and the mast in a vertical or backward tilted position Note that too much tilt backwards or forwards increases the risk of roll edge damage e When taking a roll from the stack back away only so far as to be able to lower the roll saf
9. 5 3 Hydraulic Circuit This section shows the standard hydraulic circuit schematics Please check the spare parts documentation for any changes 5 3 1 Circuit Schematic Rotation NOTE The flow resistances and bleed valves shown in the hydraulic diagram are located in the rotation cylinders 960041E User Manual Series AR Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 19 SYOJLZAIOING 4u A ALJIRAIVIC Yz 5 3 2 Rotation Valve Block Numbers in the figure correspond to those in the spare parts book 2 Pressure relief valve rotation both directions Standard setting 160 bar 16 0 MPa 2 320 psi 3 Plug 4 Throttle plug 960041E User Manual Series AR Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 20 SYOJLZAIOING A ALJIRAIVIC as 5 3 3 Circuit Schematic Clamping Unsplit long arm diagram 690066 I ll 690066 Split long arm with 2 flow divider valves diagram 690065 Short arms 31 Leng arms GDL Split long arm with 1 flow divider valve diagram 690064 t fi anne 960041E User Manual Series AR Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved EA SCT Ed be P AUFAIVIO Wri 22 5 3 4 Clamping Valve Block The clamping valve block controls arm opening and closing Numbers in the figure correspond to those in the spare parts book Only the main components
10. Manual Series AR Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 34 SYOJLZAIOING A ALJIRAIVIC as If the adjustment of the valve is too low gt 12 5 mm the split arms may open in an unsynchronised way Overly high adjustment causes unnecessary pressure losses In systems equipped with 2 flow divider valves diagram 690065 the split arm synchronisation can be adjusted with a throttle valve spindle 29 which is located on the clamping valve block This throttle valve controls the oil flow going past the flow divider valve The flow divider valve controls oil flow to and from the cylinders It also ensures that all cylinder mounted check valves open simultaneously 1 Ifthe throttle valve is completely closed the whole oil flow goes through the flow divider valve This forces the split long arms to move at equal speeds This setting is good when all paper rolls have the same diameter With a fully closed throttle valve the split arm sections adjust slower to varying roll diameters 2 Ifthe throttle valve is completely or partially open a large portion of the oil flow goes past the flow divider valve This setting is better when there are significant differences in the paper roll diameters in two roll handling and when there is enough oil flow coming from the lift truck to open the cylinder check valves simultaneously The standard setting on the throttle valve is 1 4 to 1 2 turn open This setting no
11. Manual Series AR Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 17 SYOJLZAIOING 4u P ALJIRAIVIC as In the next section you will find some guidelines on how to estimate the amount of wear in some parts Arm pivots pins bushings and their seats When moving arms up and down by hand the play should be less than 5 mm 0 2 inches measured from a 1000 mm 40 inch arm length For longer or shorter arm lengths use the following formula max play Arm length in mm 5 1000 or max play Arm length in inches 0 2 40 If the play is greater than this and disturbs normal operations worn arm bushings or clamp cylinder bushings must be replaced Rotation mechanism rack and pinion The play should be no more than 5 mm 0 2 inches measured from a 500 mm 20 inch distance from the torque centre If the play is greater than this and disturbs normal operations you have to replace the rack and or pinion The best and most durable result would be to replace both You can measure the play by gripping a vertical roll and then carefully and slowly trying to rotate it do not lift the roll in this case Another method is to rotate by hand a clamp that has been lifted up 4 3 Tightening the Bolts Bolts on Bolzoni Auramo AR series clamps are secured using LOCTITE 270 or Permapond A1046 or equivalent e g Scantech product In addition bolts under high stresses are tightened to a certain fastening torque In nor
12. User Manual Series AR Series ARC 960041E Rev 09 08 SYOJLZIOINT d P ALIreAIViO Vaz Safety Instructions WARNING Know the capacity and limitations of your machine Do not overload the lift truck or the clamp 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 for more information WARNING Never stand on the clamp attachment or on the load WARNING Never stand under a load or attachment WARNING Never stand in the attachment operating area or between the clamping arms WARNING Limit driving with a raised load to the minimum Never accelerate or brake powerfully with a raised load WARNING Handle only those products that the attachment has been designed for It is unsafe to lift any other objects WARNING Do not risk the lift truck stability by sideshifting or rotating Sideshift only when the load is lowered down or near its seat Use extreme caution when handling off centre loads WARNING Always check the operating condition of the attachment before use Never use a defective or damaged attachment Repairs may be carried out by authorised personnel only 960041E User Manual Series AR Bolzoni Auramo Group Auramo Oy 2007 All Rights Reser
13. are described below see spare parts documentation for more detailed information NOTE Check valves 1 amp 2 that appear in schematics are mounted into cylinders Also throttle valves 6 are located next to cylinders 960041E User Manual Series AR Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved SCT Ed be A ALUIFAIVIO Wri Unsplit long arm diagram 690066 lt 900 gt 22 oun 100 LR 27 lt 900 gt 25 lt 900 gt 1 Valve block 19 Check valve prevents short arm from shifting when operating clamp 21 Check valve prevents long arm from closing under its own weight 22 Control valve for stopping the free split arm 25 Pressure relief valve for compression pressure 26 Pressure relief valve for compression pressure 2 Pressure control valve for positioning the short arm 30 Throttle valve compensates pressure difference 31 Throttle valve to prevent short arm from shifting inwards 960041E User Manual Series AR Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 23 SYOJLZIOINT d P ALIreAIViO Vaz Split long arm with 2 flow divider valves diagram 690065 100 are lt 900 gt wy GER 26 lt 900 gt 21 lt 901 gt 22 lt 900 gt 1 Valve block 19 Check valve prevents short arm from shifting when operating clamp 20 Check valves are used to control the flow path when opening with a low flow
14. ctions Standard clamps require two hydraulic functions from the truck s hydraulic system 2 2 Handling and Transportation Prior to installation check the clamp carefully for any damage that may have occurred during transportation 960041E User Manual Series AR Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved SCT Ed be A ALJIRAIVIC Wrz 2 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 The attached figure shows the recommended lifting points WARNING Never go under a hanging load Beware of load swing when lifting 2 3 Installation Before installation carry out the following e Make sure that the lift truck fulfils all clamp requirements Section 2 1 e Make sure that the clamp mounting type and size are the same as the ones used on the truck e Check that the truck s hydraulic oil level is correct e Check that the truck s hosing and fittings are in good condition e Clean the truck carriage Make sure that it has no defects or wear that could prevent installation or use of the clamp 2 3 1 Installation Standard Carriages Installation on the most common lift truck standard carriages ISO 2328 classes 2 3 and 4 ITAclasses Il III and IV is done as follows e Remove the lower mounting hooks Do not touch the upper mounting hooks e If the clamp has quick release lo
15. ely Never accelerate or brake powerfully when the roll is up as this can lead to a loss of balance e Do not release the roll before it is in place Never allow the roll to fall down e Beware of slackness in the mast chains when opening the clamp arms 960041E User Manual Series AR Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 15 SYOJLZIOINT d P ALreAIViO Vaz 4 Periodic Maintenance 4 1 Daily Checks Check that there are no leaks worn hoses or loosened parts such as joints shaft connections etc in the clamp Check the clamp frame and arms for defects or cracks Check that there are no sharp edges on 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 necessary adjust the clamping pressure to suit your needs WARNING Always check the clamp operating condition before you use it Never use a defective or damaged clamp Never exceed the maximum operating pressure 4 2 Inspection and Service Carry out the following checks and services twice a year or every 300 hours whichever comes first WARNING In the following service actions the clamp is to be moved hydraulically Do not leave any body parts between moving clamp attachment parts Before servicin
16. g any of the clamp components turn the lift truck off and relieve the pressure in the hydraulic circuit by actuating all the control levers several times in both directions e Clean the clamp e Carry out all routine tasks mentioned in Section 4 1 e Apply grease to the rotation bearing Remember to rotate the clamp during this operation Wipe off all excess grease coming from the bearing 960041E User Manual Series AR Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved SYOJLZIOINI 4u i ALJIRAIVIC Yz Figure Lubricating the rotation bearing e Open the front cover plate e Rotate the clamp to its end positions and wipe off all old contaminated grease and dirt from the racks and pinion e Apply new grease to racks and pinion and remember to rotate the clamp during the operation Use a brush or an equivalent tool to apply the grease Figure Greasing points of the rack and pinion mechanism e Lubricate pivot pin bearings e Check the clamp for parts that might become defective or cause other trouble during the next service interval Especially check hinge pins and their bushings contact pads and wear plates Replace or repair all parts showing signs of excessive wear 960041E User
17. hydraulic operating pressure contact pad friction roll wrapper friction environmental conditions dynamic handling situation and other load related matters WARNING The clamp attachment decreases the rated capacity of the lift truck 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 2 1 2 Operating Pressure Please refer to clamp rating plate For standard models the following information applies 160 bar 16 0 MPa 2 320 psi max working pressure on rotation clamping and opening functions 210 bar 21 0 MPa 3 040 psi max connection pressure NOTE AR 22 ARC 48 models connection pressure max 180 bar 2700 psi WARNING Never exceed the maximum working pressure 960041E User Manual Series AR Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved S XOILAOIN 4i b ALJIRAIVIO Yz 2 1 3 Oil Flow 2 1 4 Hydraulic Oils Use petroleum based hydraulic oil as recommended by the truck manufacturer The oil type used must be a well known brand and suitable for the purpose Please contact Bolzoni Auramo before using aqueous based biohydraulic or other special oils 2 1 5 Required Hydraulic Fun
18. ing 20 100 out from the cylinder tube 10 CAUTION Do not scratch piston rod or cylinder barrel surfaces with sharp tools Note the direction of the seals 1 Open the cylinder housing and pull the piston rod assembly off the cylinder shell 2 Open the grub screw 53 If necessary heat the screw before opening Unscrew the piston 50 from the piston rod 20 Slide the housing 51 off the piston end of the rod 3 Remove old seals from housing 960041E User Manual Series AR Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 31 SYOJLZAIOING 4u P ALJIRAIVIC as 4 Clean and check piston piston rod cylinder shell and housing See if there are any scratches wear corrosion cracks or other similar damage that could prevent normal operation of the cylinder Replace all damaged or worn parts Install new seals into the housing 6 Oil seals and piston rod Slide the housing onto the rod from the piston end of the rod 7 Install the piston back onto the piston rod Screw the grub screw back into the piston Use LOCTITE 542 or equivalent e g Scantech product to lock the screw Install new seals on the piston 9 Oil the cylinder shell Slide the piston assembly into the cylinder shell Screw the housing into the cylinder shell 10 If possible test run the cylinder before re assembling it on the clamp Max test pressure is 22 MPa 220 bar 3 200 psi 11 Check the condition of pin b
19. ion is the responsibility of the truck user The paper roll clamp has been designed and manufactured in accordance with basic safety requirements It is the responsibility of the user to check the rating plates on the truck and the clamp and to ensure that they are used safely 1 1 Notices There are three different levels of notices in this manual WARNING These paragraphs contain information that will help to prevent injuries CAUTION These paragraphs contain information that will help to prevent damage to the equipment NOTE These paragraphs contain information that will help in servicing 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 Only use the clamp attachment to handle products that it has been designed for It is unsafe to lift any other objects Know the capacity and limitations of your machine 960041E User Manual Series AR Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved SYOJLZAIOING P ALJIRAIVIC Yz 2 Installation Instructions 2 1 Truck Requirements 2 1 1 Clamp Attachment Rated Capacity Refer to clamp rating plate for maximum nominal clamp capacity Please note that the actual lifting capacity of a paper roll clamp is dependant on the
20. low divider valves 6 only split arm models that are equipped with 1 flow divider valve diagram 690064 e Check and replace if necessary movement accelerates clockwise Problem short arms move simultaneously with long arms Possible cause wrong setting in pressure control valve 27 or control valve 22 e Check see section 6 1 6 the setting and tighten clockwise if necessary Problem short arms do not move Possible cause defect in short arm pressure control valve 27 or control valve 22 e Check the setting and readjust see section 6 1 6 If trouble persists replace the valve Problem shaking arm movement Possible cause air in the system e Remove air by fully opening and closing arms several times Possible cause dirt in hydraulic system e Clean system and check all cartridge valves Problem split long arms do not move at the same speed split arm models only Possible cause wrong setting on pressure control valve 28 throttle valve 29 or flow divider throttle valves 6 or the flow divider valve is defective e Check the setting see section 6 1 5 If trouble persists change the flow divider valve Check the arms for defects and wear Problem rotation end cushioning does not work Possible cause dirt or wear in cushion channel or cushion mechanism e Rotate clamp several times back and forth near the end position If this does not help clean replace cushion channel and mechanism
21. lzoni auramo com BOLZONI AURAMO SARL Rue Avogadro Technop le de Forbach Sud 57600 Forbach France Tel 33 3 87 84 65 40 Fax 33 3 87 84 65 45 E mail sales fr bolzoni auramo com BOLZONI AURAMO S L Polig Industrial Riera de Caldes C dels Basters 12 14 Apdo 62 08184 Palau solita i Plegamans Barcelona Spain Tel 34 938 648 633 Fax 34 938 648 350 E mail sales es bolzoni auramo com Lisboa Office Portugal Tel Fax 351 212 902551 Tel movil 351 917 884976 E mail lsilva bolzoni auramo com BOLZONI AURAMO LTD Unit 10 Taurus Park Europa Boulevard West Brook Warrington Cheshire WA5 7ZT United Kingdom Tel 44 1925 62 45 70 Fax 44 1925 62 45 78 E mail sales uk bolzoni auramo com BOLZONI AURAMO RENTAL LTD Unit 10 Taurus Park Europa Boulevard West Brook Warrington Cheshire WA5 7ZT United Kingdom Tel 44 1925 62 45 70 Fax 44 1925 62 45 79 E mail rental bolzoni auramo com BOLZONI AURAMO AB P O Box 172 80103 G vle Sweden Tel 46 26 64 72 30 Fax 46 26 64 72 35 E mail sales se bolzoni auramo com BOLZONI AURAMO S r l S S 16 Km 770 580 70052 Bisceglie BA Italy Tel 39 080 39 51 437 Fax 39 080 39 51 393 E mail sales it bolzoni auramo com BOLZONI AURAMO POLSKA Sp z o o Ul Wojciechowska 5A 7 20 704 Lublin Poland Tel 48 81 44 65 491 Fax 48 81 44 65 490 E mail sales pl bolzoni auramo com BOLZONI AURAMO BV Waterbeemd 6a
22. m to move e Open the long arm fully then stop the opening Wait a moment and then continue the opening function at low flow until the short arm has opened enough 3 1 2 Closing the Arms The short arm begins to close only after the long arm is fully closed Therefore before closing the short arm the long arm must be closed e Close the long arm fully Continue the closing function until the short arm has closed to the desired position 960041E User Manual Series AR Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 11 SYOJLZAIOING 4u P ALJIRAIVIC as 3 1 3 Clamping a Vertical Roll e 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 e Grip big rolls max diameter in such a way that the roll touches the clamp body and contact pads e Small rolls The short arm is adjusted in such a way that the roll is positioned centrally in relation to the truck and clamp combination and the long arm is opened when necessary Drive the truck near the roll into a position where the short arm just touches the roll e f possible grip smaller rolls so that the centre of the roll would be on a line that goes through the contact pad centre points e Do not grip the roll too much behind its centreline as the roll might ea
23. mal cases regular re tightening of the bolts is unnecessary Should loose bolts be found during daily checks open them apply some LOCTITE 270 or any equivalent product to the bolt threads and retighten the bolts Recommended fastening torques are mentioned in the spare parts documentation 4 4 Recommended Lubricants Greases Rotation bearing ESSO Beacon EP2 Shell Calithia EP Fett T2 Mobil Mobilux EP2 or other equivalent good quality greases Other components Mobil Mobilplex 47 or other equivalent good quality universal greases 960041E User Manual Series AR Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved SYOJLZAIOING A ALJIRAIVIC Yz 5 Trouble shooting 5 1 General It is estimated that up to 80 of all trouble and defects in hydraulic systems originate from contaminated or dirty hydraulic oils Bolzoni Auramo strongly recommends that the hydraulic oil and oil filters are changed regularly Also make sure that no dirt is allowed to enter the system during maintenance 5 2 Safety Warnings During all trouble shooting operations work will be carried out near the clamp Always work safely WARNING Hydraulic components can be hot Use suitable protection Beware of leaks High pressure oil can damage the eyes and skin Always wear protective goggles with side protection Do not remove cartridge valves hoses or other potentially pressurised components when pressure is on
24. ow G72 7XS Scotland U K Tel 44 141 641 3648 2359 Fax 44 141 641 51 47 E mail into mcgowaneng co uk CEMAT s r o Ul CSA 196 735 51 Bohumin Pudlov Czech Republic Tel 42 69 60 13 541 3 Fax 42 69 60 13 522 E mail cemat cemat cz 960041E User Manual Series AR IELI LAINI 2 ALJIRAIVIC Yz EUROLIFT Pty Ltd 2 81 Harrison Road Dudley Park 5008 South Australia Tel 61 8 83 46 35 55 Fax 61 8 83 46 94 22 E mail info eurolift com au INSTANT INDUSTRIES ASIA Pte Ltd 243 Ubi Avenue 4 Intrepid Warehouse Complex Singapore 408823 Tel 65 6745 60 00 Fax 65 6745 82 22 E mail industries instant com sg INSTANT MATERIALS HANDLING SDN BHD No 23 1st Floor Jalan TSB 10A Taman Industri Sungai Buloh 47000 Sungai Buloh Selangor Malaysia Tel 60 3 6157 28 96 Fax 60 3 6157 07 81 E mail imhsb tm net my ADJL INTERNATIONAL TAIWAN LTD 4 6Fl No 28 Sec 3 Chung San North Rd Taipei Taiwan Tel 886 2 2668 67 68 69 70 Fax 886 2 2668 67 73 E mail adji saturn seed net tw SHANGHAI SOLID LIFTING EQUIPMENT Co Ltd No 108 Lane 7333 Zhongchun Rd Shanghai 201101 P R China Tel 86 21 64615027 64615028 Fax 86 21 64615026 E mail guanjie mail hf ah cn PT AURAMO Mekanika Tradindo JL Agung Perkasa 10 11 Sunter Agung Podomoro Jakarta 14350 Indonesia Tel 62 21 65 21 247 Fax 62 21 65 12 378 E mail sales id bolzoni auramo com Bolzoni Au
25. ramo Group Auramo Oy 2007 All Rights Reserved 3
26. ressure relief valve for opening pressure 26 Pressure relief valve for clamping pressure 27 Short arm pressure relief valve for positioning the short arm 28 Sequence valve controls flow path when opening with high flows 29 Plug replaces throttle valve 30 Throttle valve compensates pressure difference 31 Throttle valve decreases flow 960041E User Manual Series AR Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 25 STE A ALJIRAIVIC Yz 5 4 Trouble shooting Problem no pressure in the clamp Possible cause hose connection between clamp and truck is defective e Check all connections If necessary replace them Possible cause failure in the truck hydraulic system e Check that oil is coming from the truck hydraulic system and repair any damage Problem pressure is on arms do not move Possible cause incorrect hose connection e Check the hoses Rectify connections if necessary Possible cause defective check valve defective flow divider valve e Clean or replace check valves or flow divider valves Possible cause pressure relief valve cartridge 25 or 26 defective or wrongly set e Replace valve or correct the setting Possible cause leak in pressure cylinders e Check and replace seals if necessary Problem pressure is on rotation does not work Possible cause incorrect hose connection e Check the hoses Rectify connections if necessary Possible
27. rly engaged the clamp can drop or move on the carriage 2 3 2 Installation of Special or Large Mountings Pin type and hook type mountings that are common in larger clamp models are normally installed as follows ZD E Ch e Remove lower pins e Hang the clamp on the truck carriage from the upper hooks or pins d e Centre the clamp Saf g e Al e Attach lower locking pins and securing pins NOTE Check the spare parts book for any additional instructions for installing special mountings 2 4 Hose Flush Flush the truck mast hosing before installing 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 minimise the amount of debris and dirt in the hoses e Connect each hose pair with suitable fittings If necessary use an SS extra hose e Turn the truck on and actuate control valves in both directions for about 40 seconds 960041E User Manual Series AR Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved SCT Ed be A ALJIRAIVIC Wrz 2 5 Connecting the Hoses For hydraulic connections standard clamps have a connection block on the clamp mounting side Fittings Metric models e 12 mm DIN 2353 M18x1 5 24 series AR 22 25 30 33 e 15 mm DIN 2353 M18x1 5 24 series AR 37 4X 5X 6X 7X Fittings series ARC U S
28. rmally provides a good balance between equal arm speed and split arm adjustment speed for varying roll diameters If the arms do not open at the same time slightly close the throttle valve If the problem persists check the oil flow volume entering the clamp In systems equipped with 1 flow divider valve diagram 690064 the arm synchronisation is adjusted with a flow divider throttle valve 6 located on the cylinder sides These flow divider throttle valves are used to keep the oil flows to both cylinders equal by increasing the flow resistance of the quicker flow You are recommended to start the adjustment of flow divider throttle valves by first turning the valves 6 fully closed clockwise and then opening them by one turn After this the synchronisation is carried out by tightening clockwise the flow divider throttle valve of the quicker arm 960041E User Manual Series AR Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 35 SYOJLZAIOING 4u P ALJIRAIVIC as 6 1 6 Adjustment of short arm movement Short arm operation has been described in sections 3 1 1 and 3 1 2 Read the sections before adjusting short arm movement Short arm movement is controlled by using the pressure control valve 27 and the control valve 22 The default setting of the pressure control valve is 10 0 MPa 100 bar 1 450 psi The pressure of the truck must exceed the valve setting in order to move the short arm Also check that the se
29. sily slip off the clamp Furthermore do not grip any roll too far in front of its centreline as this could lead to the clamp frame and the contact pad corners damaging the roll or the roll could slip towards the clamp and fall e When the correct gripping position has been reached grip the roll by closing the long arm Maintain closing for a couple of seconds to ensure the necessary clamping force Do not pump the valve e Always grip the roll so that the clamp attachment is well aligned to the roll Misalignment easily leads to roll damage When handling single rolls always grip the roll so that the arms are centred between the ends of the roll O Q 960041E User Manual Series AR Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 12 SYOJLZAIOING P ALJIRAIVIC as e When handling multiple rolls always use a clamp attachment with split clamping arms Grip rolls in such a way that each roll is clamped with its own contact pad 3 1 4 Clamping a Horizontal Roll e Adjust the opening of the short arm to suit the diameter of the roll Open the long arm sufficiently Short arm down long arm up e Tilt the mast completely forward minimum 5 degrees gt e Carefully adjust the truck so that the clamp is centred in relation to the roll 960041E User Manual Series AR Bolzoni Auramo Group Auramo Oy 2
30. ssible cause dirty contact pads e Clean the contact pads Possible cause worn or damaged contact pads e Replace contact pads or friction surfaces Possible cause operator error e Check that the load is clamped correctly and that there is no overloading Possible cause wrong clamp for the load e Check if the clamp capacity opening range and arm contact pad models are suitable for the load Problem loss of clamping force Possible cause leaks in hoses or fittings e Check for external leaks If necessary clean components before checking Possible cause leak in check valve 1 amp 2 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 low or much too high e Check the oil flow rate and repair the pump if necessary Possible cause hoses defective or too small e Repair or replace with the correct sizes 960041E User Manual Series AR Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 2 STE A ALJIRAIVIC as Possible cause overly tight adjustment of pressure relief valve 28 split arm models only Check see section 6 1 5 and adjust if necessary Possible cause defective flow divider valve 23 only split arm models that are equipped with 2 flow divider valves diagram 690065 e Check and replace Possible cause overly tight adjustment of f
31. tion 6 1 5 e Check the operation of the short arm Only long arms may move inwards by pressing When long arms reach the inward position the short arm must start moving When the clamps are opened the long arms move to their outer position but the short arm must not move yet Release the control switch to the central position wait a moment and continue the opening function that causes the short arm to move outwards Appropriate instructions for adjustment are given in section 6 1 6 e Check all cylinders valves hoses and fittings for leaks 2 6 1 Clamping Force Test We recommend that regular clamping force tests be carried out in order to minimise the possibility of roll damage Use a suitable testing device for testing the clamping force e Check that the clamping force is maintained when clamping for an extended period of time Leave the pressure on for 5 10 minutes and check for loss of pressure Clamping force may decrease up to 10 15 in ten minutes maximum e Check that the clamping force is correct for the load 960041E User Manual Series AR Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 10 SCT Ed be A ALUIFAIVIO Wri 3 User Instructions 3 1 Clamping the Paper Roll 3 1 1 Opening the Long and Short Arms The short arm begins to open only after the long arm has been opened completely The split long clamping arm can be synchronised in the extreme position without causing the short ar
32. ttings of the pressure relief valves 25 amp 26 exceed the setting of the pressure control valve 27 When pressing the short arm begins to move only after the long arms have closed completely If the short arm starts to move earlier the adjustment screw of the valve 27 must be tightened clockwise If the short arm will not move even when the long arms have closed completely and the checks mentioned in the previous section have been made the screw must be opened a little Adjust the valve only turn at a time in the desired direction until the required operation is completed When opening the long arms can be opened completely without causing the short arm to move If the short arm moves without the waiting time mentioned in section 3 1 1 the adjustment screw of the control valve 22 must be tightened The default setting is 3 turns clockwise from the extreme position 960041E User Manual Series AR Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 36 BOLZONI S p A 29027 Casoni di Podenzano Piacenza Italy Tel 39 0523 55 55 11 Fax 39 0523 52 40 87 Internet www bolzoni auramo com E mail sales it bolzoni auramo com AURAMO OY P O Box 78 Valimotie 22 01511 Vantaa Finland Tel 358 9 82 931 Fax 358 9 87 01 037 E mail sales fi bolzoni auramo com BOLZONI AURAMO GmbH Muhlenstr 74 41352 Korschenbroich Germany Tel 49 2161 999 36 0 Fax 49 2161 999 36 99 E mail sales de bo
33. ushings at both ends of the cylinder and replace bushings if necessary 12 Re install the cylinder onto the clamp Connect the hoses Test run all cylinder functions Check for leaks 6 1 3 Seal Change Rotation Cylinders Before changing the rotation cylinder seals the whole rotation cylinder assembly both rotation cylinders and their guide parts must first be dismantled 1 Preferably remove the clamp from the truck and set it to a horizontal position mounting side down arms up This position makes the following operations easier to perform 2 Remove the front cover plate Label all hoses before removing them from the valve block This makes re assembly easier 3 Remove hoses and pipes protect open fittings with proper caps 960041E User Manual Series AR Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 32 SCT Ed be A ALJIRAIVIC Wrz 4 Useacentre punch or similar tool to mark the position of adjustment nuts 40 Hit a mark to every nut and respective position on the clamp frame This procedure makes re assembly easier 5 Unscrew each adjustment nut slightly less than one turn Open screws from guide parts 6 Lift rotation cylinder assembly from the clamp Use proper lifting devices only 7 Slide guide parts off the cylinder shells Pull cylinder shell 10 20 off the rack 30 8 Remove old seals from the rack end CAUTION Note the direction of the seals 9 Clean and check rack
34. ved Contents SYOJLZAIOING P ALJIRAIVIC Yz 1 Introduction 1 1 Notices 1 2 Safety Instructions 2 Installation Instructions 2 1 Truck Requirements 2 2 Handling and Transportation 2 3 Installation 2 4 Hose Flush 2 5 Connecting the Hoses 2 6 Checks Before Operating the Clamp 3 User Instructions 3 1 Clamping the Paper Roll 3 2 Rotating the Clamp 3 3 Tips for Safe Operation 4 Periodic Maintenance 4 1 Daily Checks 4 2 Inspection and Service 4 3 Tightening the Bolts 4 4 Recommended Lubricants Greases 5 Trouble shooting 5 1 General 5 2 Safety Warnings 5 3 Hydraulic Circuit 5 4 Trouble shooting 6 Service and Repairs 6 1 Service Instructions 960041E User Manual Series AR Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 11 16 19 29 SYOJLZIOINT d P ALreAIViO Vaz 1 Introduction This manual contains installation start up and service instructions for the series AR and ARC paper roll clamps All the instructions include metric and U S standard measurements Please read this manual carefully before using or servicing this equipment This 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 attempting to use it The instructions in this service manual do not replace any existing legislation in force in connection with safety or industrial injury Abiding by such legislat
35. wer hooks it is enough just to open the hooks e Lift the clamp on the carriage so that it hangs from the upper mounting hooks Ensure that the centring peg goes into the central notch of the lift truck carriage Note that the centring block can be removed for easier centring e ALTERNATIVELY Position the clamp on the ground tilt the lift mast completely forward and drive the upper side of the carriage carefully under the upper hooks Ensure that the clamp is well centred and the centring peg goes into the central notch of the carriage Tilt the lift mast slowly backwards and slightly lift the carriage up Ensure that the upper mounting hooks are correctly positioned on the carriage 960041E User Manual Series AR Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved SYOJLZAIOING 4u P ALJIRAIVIC as e install lower mounting hooks In ouck change models close lower mounting hooks Note that some clamp models may require the clamp to be rotated for easier access to the lower mounting hook screws Rotate with extreme caution only e Tighten the mounting hook screws with the requested minimum torque 540 Nm 400 ft lbs Class ISO 2328 2 ITA II 540 Nm 400 ft lbs Class ISO 2328 3 ITA III 540 Nm 400 ft lbs Class ISO 2328 4 ITA IV WARNING The upper mounting hooks and centring peg must be properly engaged with the upper carriage bar before fastening lower mounting hooks If they are not prope
36. y Pull the valve block forward to gain access to all hose fittings if necessary you can secure the valve block position using a suitable rope or fastening line Do not over bend the hoses when moving the valve block 4 Now you have easy access to all hose fittings The hoses can be changed from the openings on the clamp backplane Change only one hose at a time Note the correct hose routing before removing the old hose 5 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 in the hose before fastening the hose clamp Do not over tighten hose fittings Over tightening will easily cause damage to valve blocks or fittings Make sure that hoses do not twist when tightening the fittings 960041E User Manual Series AR Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 30 EXO L AOIN P ALJIRAIVIC as 6 In order to reduce friction on the moving hoses lightly grease the hoses that lie under the rack and pinion mechanism after their installation 7 Fasten the valve block and the cover plates Install the clamp back onto the lift truck and carry out an operation test When using this procedure it is possible to change any of the rotation hoses in less than 30 minutes 6 1 2 Seal Change Clamp Cylinders 54 lt 901 gt 1 Open the seal housing part 51 2 Pull the piston rod assembly and the hous
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