User Manual Series RA
Contents
1. User Manual Series RA 960002E Rev 09 07 S O LZID NI g AURAMIO Nz EXO LAON ff A ALUreAIVIO Si Safety Instructions 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 960002E User Manual Series RA Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved Contents 3XO2. 2007 All Rights Reserved 33 BXO LZ4O NI A ALUreAIVIO Si e Open the housing 51 e Pull the piston assembly and housing 20 100 out of the cylinder shell 10 e Use blunt screwdriver to take old seals away from the piston 50 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 e 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 e Replace all damaged or worn parts e Install new seals to the housing e Oil seals and piston rod e Slide housing 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 piston Use LOCTITE 270 to lock the Screw e Install new seals on the piston e OU 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 3200 psi e Check the condition of pin bush
3. Czech Republic Tel 42 69 60 13 541 3 Fax 42 69 60 13 522 E mail cemat cemat cz 960002E User Manual Series RA ISYOJLZIOINE di ALUJPIAIVIO L 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 inhsb tm net my ADJL INTERNATIONAL TAIWAN LTD 4 6FI 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 adjl 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 Auramo Group Auramo Oy 2007 All Rights Reserved 40
4. e Check that the clamping force is correct for the load 960002E User Manual Series RA Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 14 7 A ALUreAIVIO Ss 3 7 5 Operation Times It is difficult to give exact values for clamping and rotation times because pump flow volume affects movement speeds Thus the values given below should be considered as guidelines only Rotation 180 4 8 seconds depending on the clamp size Clamping max min 4 8 seconds depending on the clamp size If measured operation times are much slower than the given values check all hydraulic system connections and the pump oil flow volume If necessary contact your Bolzoni Auramo representative 960002E User Manual Series RA Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 15 3XO LZ4O NI A ALUreAIVIO Si 4 User Instructions 4 1 Clamping the Paper Roll Using Bolzoni Auramo RA Series paper roll clamps it is possible to position short and long arms separately Positioning is carried out using pressure relief valves that open at different pressure levels thus only one hydraulic function is needed In the instructions given below you will find a description of the operation logic in the opening and clamping operations 4 1 1 Opening the Arms The short arm begins to open only after the long arm has been opened completely Therefore before opening the short arm the long arm must be open e Open the long
5. 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 Isilva 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 0 0 UI 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 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 BOLZO
6. LZ4O NI 4 A ALUreAIVIO Si 1 2 Safety Instructions 2 Introduction 2 2 Nameplate 3 Installation Instructions 3 1 Truck Requirements 3 2 Handling and Storage 3 3 Installation 3 4 Hose Flush 3 5 Connecting the Hoses 3 6 Air Removal 3 7 Checks Before Operating the Clamp 4 User Instructions 4 1 Clamping the Paper Roll 4 2 Rotating the Roll 4 3 Tips for Safe Operation 5 Periodic Maintenance 5 1 Daily Checks 5 2 Inspection and Service 5 3 Tightening the Bolts 5 4 Lubricants 6 Trouble Shooting 6 2 Safety Warnings 6 3 Hydraulics of the RA Series 6 4 Trouble Shooting 7 Service and Repairs 7 2 Notes on Service Actions 7 3 Service Instructions 8 Spare Parts 8 1 Spare Parts Book 8 2 Ordering Spare Parts 960002E User Manual Series RA Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 2 1 Bolzoni Auramo Series RA Clamps 16 22 26 32 38 3XO LZ4O NI A ALUreAIVIO Si 1 General This manual contains installation maintenance and service instructions for standard Bolzoni Auramo Series RA clamp attachments 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 Every country has its own safety regulations concerning lift trucks and lift truck attachments It is the responsibility of the user to k
7. 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 inch measured from 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 inch 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 inch measured from a 500 mm 20 inch distance from the torque center If the play is greater than this and disturbs normal operations you have to replace 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 5 3 Tightening the Bolts Bolts on Bolzoni Auramo RA Series clamps are secured using LOCTITE 2 0 Bolts under high stresses are also tightened to a certain fastening torque In normal cases re tightening 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 960002E User Manual Se
8. 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 1 ft above the floor when driving 4 2 Rotating the Roll RA Clamps have a hydraulic cushioning in the vertical positions of the rotation mechanism This reduces forces that are directed to the roll during rotation e Grip the roll and lift it high enough before rotating e Rotate the roll 960002E User Manual Series RA Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 20 SYOJLZIOIN ff A ALJFAMO Ss 4 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 tilt position Note that too much tilt backward or forward 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 safely Never accelerate or brake powerfully when the roll is up as this can lead to loss of balance e Do not release the roll before it is in its place Never allow the roll to fall down e Beware of slackness in the mast chains 960002E User Manual Series RA Bolzoni Auramo
9. arm fully e Continue the opening function until the short arm has opened enough 960002E User Manual Series RA Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 16 SYOJLZOINT A A ALUrFeAIVIO Nz 4 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 e Continue the closing function until the short arm has closed 4 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 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 960002E User Manual Series RA Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 17 BXO LZ4O NI A ALUreAIVIO Si e Grip 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 e Grip big rolls max diameter max diameter 10 in such a way that the roll touches the clamp body and contact pads e f possible grip smaller rolls so that the center of the roll would be on a line that goes through the contact pad center p
10. can be found in the clamp spare parts book or in separate mounting instructions 3 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 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 Figure An example of a hose flush connection 960002E User Manual Series RA Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 11 BXO LZ4O NI A ALUreAIVIO Si 3 5 Connecting the Hoses Dimensions of truck hosing and other hydraulic components must be adequate to meet the needs of a clamp attachment In this way there are no excessive power losses or damages caused by oil overheating Avoid 90 degree fittings as these cause large pressure losses For hydraulic connections standard RA Clamps have a connection block in the clamp mounting side Sizes of the fittings DIN 2353 are as follows Clamp capacity 0 ca 3500 kg 0 ca 7 800 Ibs e 12 mm M18x1 5 24 Clamp capacity 3500 kg and up 7 800 Ibs and up e 15 mm M18x1 5 24 In US amp Canadian models JIC 8 fittings are used Clamp hose connections are loca
11. of the clamp attachment Check valve cartridge 2 pcs 20 One check valve keeps the clamping pressure on and the other one prevents long arms from closing under their own weight during horizontal lifts Short arm pressure relief valve cartridge 21 This valve also functions as a check valve This valve controls short arm movement it allows short arms to move only when long arms are totally open Part B Rotating Valve Block The rotating valve block controls the rotation function In the figure below the main components and functions of a rotating valve are indicated and described Numbers in the figure correspond to those in the spare parts book Figure Rotating Valve Block Flow control valve cartridge 2 pcs 1 Controls the rotating speed of the clamp Counterbalance valve cartridge 2 pcs 3 Prevents the load from rotating too fast rushing during the rotation 960002E User Manual Series RA Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 28 BXO LZ4O NI A ALUreAIVIO Si 6 4 Trouble Shooting Problem No pressure in the clamp Possible cause Hose connection between 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 need
12. 0 e Remove old seals from the rack end CAUTION Do not scratch piston rack surfaces with sharp tools Note the direction of the seals e Clean and check rack cylinder shell and guide parts See if there are scratches wear corrosion cracks or other similar damage that could effect normal operation of the cylinder e Replace all damaged or worn parts e Check and clean the cushion bushing in the other end of the rack Clean cushion channel from the other end of the cylinder shell e Install new seals onto end of the rack e Apply a thick layer of grease to the rack and seals e Slide cylinder shell onto the rack e f necessary repeat the operation with the other cylinder shells e Slide guide parts onto cylinder shells e Check the condition of hoses located under the rotation cylinder assembly Replace hoses if necessary Clean and grease these hoses e Apply a thick layer of grease to the rack and pinion teething e Lift rotation cylinder assembly back to the clamp Note that cylinders must be in the same position as they were previously Make sure that centering marks found on rack and pinion teething are in correct positions otherwise full 180 degree motion will not be attained e See that holes in cylinder shell ends settle correctly into centering pins which are located in the clamp frame e Adjust and fasten guide parts Make sure that guides settle properly to their seats e Screw cylinder
13. Group Auramo Oy 2007 All Rights Reserved EN 3XO LZ4O NI P ALUreAIVIO Si 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 Use an Bolzoni Auramo test cylinder if necessary 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 clamp s maximum operating pressure 5 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 Do not remove pressurized parts Beware of part movements when removing hoses or pipes Do not climb on the clamp e Clean the clamp e Carry out all routine tasks mentioned in Section 5 1 e Apply grease to the rotation bearing Remember to rotate the clamp du
14. IO Si Problem Short arms move simultaneously with long arms Possible cause Defect in short arm pressure relief valve e Change valve If trouble persists contact Bolzoni Auramo Problem Short arms do not move Possible cause Defect in short arm pressure relief valve e Change valve If trouble persists contact Bolzoni Auramo 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 change oil and oil filter Problem Split long arms do not move at the same speed J models only Possible cause Dirt between arms and body or uneven wear e Clean the clamp If this does not help adjust restrictor valves on cylinders see Section 7 3 5 Problem Rotation end cushioning does not work Possible cause Dirt in cushion channel or cushion mechanism e Rotate clamp several times back and forth near the end position If this does not help clean cushion channel and mechanism which are located at the end of the rotation cylinders See Section 7 3 3 for instructions Possible cause Incorrect hose connection e Check the hoses Rectify connections if needed Problem Rotation is too fast or too slow Possible cause Counterbalance valves are wrongly set e Counterbalance valves can be adjusted using adjustment screws that are located in the cartridge valve Clockwise faster counterclockwise slo
15. NI 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 Isidora 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 2153 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 S jam e 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 Lightburn Road Cambuslang Glasgow G72 7XS Scotland U K Tel 44 141 641 3648 2359 Fax 44 141 641 51 47 E mail info mcgowaneng co uk CEMAT s r o Ul CSA 196 735 51 Bohumin Pudlov
16. do anything Repairs done incorrectly are safety hazards Follow all safety instructions given in previous chapters 960002E User Manual Series RA Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 32 7 A ALUreAIViO Sis 7 3 1 Hose Change e Clean the clamp carefully before removing or replacing any parts e If the hose leaks from the fitting first try to tighten the fitting Change the hose only if this does not help e Label all hoses before removing them This makes re assembly significally easier e Protect all open fittings with a proper cap e Make sure that hose length is correct before installing it Always compare the length of new and old hoses e Make sure that enough play length is left on the hose before fastening e Donotover 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 e Grease the hoses that lie under rack and pinion mechanism after their installation These hoses are in continuous rubbing motion against the clamp frame during the rotation WARNING Never remove pressurized parts or hoses 7 3 2 Seal Change Clamp Cylinders e Remove hoses protect open fittings with proper caps WARNING Never remove pressurized parts or hoses Remove the cylinder from the clamp Figure Clamp Cylinder 960002E User Manual Series RA Bolzoni Auramo Group Auramo Oy
17. ect all parts that are likely to rust with a suitable corrosion inhibitor or grease If possible put protective oil into cylinders e Move arms to a totally open position so that piston rods are totally in 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 960002E User Manual Series RA Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved BXO LZ4O NI A ALUreAIVIO Si 3 3 Installation Before installation carry out the following Make sure that the truck fulfills all camp requirements Section 3 1 Make sure that the clamp mounting type is the same as the one used on the truck Check that the truck s hydraulic oil level is correct Check that the truck s hosing and fittings are in a good condition Clean the truck carriage Make sure that it has no defects or wear that could prevent installation or use of the clamp 3 3 1 Installation Standard Carriages Installation to the most common standard carriages types ISO 2328 2 2328 3 2328 4 is as follows Remove clamp s lower mounting hooks In quick change models open lower mounting hooks Lift the clamp to the carriage so that it hangs from the upper mounting hooks Center the clamp horizontally on the carriage Install lower mounting hooks In quick change m
18. ed Possible cause Dirt in check valve e Clean or replace check valves or short arm pressure relief valve Possible cause Pressure relief valve cartridge 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 Pressure is on rotation does not work Possible cause Incorrect hose connection e Check the hoses Rectify connections if needed Possible cause Dirt in flow control valve e Clean or replace flow control valves 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 e Check for external leaks If needed clean components before checking 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 960002E User Manual Series RA Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 29 BXO LZ4O NI A ALUreAIVIO Si Possible cause Leak in check valve e Clean or replace check valves or short arm pressure reli
19. eeds using normal running power e Slightly tighten the adjustment screw of the faster arm Test the speed again Continue adjusting until both arms move at the same speed 960002E User Manual Series RA Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 3 3XO LZ4O NI A ALUreAIVIO Si 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 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
20. ef valve Possible cause Leak in cylinder seals e Replace seals Possible cause Too much pressure in tank line e Check hoses and repair if needed Problem Clamping force OK load falls Possible 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 needed clean components before checking 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 Problem Clamp arms close or open too slowly Possible cause Oil flow from the pump is too small or much too big e Check the pump and replace 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 Possible cause Restrictor valves in the cylinders have wrong setting J models only e Adjust valves 960002E User Manual Series RA Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 30 BXO LZ4O NI A ALUreAIV
21. 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 960002E User Manual Series RA Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 38 7 A AUAMO Sis 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 960002E User Manual Series RA Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 39 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 bolzoni 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
22. ings at both ends of the cylinder and replace bushings if necessary 960002E User Manual Series RA Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 34 7 A AUAMO Sis e Re install the cylinder to the clamp e Connect hoses e Test run all cylinder functions Check for leaks 7 3 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 removed e Remove the clamp from the truck and set it to a horizontal position mounting side down arms up e Remove the cover plate e Label all hoses before removing them This makes re assembly significally easier e Remove hoses and pipes protect open fittings with proper caps WARNING Never remove pressurized parts or hoses e Use a center 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 e Unscrew each adjustment nut slightly less than one turn e Open screws from guide parts e Lift rotation cylinder assembly from the clamp Use proper lifting devices only e Slide guide parts off the cylinder shells Figure Rotation cylinder 960002E User Manual Series RA Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 35 BXO LZ4O NI A ALUreAIVIO Si e Pull cylinder shell 10 20 off the rack 3
23. mended by the truck manufacturer If you wish to use aqueous based or biohydraulic oils please contact Bolzoni Auramo 3 1 5 Required Hydraulic Functions Standard Bolzoni Auramo RA Series clamps require two hydraulic functions from the truck hydraulic system in order to enable clamping and rotating motions 960002E User Manual Series RA Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved BXO LZ4O NI A ALUreAIVIO Si 3 2 Handling and Storage Prior to installation check the clamp carefully for possible 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 d WARNING Never go under a hanging load Beware of load swing when lifting 4 ENN WARNING el Le If the lifting device is attached to one part of a split long arm only it is possible that long arms may move when the clamp is lifted RA J models only II To prevent this movement attach the lifting device to all long arm parts or i lock all parts together before the lifting operation 3 2 2 Long Period Storage If for any reason you have to store the clamp for an extended period follow the instructions given below in order to prevent damage caused by corrosion e Clean the clamp carefully e Lubricate and grease all parts that require lubrication see Chapter 5 for instructions e Prot
24. movement Several different arm and contact pad options in standard production series e Optional split arm design on long arms enables simultaneous handling of two to four paper rolls with different diameters e Thin arm profile allows tight stacking with excellent visibility and damage free handling e Hydraulic positioning of the short arm improves handling e Well proven 180 degree rotation with hydraulic cushioning in the vertical positions eliminates the risk of edge damage e Rack and pinion drive system with high rotating torque ensures fast safe handling e Strong lightweight body with favorable lost load center maximizes the residual capacity of the truck 1 Clamp body 2 Long arm split 3 Short arm 4 Contact pad Figure Main components of the RA Series clamp attachment 960002E User Manual Series RA Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved BO LZOINI Mt A ALUFAIVIO CC 2 2 Nameplate Every Bolzoni Auramo clamp attachment has a unique serial number This and other identification information can be found on the attachment nameplate which is fastened to the clamp body Serial number and clamp attachment type must always be given when ordering spare parts or when making inquiries concerning the clamp AURAMO Manufacturer AURAMO OY FINLAND WARNING The capacity of the truck and at
25. now and follow these regulations If safety recommendations given in this manual should differ from local regulations the local regulations should always be followed 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 to 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 with the clamp attachment that it has been designed for It is unsafe to lift any other objects Know the capacity and limitations of your machine 960002E User Manual Series RA Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved BYOJLZ4OJINI fd A ALJFAMO Wrz 2 Introduction 2 1 Bolzoni Auramo Series RA Clamps Bolzoni Auramo RA Series clamp attachments have several different models that have been designed to handle 1 to 4 paper rolls in weight ranges between 1000 to 8000 kg 2200 to 17000 Ibs AII clamps in the Bolzoni Auramo RA Series have the following properties in common e Pivoting arm
26. odels close lower mounting hooks To prevent the clamp from moving on the carriage two centering blocks are to be welded to the upper carriage bar Centering blocks can also be welded to the upper mounting hooks In which case the block must be positioned so that it is properly engaged in the mating notch on the truck carriage In such a case it might be slightly more difficult to center the clamp Welding instructions come supplied with the clamp Figure Positioning centering blocks to the upper mounting hook or to the upper carriage bar 960002E User Manual Series RA Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 10 FO a SYOJLZAQWOIN A ALUreAIVIO Si WARNING Upper mounting hooks must be properly engaged to the upper carriage bar before fastening lower mounting hooks If not properly engaged the clamp might drop 3 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 CH e Remove lower pins e Hang the clamp to the truck carriage from upper hooks or pins e Center the clamp e Attach lower pins and bolt pins e f necessary weld lower mounting links WARNING Upper mounting hooks must be properly engaged to the upper carriage bar before fastening lower mounting hooks If not properly engaged the clamp might drop Instructions for special mountings
27. oints e Do not grip the roll too much behind its centerline as the roll might easily slip off the clamp Furthermore do not grip any roll too far in front of its centerline as this could lead to the clamp frame and the contact pad corners damaging the roll e Always grip the roll so that the clamp attachment is aligned to the roll Misalignment easily leads to roll damage When handling singular rolls always grip the roll so that the arms are centered between the ends of the roll E e When handling multiple rolls always use a clamp attachment having split clamping arms Grip rolls in such a way that each roll is clamped with own contact pad 960002E User Manual Series RA Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 18 BXO LZ4O NI A ALUreAIVIO Si 4 1 4 Clamping a Horizontal Roll e Adjust the opening of the short arm to suit the diameter of the roll Open long arm sufficiently Short arm down long arm up e Carefully adjust the truck so that the clamp is centered to the roll e Slowly lower the clamp until the short arm just touches the floor 960002E User Manual Series RA Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 19 BXO LZ4O NI A ALUreAIVIO Si e Slowly approach the roll and stop when the lower contact pad touches the roll e Grip the roll with the long
28. re 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 960002E User Manual Series RA Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 26 BO LZOINI Mt A ALJRAIVIO Wrz 6 3 Hydraulics of the RA Series This section shows only an example of the standard hydraulic system Please refer to the spare parts book for actual hydraulic diagrams 6 3 1 Circuit Schematic HA I C ocety a den der Figure Circuit Schematic Standard RA NJ Series clamps 6 3 2 Hosing Diagram and Valves In the figure below can be seen the hydraulic components of a standard RA NJ Series clamp Figure Hosing Diagram 960002E User Manual Series RA Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 2 7 A AUAMO Sis Part A Clamping Valve Block The clamping valve block controls the arm functions In the figure below the main components and functions of a clamping valve are indicated and described Numbers in the figure correspond to those in the spare parts book 1 d by 21 20A i i AGI 1 a w VW 4 Lo k U a i d Pa 7 a P AA D ie ON Ge Figure Clamping Valve Block Main pressure relief valve cartridge 1 This valve is used to control the clamping force
29. ries RA Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 24 SYOJLZIOIN fd A ALUJAMO Wrz The following bolts are to have the specific fastening torque of Mounting bolts M20 torque 540 Nm 55 kom 400 Ibs ft Rotation bearing bolts M16 torque 280 Nm 29 kom 210 lbs ft Pinion bolts M16 torque 280 Nm 29 kom 210 lbs ft 5 4 Lubricants Greases All lubrication points on Bolzoni Auramo RA Clamps are greased using following lubricant Mobilplex 47 or equivalent good quality grease 960002E User Manual Series RA Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 25 3XO LZ4O NI A ALUreAIVIO Si 6 Trouble Shooting 6 1 General It is estimated that up to 80 of all trouble 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 are changed regularly 6 2 Safety Warnings During all trouble shooting 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 Bewa
30. ring this operation 960002E User Manual Series RA Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 22 7 A AUJAMO Si Figure Rotation bearing grease nipples e Open the cover plate that protects the rotation mechanism e Rotate the clamp to its end positions and wipe all grease and dirt from the racks and pinion e Apply grease to racks and pinion remember to rotate the clamp during the operation Use brush or an equivalent tool to apply the grease Figure Greasing points of the rack and pinion mechanism e Protect all such moving parts that are susceptible to rust such as springs and pull rods Apply grease to hinge pins Be careful not to use too much grease or other lubricants as these should not be allowed to touch roll or contact pads 960002E User Manual Series RA Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 23 BXO LZ4O NI A ALUreAIVIO Si e Check the amount of oil in the truck s system check oil purity and the condition of the oil filter e Flush mast hoses see Section 3 4 for instructions 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 In the next section you will find some guidelines on how to estimate the
31. roup Auramo Oy 2007 All Rights Reserved 13 BXO LZ4O NI A ALUreAIVIO Si 3 7 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 to the truck is correct e Check that the clamp is centered to the truck 3 2 Hydraulic Parts e Wipe clean all hydraulic parts e Run all movements clamping and rotation several times between respective end positions e Check all cylinders valves hoses and fittings for leaks e Check that hosing is correct with and without pressure e Check truck oil level e Check that split long arms move at the same speed J models only and if necessary adjust the speed see Section 7 3 5 for instructions 3 7 3 Clamping Force Test It is recommended that regular clamping force tests are carried out in order to minimize the possibility of roll damage e Check the clamping force with a suitable testing device 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 the loss of pressure Clamping force may decrease up to 10 in ten minutes maximum 3 7 4 Clamp Action Test e f possible test all clamp attachment functions with an actual load e Check that all movements also work when handling a load e Check the hydraulic system for any leaks or other problems
32. shell end adjustment nuts back to their original positions Use previously made marks to define correct position e Assemble hoses and pipes 960002E User Manual Series RA Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 36 7 A AUAMO Sis e Attach the clamp back to 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 e Fasten the cover plate 7 3 4 Replacement of Wear Plates The short arms of the RA 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 Check also if there is excessive wear to other parts of the clamp and repair if necessary Figure Wear plates and other typically wearing parts 7 3 5 Split Arm Synchronization RA Series clamps with split long arms J models have restrictor valves in long arm cylinders These valves enable arm movement synchronization Restrictor valves are adjusted at our factory but due to operating conditions or wear it is possible that arms may begin to move with different speeds In such cases valves must be re adjusted e Open fully adjustment screws of both restrictor valves e Test arm sp
33. tachment combination must be complied with Figure Nameplate 1 Clamp attachment type Serial number production year Clamp rated load capacity allowed load in kg or lbs at given load center Clamp weight and center of gravity Effective thickness Maximum operating pressure oe OL Roll range max min Serial number is also marked on the fastening plate of the nameplate NOTE A damaged or lost nameplate should be replaced 960002E User Manual Series RA Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 3XO LZ4O NI A ALUreAIVIO Si 3 Installation Instructions 3 1 Truck Requirements 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 s rated capacity and the truck s rated capacity at certain heights loads and working conditions Net Capacity The lift truck dealer or manufacturer must calculate the net working capacity for truck clamp combination The net capacity can be calculated with a moment calculation method when dimensions and weights of the truck clamp and load are known WARNING Clamp attachment decreases lift truck s rated capaci
34. ted as follows seen from driver s seat clamp functions on the right side rotation functions on the left side Figure Hose connections of the RA Series clamp e Attach 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 during operation e Do not use a smaller hose bending radius than recommended by the hose manufacturer CAUTION Do not over tighten the hose fittings 960002E User Manual Series RA Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 12 7 A AUAMO Sis Bolzoni Auramo has several hosing accessories that can be supplied on request For example hoses of a certain length and equipped with a quick connection coupling a four stage pressure relief valve manual or electric and a magnet valve designed to divide one pressure line between two functions Figure Different mast hosing systems 3 6 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 rotation several times between respective end positions WARNING Clamp arms can move unpredictably if there is air in the system 3 Checks Before Operating the Clamp Check the mounting and all functions of the clamp before using it for the first time 960002E User Manual Series RA Bolzoni Auramo G
35. ty 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 960002E User Manual Series RA Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved BXO LZ4O NI A ALUreAIVIO Si 3 1 2 Hydraulic Pressure Clamp attachment maximum hydraulic pressure is given on the attachment nameplate and on the machine card Rated capacity is calculated using this pressure If a lower operating pressure is used the clamping force will be smaller and also the rated capacity WARNING Never exceed the maximum operating pressure 3 1 3 Oil Flow The volume of oil that flows to the clamp must be as specified Too small a volume will slow down clamp motions Too large a volume can cause excessive heating faulty clamp operation and possible damage to the clamp or truck hydraulic system Recommended oil flow volumes for Bolzoni Auramo RA Clamps are as follows Clamp capacity Recommended oil flow rate 1300 kg 20 30 l min 1300 2200 kg 30 40 l min 2200 3500 kg 40 50 l min 3500 4500 kg 40 60 I min 4500 6000 kg 50 70 l min 6000 8000 kg 50 90 l min 3 1 4 Hydraulic Oils Use petroleum based hydraulic oil as recom
36. wer Only screw 1 8 1 4 turns at a time and test with load after each adjustment Both valves have to be adjusted equally 960002E User Manual Series RA Bolzoni Auramo Group Auramo Oy 2007 All Rights Reserved 31 3XO LZ4O NI A ALUreAIVIO Si 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 to resolve any problem you may be having as fast and accurately as possible please check the following information before contacting us e Clamp attachment type serial number and production year This information can be found on the clamp nameplate e How and under which operating conditions the trouble occurs e Type of operation estimated work hours of the clamp e Any other information you think will help us to 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
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