User Manual Series B Series BA
Contents
1. m Pk kg mm AURAMO Manufacturer Mass Centre of grav Mp Ph kg mm WARNING Effective thickness _ E ml i The capacity of A the truck and attachment Operating pressure p g lt T 4012 combination must be complied with Figure Nameplate 1 Attachment model 2 Serial number production year 3 Rated load capacity allowed load in kg or lbs at given load center Weight and center of gravity Effective thickness Maximum operating pressure a OY oF Opening range or roll range max min NOTE Damaged or lost nameplate should be replaced 960003E User Manual Series B amp BA Auramo Oy 2002 All Rights Reserved ALRAMO EB 3 Installation Instructions 3 1 Lift Truck Requirements All lift truck capacity tables assume that the lift truck is operated with forks only The rated capacity is given for a load with a center of gravity a particular distance from the vertical face of the forks This distance is called the load center Loads with a center of gravity further than this will reduce the lift truck rated capacity Attachments reduce the lift truck rated capacity The lift truck capacity must be re rated when an attachment is selected At the very least he following factors should be taken into account when selecting the lift truck for the application e The effective thickness of the attachment pushes the load center fo2. Do not scratch housing surfaces with sharp tools Note the direction of the seals e Clean and check piston piston rod cylinder shell and housing See if there are any scratches wear corrosion cracks or other similar defects that could prevent normal operation of the cylinder e Replace all damaged or worn parts e Install new seals to the housing e Lubricate seals and piston rod e Slide 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 the piston Use LOCTITE 270 to lock the screw e Install new seals on the piston e Oil the cylinder shell e Slide piston assembly into the cylinder shell e Screw the housing into the cylinder shell e f possible test run the cylinder before re assembling it to the clamp Max test pressure is 22 MPa 220 bar 3 200 psi e Re install the cylinder to the clamp e Connect hoses e Test run all cylinder functions Check for leaks 960003E User Manual Series B amp BA Auramo Oy 2002 All Rights Reserved 31 ALANIS Cal 7 3 3 Arm Synchronization B Series and BA Series clamps have resirictor valves in arm cylinders These valves enable arm movement synchronization Restrictor valves have been adjusted at our factory but due to operating conditions or wear it is possible that the arms may begin to move at different speeds In this case you
3. User Manual Series B Series BA 960003E Rev 2 SO L AOIN Yd AURAMON AUrAIVIO Yz 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 960003E User Manual Series B amp BA Auramo Oy 2002 All Rights Reserved AURAIVIO Contents LOG recite a coccinea cerca 4
4. t 3 3 2 Installation of Special or Large Mountings Pin type and hook type mountings which are common in heavy duty clamp models are normally installed as follows Sg Le 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 fasten them properly WARNING Upper mounting hooks must be properly engaged on the upper carriage bar before fastening lower mounting hooks If not properly engaged the clamp might drop Instructions for special mountings can be found in the clamp spare parts book or in separate mounting instructions 960003E User Manual Series B amp BA Auramo Oy 2002 All Rights Reserved 11 AURAIVIO G 3 4 Hose Flush Flush the truck mast hosing before you connect it to the clamp attachment It is estimated that up to 80 of all defects in hydraulic systems are caused by dirty hydraulic oil Oil from the mast hoses should be run through the oil filter during the flushing to minimize the amount of debris and dirt in the hoses e Connect each hose pair with suitable fittings If needed use an extra hose e Turn the truck on and actuate control valves in both directions for about 40 seconds Figure An example of a hose flush connection NOTE Hose flushing reduces the service costs in the long run 3 5 Connecting the Hoses Dimensions of the lift truck mast hoses and other hydraulic components must be adequat
5. Always wear protection goggles having side protection Do not remove cartridge valves when pressure is on Do not put your body parts between or near moving clamp parts Do not climb on the clamp 6 3 Hydraulic System B Series B Series clamp attachments are manufactured with several different hydraulic options In this manual you will find a description of our standard hydraulics Standard hydraulics have a clamping function a fast opening and a built in sideshift two hydraulic functions required Other possible hydraulic options are e Clamping hydraulics Clamping and opening of the arms One hydraulic function required No sideshift e Independent hydraulics Arms can be moved independently Two hydraulic functions required No sideshift 960003E User Manual Series B amp BA Auramo Oy 2002 All Rights Reserved 22 AURAIVIO 6 3 1 Circuit Schematic B Series Standard Hydraulics Figure Circuit Schematic Standard B Series clamps 6 3 2 Hosing Diagram and Valves B Series The figure below shows the hydraulic components of a standard B Series clamp kA sis wo d l i 2 es wm ee 8 Suns te gt Mo ae ut oe HETE Il il il TET Il Il LEE wit tf il 7 ii pp i ey iia lt P Te rT L lu ites P Le A iil ae A an gy a il ao Ir PT e e a Let vas 7 co re il SET oe s z Pa Le WW 2 7 FT p 227 LL a Pa 4507 Pt of Ze r ce 527 e amp Ce d PT 7 er S
6. OR dS I DAT hs OL i pi I i oJ ry Li o i Lo aem a a i I I I i i Ly 4 i semi TT no oro xo ad ee ee nes a j SM2 Tout a svi en E Figure Circuit Schematic Standard BA Series clamps 960003E User Manual Series B amp BA Auramo Oy 2002 All Rights Reserved EXO LAVE h FF 6 3 2 Hosing Diagram and Valves BA Series The figure below shows the hydraulic components of a standard BA series clamp Figure Hosing Diagram Clamping Valve Block Series BA The clamping valve block controls all 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 e Main pressure relief valve cartridge 1 This valve is used to control the clamping force of the clamp attachment e Check valve cartridges 3 pcs 20 One check valve 20P keeps the clamping pressure and the other two enable the built in sideshift function Figure Clamping Valve Block 960003E User Manual Series B amp BA Auramo Oy 2002 All Rights Reserved 25 AURAIVIO G 6 5 Trouble Shooting Problem No pressure in the clamp Possible cause Hose connection between the clamp and truck is defective e Check all connections If needed replace them Possible cause Failure in the truck hydraulic system e Check that oil is coming from truck hydraulic sy
7. damage occurred during transportation 3 2 1 Lifting the clamp If you have to lift the clamp during installation make sure that the capacity of your lifting device is adequate for the load WARNING Never go under a hanging load Beware of load swing when lifting 960003E User Manual Series B amp BA Auramo Oy 2002 All Rights Reserved AURAVIO EB 3 2 2 Long Period Storage If for any reason the clamp has to be stored for an extended period follow the instructions given below in order to prevent damage caused by corrosion e Clean the clamp carefully e Lubricate and grease all parts that require lubrication see Chapter 5 for instructions e Protect all parts that might corrode with a suitable corrosion inhibitor or grease e Move arms to a totally closed position so that the piston rods are completely inside the cylinders e Protect the clamp from the effects of the weather Store it inside or under a proper cover e Check the condition of the clamp during storage and if possible regularly run all hydraulic functions of the clamp several times 3 3 Installation Before installation carry out the following checks e Make sure that the lift truck fulfills all clamp requirements Section 3 1 e Check that the clamp mounting type is the same as the one used on the truck e Check that the lift truck hydraulic oil level is correct e Check that the lift truck auxiliary hosing and fittings are i
8. the clamping force is maintained when clamping for an extended time period 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 Figure Bolzoni Auramo Test Cylinder for testing the clamping force 960003E User Manual Series B amp BA Auramo Oy 2002 All Rights Reserved SERA al 3 7 4 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 e Check that the clamping force is correct for the load 3 7 5 Operation Times It is difficult to give exact values for clamping and sideshift times because the available pump flow volume affects movement speeds Thus the values given below should be considered as guidelines only Clamping max min 4 15 seconds depending on the clamp size Opening min max 4 15 seconds depending on the clamp size Sideshift 4 15 seconds depending on the clamp size If measured operation times are much slower than given values check all hydraulic system connections and the pump flow volume If necessary contact your Bolzoni Auramo representative 960003E User Manual Series B amp BA Auramo Oy 2002 All Rights Reserved 15 AUrAIVIO Wrz 4 User Instructions This section gives some basic instructions on how to handle loads with different B and BA Series clam
9. 1 1 Notices 1 2 Safety Instructions 2 INTFOQUCUHON ennemis 5 2 1 Bolzoni Auramo B Series and BA Series 2 2 Nameplate 3 Installation Instructions cceeeeeeeeeeeeeeeees 7 3 1 Lift 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 ns 16 4 1 General Instructions 4 2 Bale Handling 4 3 Roll Handling 4 4 Tips for Safe Operation 5 Periodic Maintenance 19 5 1 Daily Checks 5 2 Inspection and Service 5 3 Tightening the Bolts 5 4 Lubricants 6 Trouble Shooting cccesecceeeeseeeeeeeseeneeneenees 22 6 1 General 6 2 Safety Warnings 6 3 Hydraulic System B Series 6 4 Hydraulic System BA Series 6 5 Trouble Shooting 7 Service and Repairs 29 7 1 General 7 2 Notes on Service Actions 7 3 Service Instructions D Spare PASS aa 33 8 1 Spare Parts Book 8 2 Spare Parts Orders 960003E User Manual Series B amp BA Auramo Oy 2002 All Rights Reserved AUrAIVIO Yz 1 General This manual contains installation maintenance and service instructions for standard Bolzoni Auramo B Series and BA Series clamp attachments Please read this manual carefully before using or servicing this equipment In this way you will ensure safe and error free operation of the clamp attachment right from the start Make sure that you know ho
10. O od of I P e z sf of Figure Hosing Diagram Clamping Valve Block B Series The clamping valve block controls all 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 960003E User Manual Series B amp BA Auramo Oy 2002 All Rights Reserved 23 RT ASNI 24 Figure Clamping Valve Block Check valve cartridge 2 This valve holds the clamping pressure on Check valve cartridges 2 pcs 3 These valves enable sideshift motion Check valve cartridge 4 Controls the opening function Main pressure relief valve cartridge 5 This valve is used to control the clamping force of the clamp attachment 6 4 Hydraulic System BA Series BA Series clamp attachments are manufactured with several different hydraulic options In this manual you will find a description of the standard hydraulic system Standard hydraulics has a clamping function and a built in sideshift two hydraulic functions required Other possible hydraulic options are Clamping hydraulics Clamping and opening of the arms One hydraulic function required No sideshift Independent hydraulics Arms can be moved independently Two hydraulic functions required No sideshift 6 3 1 Circuit Schematic BA Series Standard Hydraulics ehde A eee SS cee cs pp A I DU NM A I nt
11. ad handling operations All models have the following properties in common e Parallel arm opening and closing movement e Built in sideshift e Well protected valve block and connection hoses behind the attachment body e Rugged design e Strong body with favorable lost load center maximizing the residual capacity of the truck B Series clamps have an aluminum profile frame with T profile arm carriers BA Series clamps have a steel profile frame with T profile arm carriers Clamp and fork arms are available for varying load handling needs Typical applications include pulp bale handling wastepaper bale handling paper roll handling pallet handling drum handling tine handling and other similar applications Please refer to Bolzoni Auramo product specifications for further information about handling possibilities 1 Clamp body 2 Clamp arms Picture Main components of a B BA Series clamp attachment 960003E User Manual Series B amp BA Auramo Oy 2002 All Rights Reserved ADRAMO E08 2 2 Nameplate Every Bolzoni Auramo lift truck attachment has a unique serial number This identification information can be found on the attachment nameplate which is fastened to the clamp body Serial number and clamp attachment model must always be given when ordering spare parts or when making inquiries concerning the clamp Attachment model type __ _ Serial Number Year _ Rated load capacity
12. ch edges for example by grinding them Check all arms and contact pads and clean them if necessary Contact pads roll clamp models only 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 the maximum operating pressure 5 2 Inspection and Service WARNING In the following service actions the clamp is to be moved hydraulically Do not leave any body parts between moving clamp attachment parts Do not remove pressurized parts Beware of part movements when removing hoses or pipes Do not climb on the clamp Carry out the following checks and services twice a year or every 300 hours whichever comes first e Clean the clamp e Carry out all routine tasks mentioned in Section 5 1 e Open arms completely and apply an even layer of grease to the arm carriers and bearings Open and close arms several times and add grease wherever necessary 960003E User Manual Series B amp BA Auramo Oy 2002 All Rights Reserved 19 20 EE ALRAMO C8 e Protect all moving parts that are susceptible to rust such as springs and pull rods Apply grease to hinge pins roll clamp models o
13. e 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 Possible cause Too much pressure in tank line e Check hoses and repair if needed Possible cause Dirty arm carriers or arm carrier bearings e Clean and lubricate arm carriers and bearings Possible cause Defective or worn arm carriers or arm carrier bearings e Clean and repair or replace arm carrier bearings and or arm carriers Problem Clamping force OK load falls Possible cause Worn friction surfaces e Replace contact pads or friction surfaces Possible cause Damaged arms e Check the tightness of all arm fastening bolts Check the condition of the arms Repair or replace arms 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 clamp capacity arm opening range and arm models are suitable for the load Problem Loss of clamping force Possible cause Leaks in hoses or fittings e Check for external leaks If needed clean components before check Possible cause Leak in check valve e Clean or replace check valves Possible cause Leak in cylinder seals e Replace seals Problem Clamp arms close or open too slowly Possible cause Oil flow from the pump is too small or much too high e Check the pump and replace repair it if needed Note flow ra
14. e to meet the needs of a clamp attachment In this way there is no excessive power loss or damage caused by oil overheating Whenever possible avoid 90 degree fittings as these cause large pressure loss For hydraulic connections standard clamps have a connection block at the back of the clamp Standard connection fitting sizes B and BA Series clamps e B Series European and international models 12 mm M18x1 5 24 DIN 2353 e BA Series European and international models 15 mm M18x1 5 24 DIN 2353 e US amp Canadian models JIC 8 e Special connection fittings are available on request 960003E User Manual Series B amp BA Auramo Oy 2002 All Rights Reserved AURAIVIO Hose connections are located as follows as seen from driver s seat e opening and closing of the arms on the right side e sideshift on the left side Figure Hose connections of the B and BA Series clamp e Attach connection hoses to fittings as shown in the figure Make sure that hoses do not twist when tightening the fittings e Check that the hose lengths are correct Check that the hoses are not pressed or chafed by any of the lift mast or attachment components e Do not use a smaller hose bending radius than recommended by the hose manufacturer CAUTION Do not over tighten hose fittings 3 6 Air Removal Air in the hydraulic system can cause extra flex or movements in clamp functions e Remove air by carr
15. each other clamp attachments having split long arms are to be used Grip the rolls in such a way that each roll is clamped by its own contact pad En li Vor rot 1 Yi j eg Lol igre is Li ESEE VA ee 4 Vif te es i Rs ad pews T PTT ee i mei i WARNING Always work safely Do not stand in the lift truck operating area or in front of the moving direction Never stand under a load or clamp attachment 4 3 Tips for Safe Operation e Clamp the load correctly e Drive carefully and safely Avoid strong acceleration and braking e Always drive with the load lowered down and with the mast in a vertical or backward tilt position Note that too much tilt backward or forward increases the risk of roll or bale edge damage e When taking a load from the stack back away only so far as to be able to lower the load safely Never accelerate or brake powerfully when the load is up as this can lead to loss of balance e Do not release the load before it is in place Never let the load fall down e Beware of slackness in the mast chains 960003E User Manual Series B amp BA Auramo Oy 2002 All Rights Reserved COZ INI TEAR 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 su
16. ease the ball surfaces of the nut and its counterparts BA 50 XX Apply some LOCKTITE 270 glue onto the thread Tighten BA 65 XX the nut until it stops Open the nut 1 4 to 1 2 rounds 5 4 Lubricants Greases The following lubricants are to be used on lubrication points on Bolzoni Auramo B and BA Series clamps Rounded sides of cylinder fastening nuts clamping cylinders e Molyb Alloy MA412 or equivalent All other lubrication points e Mobilplex 47 or equivalent good quality grease 960003E User Manual Series B amp BA Auramo Oy 2002 All Rights Reserved 21 AUrAIVIO Yz 6 Troubleshooting 6 1 General It is estimated that up to 80 of all problems and defects in hydraulic systems originate from dirty hydraulic oils In most cases dirty oil is the reason for various valve problems and excessive wear in seals and o rings Because all clamp attachment hydraulic functions move back and forth it is possible that the same debris might be moving in the oil for a very long time unless special attention is paid to cleanliness Bolzoni Auramo strongly recommends that the hydraulic oil and oil filters be changed regularly 6 2 Safety Warnings During all troubleshooting operations work will be carried out near the clamp Always work safely WARNING Do not open pressurized components Hydraulic components can be hot Use suitable protection Beware of leaks High pressure oil can damage the eyes and skin
17. ghts Reserved CorZa INI TEAR 4 2 Bale Handling Pulp bales wastepaper bales and other equivalent bales e Always grip bales or bale units in such a way that they are properly held between clamp arms e Do not push bale arms too deep bales should not touch the clamp body e Do not clamp or lift bales with clamp arm tips only Use the whole arm length to clamp the load WARNING Always work safely Do not stand in the lift truck operating area or in front of the moving direction Never stand under a load or clamp attachment 4 3 Paper Roll Handling e Open arms only so far as to allow a roll to be clamped safely e Drive the truck into a position where the roll guides on the arms just touch the roll e Never drive the truck so near that the roll touches the arm carriers because in such a position the roll can easily be damaged during the clamping operation 960003E User Manual Series B amp BA Auramo Oy 2002 All Rights Reserved 17 ADRAMO E 8 e Always grip the roll in such a way that the clamp attachment is aligned to the roll Misalignment leads easily to roll damage When handling single rolls or two parallel rolls always grip the roll s so that the arms are centered between the ends of the roll e Rolls must be side by side when clamping two parallel rolls Otherwise rolls can slide on the floor during clamping thus causing roll end damage e When handling multiple rolls on top of
18. have to re adjust the valves e Fully open the adjustment screws of both restrictor valves e Test the arm speeds at 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 7 3 4 Replacement of Wear Bars Bale clamps have welded wear bars underneath the arms These bars are made of special wear resistant steel The purpose of these bars is to protect the arms from wearing during normal bale handling operations Bars should be replaced before they become totally worn out e Remove the remnants of an old bar by for example grinding Weld a new bar at the same location e Check also if there is excessive wear to other parts of the clamp and repair if necessary Figure Location of wear bars 960003E User Manual Series B amp BA Auramo Oy 2002 All Rights Reserved 32 COZ INI TEAR 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 co
19. immediate area The following bolts are to have the specific fastening torque of Mounting Bolts Model Bolt Size Recommended fastening torque Nm kpm LES B 150 XX M20 540 Nm 55 kpm 400 Ibs ft B 200 XX M20 540 Nm 55 kpm 400 Ibs ft B 250 XX M20 540 Nm 55 kpm 400 lbs ft B 320 XX M20 540 Nm 55 kpm 400 Ibs ft B 400 XX M20 540 Nm 55 kpm 400 Ibs ft BA 50 XX M20 540 Nm 55 kpm 400 lbs ft BA 65 XX M20 540 Nm 55 kpm 400 Ibs ft Arm fastening bolts Model Bolt Size Recommended fastening torque Nm kpm B 150 XX M16 280 Nm 29 kpm 210 Ibs ft B 200 XX M16 280 Nm 29 kom 210 Ibs ft B 250 XX M16 280 Nm 29 kpm 210 Ibs ft B 320 XX M16 280 Nm 29 kom 210 Ibs ft B 400 XX M20 540 Nm 55 kpm 400 Ibs ft BA 50 XX M24 950 Nm 97 kom 710 lbs ft BA 65 XX M24 950 Nm 97 kom 710 lbs ft 960003E User Manual Series B amp BA Auramo Oy 2002 All Rights Reserved POZE UN TEAR Arm girder aluminum profile bolts Model Bolt Size Recommended fastening torque Nm kpm LES B 150 XX M16 190 Nm 19 kpm 140 Ibs ft B 200 XX M16 190 Nm 19 kpm 140 Ibs ft B 250 XX M16 190 Nm 19 kpm 140 Ibs ft B 320 XX M16 190 Nm 19 kpm 140 Ibs ft B 400 XX M16 190 Nm 19 kpm 140 Ibs ft Cylinder fastening nuts Model Nut Size Recommended fastening torque Nm kpm LES B 150 XX The clamping cylinder fastening nuts must be left relatively B 200 XX loose as the the cylinder and piston rod must be able B 250 XX to move in relation to the clamp body B 320 XX B 400 XX Gr
20. n good condition e Clean the fork carriage Make sure that it has no defects or wear that could prevent the installation or use of the clamp attachment 3 3 1 Installation Standard Carriages Installation to the most common standard fork carriages types ISO 2328 2 2328 3 2328 4 is as follows e Remove the lower mounting hooks With quick change mounting S models open the lower mounting hooks D amp e Lift the clamp to the carriage so that it hangs from the upper mounting hooks e Center the clamp horizontally on the carriage 960003E User Manual Series B amp BA Auramo Oy 2002 All Rights Reserved AUrAIVIO Yz e Install the lower mounting hooks With quick change models close the lower mounting hooks e To prevent the clamp from moving on the carriage two side locator blocks have to be welded to the upper carriage bar e Side locator blocks can also be welded to the upper mounting hooks in which case the blocks must be positioned so that they are properly engaged in the mating notch on the truck carriage In turn centering the clamp might prove slightly more difficult Welding instructions come supplied with the clamp Figure Positioning side locator blocks to the upper mounting hook or alternatively to the upper carriage bar WARNING Upper mounting hooks must be properly engaged on the upper carriage bar before fastening lower mounting hooks If not properly engaged the clamp can drop
21. nly Be careful not to use too much grease or other lubricants as these should not be allowed to touch roll or contact pads 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 e Especially check arm carriers hinge pins and their bushings e Roll clamps Check contact pads contact pad pull rods contact pad springs and wear plates Check also the arm pivot mechanism split arm clamps only e Bale clamps Check wear bars check arm welds and mounting bolts e Fork clamps Check the forks Ensure that there are no visible cracks especially in the fork heel area Replace excessively worn defective or damaged forks e Replace or repair all parts showing signs of excessive wear e Arm carriers arm bearings and or the clamp frame should be replaced if the play is such that it disturbs the normal use Replacement is also necessary if arm movement is blocked or slowed down due to excessive wear or bending 5 3 Tightening the Bolts Most bolts on Bolzoni Auramo B and BA Series clamps are secured using LOCTITE 270 Bolts under high stresses are also tightened to a certain fastening torque Normally retightening of the bolts is unnecessary Should loose bolts be found during daily checks open them apply some LOCTITE 270 to the bolt threads and retighten them Also remember to check the tightness of bolts within the
22. nstruction 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 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 960003E User Manual Series B amp BA Auramo Oy 2002 All Rights Reserved 33 REAR CS 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 960003E User Manual Series B amp BA Auramo Oy 2002 All Rights Reserved 34 l ALRAMO 6 960003E User Manual Series B am
23. orklift attachment combination 3 1 2 Hydraulic Pressure and Oil Flow Recommendations Recommended Maximum Maximum Hydraulic Oil Flow Connection Clamping Functions Rate Pressure Pressure l min MPa MPa B 150 XX 25 40 16 0 16 0 2 B 200 XX 40 50 16 0 14 0 2 B 250 XX 40 50 16 0 16 0 2 B 320 XX 50 60 16 0 16 0 2 B 400 XX 50 60 16 0 16 0 2 BA 50 XX 60 80 16 0 16 0 2 BA 65 XX 60 80 16 0 16 0 2 Recommended Maximum Maximum Hydraulic Oil Flow Connection Clamping Functions Pressure Pressure B 150 XX 6 6 10 6 2 320 2 320 2 B 200 XX 10 6 13 2 2 320 2 030 2 B 250 XX 10 6 13 2 2 320 2 320 2 B 320 XX 13 2 15 9 2 320 2 320 2 B 400 XX 13 2 15 9 2 320 2 320 2 BA 50 XX 15 9 21 2 2 320 2 320 2 BA 65 XX 15 9 21 2 2 320 2 320 2 Hydraulic pressure defines the operation force of the attachment The attachment structure cylinder seals hoses and other hydraulic components define the maximum allowed hydraulic pressure If the lift truck produces more hydraulic pressure than what is allowed to any of the unprotected functions of the attachment separate pressure relief valves must be installed into the lift truck or attachment hydraulic system WARNING Never exceed the maximum connection and operating pressures Oil flow to the attachment defines the operation speed of the attachment forks or arms Generally it could be said that the higher the oil flow the faster the forks or arm
24. p BA Auramo Oy 2002 All Rights Reserved 35
25. p attachment models 4 1 General Instructions Using the lift truck Only trained and authorized operators may use the lift truck and the clamp attachment Driving with the load Drive carefully and safely Avoid strong acceleration and braking Always drive with the load lowered down and if possible the mast tilted backwards No speeding No overloading consult the lift truck nameplate for available lifting capacity I E O Ta LO Parking Always lower the load and attachment down when parking Shut the power off and set the brakes on when leaving the truck unattended Loading When taking a load or pallet from a stack back away only so far as to be able to lower the load safely Never accelerate or brake powerfully when the load is up as this can lead to loss of balance Use extreme care when sideshifting or tilting raised loads Sideshifting Do not risk the lift truck stability with sideshift Sideshift only when the load is lowered down or near its seat Use extreme caution when handling off centered loads WARNING All B and BA Series clamps with an internal sideshift may be able to sideshift more that 100 mm 4 The amount of available internal sideshift depends on the frame width and the arm opening When the clamping arms or forks are in a totally open or closed position there is no sideshift available 960003E User Manual Series B amp BA Auramo Oy 2002 All Ri
26. resentatives are anxious to answer all customer questions concerning Bolzoni Auramo service and products To help us resolve any problem you may be having as fast and accurately as possible please check the following information before contacting us Clamp attachment type serial number and production year This information can be found on the clamp nameplate How and under which operating conditions the trouble occurs Type of operation estimated work hours of the clamp Any other information you think will help us to help you 7 2 Notes on Service Actions Clean the clamp carefully before removing or replacing any parts Protect the environment Always put used oil into a proper tank Do not let dirt or debris enter into the hydraulic system Always protect open fittings with a proper cap Clean all parts carefully before installing them onto the clamp 7 3 Service Instructions In the following pages you will find instructions on how to perform such service actions and repairs that are outside the normal maintenance schedule WARNING Read instructions carefully before you do anything Repairs done incorrectly are safety hazards Follow all safety instructions given in previous chapters 960003E User Manual Series B amp BA Auramo Oy 2002 All Rights Reserved 29 SOL 30 ALRAMO C8 7 3 1 Hose Change Clean the clamp carefully before removing or replacing any parts If the hose leaks from
27. rward e Attachment operation may further increase the load center Example Load extenders and tilting attachments e Attachment s own weight increases the lifted total load WARNING Never use the lift truck amp attachment combination to lift more than its rated capacity as stability factors will be changed The lift truck may become unsafe 3 1 1 Clamp Attachment Rated Capacity Rated Capacity The rated capacity given for each clamp is a nominal value defined by the clamp construction and clamping force Rated capacity does not take into consideration properties of the load or working conditions Therefore the net working capacity of a truck clamp combination is not a fixed value It is defined by the clamp rated capacity and the truck rated capacity at certain heights loads and working conditions Net Capacity The lift truck dealer or manufacturer must calculate the net working capacity for the lift truck clamp combination WARNING Clamp attachment decreases the lift truck rated capacity 960003E User Manual Series B amp BA Auramo Oy 2002 All Rights Reserved Bel A EAEN 55 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 f
28. s move However there is a limit on how much oil can be forced through the lift truck and attachment hydraulic system Too much oil flow may lead to e Excessive oil heating 960003E User Manual Series B amp BA Auramo Oy 2002 All Rights Reserved AUrAIVIO Yz e Decreased component lifetime e Possible operation malfunctions Too little oil flow also has its drawbacks as the following symptoms may occur e Slow operation e Problems with simultaneous arm movement with multiple arm clamps e Possible operation malfunctions Normally the attachments operate well within a wide oil flow range More than normal attention should be paid into the oil flow when selecting an attachment with multiple arm pairs or a very wide opening Note also that the hydraulic hoses going over the lift mast hose reels swivel blocks and hose connectors may throttle the oil flow to the attachment and affect the available operation speed 3 1 3 Hydraulic Oils Use petroleum based hydraulic oil as recommended by the truck manufacturer If you wish to use aqueous based or biohydraulic oils please contact Bolzoni Auramo 3 1 4 Hydraulic Functions Standard Bolzoni Auramo B Series and BA Series clamps require two 2 hydraulic functions from the lift truck hydraulic system in order to enable clamping and sideshifting motions 3 2 Handling and Storage of the Clamp Attachment Prior to installation check the clamp carefully to ensure that no
29. stem Problem Pressure is on arms do not move Possible cause Defective or worn arm carriers or arm carrier bearings e Clean and repair or replace arm carrier bearings and or arm Carriers Possible cause Bent frame girders or clamp frame e Check and straighten or replace damaged parts Possible cause Incorrect hose connection e Check the hoses Rectify connections if needed Possible cause Dirt in check valve e Clean or replace check valves Possible cause Pressure relief valve defective or wrongly set e Replace valve or correct the setting Possible cause Leak in pressure cylinders e Check and replace seals if needed Problem Clamping force too small Possible cause Hydraulic pressure is too low e Check truck pressure settings Measure pressure coming from the truck Pressure must be the same as or higher than what is required for the clamp e Check the oil level e Check for external leaks If needed clean components before examination e Blocked hose or fitting Repair or replace Possible cause Wrong setting in the main pressure relief valve e Check clamping pressure with the Bolzoni Auramo test cylinder The pressure can be adjusted by turning the adjustment screw clockwise pressure increases counterclockwise pressure decreases Never exceed the maximum operating pressure of the clamp 960003E User Manual Series B amp BA Auramo Oy 2002 All Rights Reserved 26 BAN lal Possibl
30. te recommendation see Section 3 1 3 960003E User Manual Series B amp BA Auramo Oy 2002 All Rights Reserved 2 AURAIVIO Gs 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 e Adjust valves Problem Arms move roughly Possible cause Air in the system e Remove air by totally opening and closing arms several times Possible cause Dirt in hydraulic system e Clean system and change oil and oil filter Problem Arms do not move at the same speed Possible cause Dirt between arms and body or uneven wear e Clean the clamp If this proves ineffective adjust restrictor valves from cylinders see Section 7 3 Problem Built in sideshift does not work Possible cause Arms are either too open or too closed e The built in sideshift function is carried out using the same cylinders as the clamping function Thus possible sideshift movement depends on the position of the arms When the arms are totally open or totally closed there is no available sideshift Maximum sideshift is available when the arms are in the middle of their movement range Possible cause Leak in check valve e Clean or replace check valves 960003E User Manual Series B amp BA Auramo Oy 2002 All Rights Reserved 28 COZ INI TEAR 7 Service and Repairs 7 1 General Bolzoni Auramo Oy and its authorized rep
31. the fitting first try to tighten the fitting Change the hose only if this does not help Label all hoses before removing them This makes re assembly significantly easier Protect all open fittings with a proper cap Make sure that hose length is correct before installing it Always compare the length of new and old hoses Make sure that enough play length is left on the hose before fastening Do not over tighten hose fittings Over tightening will easily cause damage to valve blocks or fittings Make sure that hoses do not twist when tightening the fittings WARNING Never remove or tighten pressurized parts or hoses 7 3 2 Seal Change Clamp Cylinders Remove hoses protect open fittings with proper caps WARNING Never remove pressurized parts or hoses Figure Clamp Cylinder Open the housing 51 Pull the piston assembly and housing 20 51 50 out of the cylinder shell 10 960003E User Manual Series B amp BA Auramo Oy 2002 All Rights Reserved BAN lal e Use a blunt screwdriver to take old seals away from the piston If necessary cut the seals to remove them CAUTION Do not scratch piston surfaces with sharp tools Note the direction of the seals e Open the grub screw 53 If necessary heat the screw before opening e Unscrew the piston 50 from the piston rod 20 e Slide the housing 51 off the piston end of the rod e Remove old seals from housing CAUTION
32. w the clamp works before you attempt to use it Every country has its own safety regulations concerning lift trucks and lift truck attachments It is the responsibility of the user to know and follow these regulations If safety recommendations given in this manual should differ from your local regulations you should always follow the local regulations 1 1 Notices You will find three different levels of notices in this manual WARNING These paragraphs contain information that will help you prevent injuries CAUTION These paragraphs contain information that will help you prevent damage to the equipment NOTE These paragraphs contain information that will help you service the equipment 1 2 Safety Instructions Always check the operating condition of the clamp attachment before use Never use a defective or damaged attachment Never stand under a load or clamp attachment Never stand in the clamp operating area or between the clamping surfaces Handle only those products which the clamp attachment has been designed for It is unsafe to lift any other objects Know the capacity and limitations of your machine 960003E User Manual Series B amp BA Auramo Oy 2002 All Rights Reserved AUrAIViIO Yz 2 Introduction 2 1 Bolzoni Auramo B Series and BA Series Bolzoni Auramo B and BA series clamp attachments and fork positioners have several different models which can be used for various lo
33. ying out all movements clamping and sideshift several times between respective end positions WARNING Clamp arms can move unpredictably if there is air in the system 960003E User Manual Series B amp BA Auramo Oy 2002 All Rights Reserved AURAIVIO Gz 3 Checks Before Operating the Clamp Check the mounting and all functions of the clamp before using it for the first time 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 on the truck is correct e Check that the clamp is centered on the truck 3 7 2 Hydraulic Parts e Wipe clean all hydraulic parts e Check truck oil level e Run all movements clamping and sideshift several times between respective end positions e Check all cylinders valves hoses and fittings for any leaks e Check that hosing is correct also when pressurized e Check that arms move at the same speed and if necessary adjust the speed see 7 3 3 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 load damage This is especially important with paper roll clamps and other clamps handling sensitive loads e Check clamping force by using the Bolzoni Auramo Test Pad Test Stand Test Cylinder or any other suitable device e Check that
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