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ATiB 474.160 Use And Maintenance Manual

Gripper for one or two drums, gripper for two or four drums, gripper for drum rotating 180
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USE AND
MAINTENANCE
MANUAL
GRIPPER FOR ONE OR TWO DRUMS TYPE 474.160 |
GRIPPER FOR TWO OR FOUR DRUMS TYPE 474.190 |
GRIPPER FOR DRUM ROTATING 180°
I-D02-01-86 - Rev.2

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  • Page 1 USE AND MAINTENANCE MANUAL GRIPPER FOR ONE OR TWO DRUMS TYPE 474.160 | GRIPPER FOR TWO OR FOUR DRUMS TYPE 474.190 | GRIPPER FOR DRUM ROTATING 180° I-D02-01-86 - Rev.2...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS GRIPPER FOR ONE OR TWO DRUMS TYPE 474.160 | GRIPPER FOR TWO OR FOUR DRUMS TYPE 474.190 | GRIPPER FOR DRUM ROTATING 180° 1 SAFETY REGULATIONS FOR THE OPERATOR ................3 2 INTRODUCTION ..........................4 Use and Storage of the Manual ..................4 Equipment Description .......................
  • Page 3 Maintenance Every 2000 Hours ..................36 7 DISASSEMBLY PROCEDURE ....................... 37 Removing the Equipment from the Forklift Truck ............37 Disassembling the Clamping Unit – TYPE 474.190 ............38 7.2.1 Disassembling the Rubber Pads ................38 7.2.2 Disassembling the jaws ....................39 Removing the Jaws from the Equipment ................

  • Page 4: Safety Regulations For The Operator

    1 SAFETY REGULATIONS FOR THE OPERATOR 1 SAFETY REGULATIONS FOR THE OPERATOR Do not cross the upright Do not transport passengers Tilting Lifting 75 mm Travel Do not stand under the load Page 3 of 58...

  • Page 5: Introduction

    This "Use and Instruction Manual" (hereinafter referred to as the Manual) is issued together with the A.T.I.B. equipment. – “GRIPPER FOR ONE OR TWO DRUMS TYPE 474.160 | GRIPPER FOR TWO OR FOUR DRUMS TYPE 474.190 | GRIPPER FOR DRUM ROTATING 180°”...

  • Page 6: Equipment Description

    2 INTRODUCTION 2.2 Equipment Description TYPE 474.160 TYPE 474,160 WITH SISS WITH TYPE 474.190 TYPE 474.190 WITH SISS Page 5 of 58...
  • Page 7 MULTI-DIAMETER BALE CLAMP All the A.T.I.B. equipment – “GRIPPER FOR ONE OR TWO DRUMS TYPE 474.160 | GRIPPER FOR TWO OR FOUR DRUMS TYPE 474.190 | GRIPPER FOR DRUM ROTATING 180°” are identified by means of an adhesive plate (see Table 1) located on the equipment (see Figure 1), always refer to the serial number.
  • Page 8 25020 Dello (BS) - ITALY NOTE: OSSERVARE I LIMITI DI PORTATA SPESSORE / THICKNESS +39 030 9771711 DELL’INSIEME CARRELLO CON ATTREZZATURA / WARNING: OBSERVE THE info@atib.com - atib.com CENTRO DI GRAVITÀ / NOMINAL CAPACITY OF TRUCK AND CENTER OF GRAVITY ATTACHMENT COMBINED Table 1...
  • Page 9 2 INTRODUCTION 1. TYPE Indicates equipment model as shown in the catalogue. 2. CODE Indicates the equipment ordering code. 3. SERIAL N° It progressively identifies the individual equipment. In the event that the plate is missing or is damaged, the serial number is also stamped on the profile for connection to the fork-holder plate;...
  • Page 10 2 INTRODUCTION The A.T.I.B. equipment – “GRIPPER FOR ONE OR TWO DRUMS TYPE 474.160 | GRIPPER FOR TWO OR FOUR DRUMS TYPE 474.190 | GRIPPER FOR DRUM ROTATING 180°” has been conceived, designed and manufactured to handle a single drum or several drums simultaneously (1 or 2 / 2 or 4 depending on the type of equipment).

  • Page 11: Installation

    Values are for indicative purposes only and may vary depending on the equipment. FLOW RATE (l/mm) Operating pressure TYPE and ISO minimum maximum recommended Maximum (Bar) 474.160 ISO II 474.190 ISO II 474.190 ISO III Table 2 ATTENTION!! OBSERVE THE INDICATED MAXIMUM OPERATING PRESSURES Page 10 of 58...

  • Page 12: Installation Procedure

    3. Check the condition of the pipes, replacing those in a poor condition. N.B. Although only type 474.160 is shown in the installation phase, the equipment installation procedure is identical for different versions (.190, WITHOUT SISS).
  • Page 13 3 INSTALLATION 5. For handling, use straps and/or chains that are suitably sized in relation to the weight of the equipment as indicated on the plate (see Figure 1 and Table 1 on page 7). Figure 3 6. Then hook on the equipment using an overhead crane or hoist of sufficient capacity and position it on the fork carriage, taking care to fit centring pin C into the central notch on the fork carriage (see Figure 3).
  • Page 14 3 INSTALLATION 7. Screw on the 2 lower couplings G in such a way that their bodies also remains coupled to the lower part of the fork carriage P (with max. clearance of 1.5 mm, see detail Figure 4), tightening with the torque indicated in Table 3. CLASS THREAD TIGHTENING TORQUE...

  • Page 15: Installing The Equipment - With Siss

    3. Check the condition of the pipes, replacing those in a poor condition. N.B. Although only type 474.160 is shown in the installation phase, the equipment installation procedure is identical for different versions (.190, WITH SISS).
  • Page 16 3 INSTALLATION 5. Remove the lower couplings from the equipment and grease the sliding gibs (see Figure 6). If quick-release couplings are fitted, simply remove the cotter pin and turn them downwards (a). If standard couplings are present, remove the bolts and their washers (b).
  • Page 17 3 INSTALLATION 8. Replace the protection bracket. 9. Screw on the 2 lower couplings G in such a way that their bodies also remains coupled to the lower part of the fork carriage P (with max. clearance of 1.5 mm, see detail Figure 8), tightening with the torque indicated in Table 4.

  • Page 18: Assembling The Aluminium Profiles

    3 INSTALLATION 3.2 Assembling the Aluminium Profiles ALUMINIUM 1. Release the pressure from the hydraulic system and disconnect PROFILES the lines. 2. Install the aluminium profiles one at a time, using the bolts provided (see Figure 9 and Figure 10). Figure 9 Figure 10 Page 17 of 58...

  • Page 19: Assembling The Nylon Bushes

    3 INSTALLATION 3.3 Assembling the Nylon Bushes NYLON BUSHES 1. Release the pressure from the hydraulic system and disconnect the lines. 2. Insert the nylon bushes and secure them using the grub screws provided (see Figure 11 and Figure 12). Figure 11 Figure 12 Page 18 of 58...

  • Page 20: Installing The Jaws Onto The Equipment

    3 INSTALLATION 3.4 Installing the Jaws onto the Equipment N.B. Although only type 474.160 is shown, the procedure for JAWS installing the jaws on the equipment is identical for the other versions (.190). 1. Release the pressure from the hydraulic system and disconnect the lines.

  • Page 21: Assembling The Clamping Unit - Type 474.190

    3 INSTALLATION 3.5 Assembling the Clamping Unit – TYPE 474.190 3.5.1 Assembling the Jaws 1. Open the fork cylinders to install the jaws easily and in safety. JAWS 2. Release the pressure from the hydraulic system and disconnect the lines. 3.

  • Page 22: Assembling The Rubber Pads

    3 INSTALLATION 3.5.2 Assembling the Rubber Pads 1. Open the jaw cylinders to install the rubber pads easily and in RUBBER PADS safety. 2. Release the pressure from the hydraulic system and disconnect the lines. 3. Install the rubber pads, using the associated nuts and bolts (see Figure 17 and Figure 18). Figure 17 Figure 18 Page 21 of 58...

  • Page 23: Assembling The Clamping Unit - Type 180° Rotating

    3 INSTALLATION 3.6 Assembling the Clamping Unit – TYPE 180° rotating 3.6.1 Assembling the Jaws N.B. Although only the type with ‘V’-shaped pads (multi-diameter PADS pads) is shown in the various stages, disassembly is identical for all types of equipment. 1.
  • Page 24 3 INSTALLATION 4. Position the pad pin on the axis with the clamping unit and, keeping it parallel with the plane of the fork, insert the pad into the clamping unit, taking care to engage the crown gear with the rotating rack (see Figure 20) PAD PIN CROWN GEAR ROTATION ASSEMBLY...
  • Page 25 3 INSTALLATION 5. After fitting the pad, tighten the ring nut E (see Figure 21) ROTATION ASSEMBLY Figure 21 6. Carry out the timing by positioning the stop nut F against the cylinder piston rod G and fit the rack securing fork assembly H, screwing it in until it stops at the stop nut F (see Figure 22) Figure 22 Page 24 of 58...
  • Page 26 3 INSTALLATION 7. If the pad is parallel to the mount and the two left and right pads are also aligned with each other, the timing is correct (see Figure 23) MOUNT Figure 23 8. If the pad is not parallel to the mount (as shown in Figure 23) or the two pads are not aligned with each other, adjust the position of the fork assembly by screwing it or unscrewing it to turn the pad clockwise or counter-clockwise to bring it into the correct position (timing)

  • Page 27: Hydraulic System

    4 HYDRAULIC SYSTEM 4 HYDRAULIC SYSTEM N.B. Although only type 474.160 is shown in the images, the position of the solenoid valves is identical for the other versions (.190). 4.1 Hydraulic System - Valve B2383022 VALVE B2383022 SUPPLY CYLINDERS Figure 24...

  • Page 28: Hydraulic System - Valve B2383022 With Siss

    4 HYDRAULIC SYSTEM 4.2 Hydraulic System - Valve B2383022 with Siss VALVE B2383022 SUPPLY SIDESHIFT CYLINDERS (SISS) SUPPLY CYLINDERS Figure 25 Page 27 of 58...

  • Page 29: Hydraulic System - Iss - Valve B2383023

    4 HYDRAULIC SYSTEM 4.3 Hydraulic System – Iss – Valve B2383023 VALVE B2383023 SUPPLY CYLINDERS Figure 26 Page 28 of 58...

  • Page 30: Hydraulic System - 180° Rotation

    4 HYDRAULIC SYSTEM 4.4 Hydraulic system – 180° rotation N.B. Although only type 877 with ‘V’-shaped pads (multi-diameter 180° ROTATION pads ) is shown during installation, the position of the system is identical for all other versions. Figure 27 C= pad rotation cylinder R= flow regulator T= cylinder discharge (front rotation) P= cylinder supply (rear rotation)

  • Page 31: Rules Governing Use

    5 RULES GOVERNING USE 5 RULES GOVERNING USE Before using the equipment, check the tightness of the piping and the correctness of assembly and also the connection by performing a dozen preliminary operations. The following instructions must be followed when using the equipment: 1.
  • Page 32 5 RULES GOVERNING USE All ATIB equipment is designed and manufactured according to a load positioned (with respect to its centre of gravity) at a certain distance from the vertical plane of the jaws. If the distance of the centre of gravity from the vertical part of the jaws needs to be increased, the weight of the load must be reduced.
  • Page 33 5 RULES GOVERNING USE The attainable sideshift may compromise the stability of the forklift truck. It is advisable to consult the manufacturer of the forklift truck to check the residual capacity of the forklift truck-equipment assembly. The condition of the road surface, the speed at which the load is handled and the elevation may all affect the load’s grip, which must be taken into account on a case-by-case basis.

  • Page 34: Integral Sideshift

    5 RULES GOVERNING USE 5.1 Integral Sideshift This is the type most frequently used in “GRIPPER FOR ONE OR TWO DRUMS TYPE 474.160 | GRIPPER FOR TWO OR FOUR DRUMS TYPE 474.190 | GRIPPER FOR DRUM ROTATING 180°” and uses the same cylinders that clamp the jaws. The stroke depends on the opening and will be equal to zero in maximum opening and minimum closing.

  • Page 35: Handling Loads

    5 RULES GOVERNING USE 5.2 Handling Loads The minimum transportable dimensions must be greater than the minimum grip. Depending on the load to be transported, this difference may vary and must be evaluated on a case by case basis by the operator. Avoid handling and/or sideshift of the forklift truck/equipment with a load that is excessively high off the ground, as this may affect its stability.

  • Page 36: Periodic Maintenance

    6 PERIODIC MAINTENANCE 6 PERIODIC MAINTENANCE Failure to comply with the rules and intervals established for maintenance will compromise the correct operation of the equipment and will void the conditions of the warranty. All maintenance operations must be carried out with the forklift truck stationary and the hydraulic circuit disconnected and depressurised.

  • Page 37: Maintenance Every 1000 Hours

    6 PERIODIC MAINTENANCE 6.3 Maintenance Every 1000 Hours 1. Check condition of bushes and sliding gibs. If excessively worn component are detected, replace the entire component assembly in question. 2. Carry out the additional operations listed in the previous points (Point 6.1 and 6.2 on page 35).

  • Page 38: Disassembly Procedure

    7 DISASSEMBLY PROCEDURE 7 DISASSEMBLY PROCEDURE All maintenance operations must be carried out with the forklift truck stationary and the hydraulic circuit disconnected and depressurised. The entire maintenance area must be barricaded using regulation protection devices and, if the cylinders require disassembly, a tray or container must be provided to catch the oil present in the cylinder.

  • Page 39: Disassembling The Clamping Unit - Type 474.190

    7 DISASSEMBLY PROCEDURE 7.2 Disassembling the Clamping Unit – TYPE 474.190 7.2.1 Disassembling the Rubber Pads 1. Open the jaw cylinders to remove the rubber pads easily and in RUBBER PADS safety. 2. Release the pressure from the hydraulic system and disconnect the lines. 3.

  • Page 40: Disassembling The Jaws

    7 DISASSEMBLY PROCEDURE 7.2.2 Disassembling the jaws 1. Open the fork cylinders to remove the jaws easily and in safety. JAWS 2. Release the pressure from the hydraulic system and disconnect the lines. 3. Remove the jaws from the forks (see Figure 32 and Figure 33). Figure 32 Figure 33 Page 39 of 58...

  • Page 41: Removing The Jaws From The Equipment

    7 DISASSEMBLY PROCEDURE 7.3 Removing the Jaws from the Equipment N.B. Although only type 474.160 is shown, the procedure for JAWS removing the jaws from the equipment is identical for the different versions (.190). 1. Release the pressure from the hydraulic system and disconnect the lines.

  • Page 42: Disassembling The Nylon Bushes

    7 DISASSEMBLY PROCEDURE 7.4 Disassembling the Nylon Bushes NYLON BUSHES 1. Remove the fork assembly from the equipment. 2. Release the pressure from the hydraulic system and disconnect the lines. 3. Remove the nylon bushes after unscrewing the corresponding grub screws (see Figure 36 and Figure 37).

  • Page 43: Disassembling The Aluminium Profiles

    7 DISASSEMBLY PROCEDURE 7.5 Disassembling the Aluminium Profiles ALUMINIUM 1. Release the pressure from the hydraulic system and disconnect PROFILES the lines. 2. Remove the aluminium profiles, one at a time, after unscrewing the bolts (see Figure 38 and Figure 39). Figure 38 Figure 39 Page 42 of 58...

  • Page 44: Disassembling The Clamping Unit - Type 180° Rotating

    7 DISASSEMBLY PROCEDURE 7.6 Disassembling the Clamping Unit – TYPE 180° rotating 7.6.1 Disassembling the Pads N.B. Although only the type with ‘V’-shaped pads (multi-diameter PADS pads) is shown in the various stages, disassembly is identical for all types of equipment. 1.
  • Page 45 7 DISASSEMBLY PROCEDURE 4. Remove pad D by extracting it from the front as indicated in Figure 42. If there is any difficulty in removing the pad, use a rubber mallet and a nylon rod with a smaller diameter than the pad pin to hammer in on side E as shown in Figure 42 PAD PIN ROTATION ASSEMBLY Figure 42...

  • Page 46: Disassembling The Cylinder

    7 DISASSEMBLY PROCEDURE 7.6.2 Disassembling the Cylinder N.B. Although only the type with ‘V’-shaped pads (multi-diameter CYLINDER pads) is shown in the various stages, disassembly is identical for all types of equipment. 1. Release the pressure from the hydraulic system and disconnect the lines. 2.
  • Page 47 7 DISASSEMBLY PROCEDURE 3. Remove the snap ring F at the rear of the cylinder, and pull out the pin G that secures the cylinder to the bracket. Carry out the same procedure for the pin that secures the front of the cylinder (see Figure 44) CYLINDER Figure 44...

  • Page 48: Disassembling The Rack

    7 DISASSEMBLY PROCEDURE 7.6.3 Disassembling the Rack N.B. Although only the type with ‘V’-shaped pads (multi-diameter RACK pads) is shown in the various stages, disassembly is identical for all types of equipment. 1. Release the pressure from the hydraulic system and disconnect the lines. 2.

  • Page 49: Disassembling The Bushes

    7 DISASSEMBLY PROCEDURE 7.6.4 Disassembling the Bushes N.B. Although only the type with ‘V’-shaped pads (multi-diameter BUSHES pads) is shown in the various stages, disassembly is identical for all types of equipment. 1. Release the pressure from the hydraulic system and disconnect the lines. 2.

  • Page 50: Removing The Jaw Cylinders From The Equipment

    7 DISASSEMBLY PROCEDURE 7.7 Removing the Jaw Cylinders from the Equipment N.B. Although only type 474.160 with siss is shown, the procedure JAW CYLINDERS for removing and disassembling the jaw cylinders is identical for the other versions (.190). 1. Open the cylinders.

  • Page 51: Disassembly Procedure

    7 DISASSEMBLY PROCEDURE 6. Release the pressure from the hydraulic system and disconnect the lines. 7. Remove the nuts D that secure the cylinders to the equipment assembly and remove the cylinders, taking care not to damage them (see Figure 48). Figure 48 Page 50 of 58...

  • Page 52: Disassembling And Reassembling The Jaw Cylinders

    7 DISASSEMBLY PROCEDURE 7.7.1 Disassembling and Reassembling the Jaw Cylinders If the entire cylinder needs to be replaced, reassemble following the instructions listed in the previous point. If any cylinder components need to be replaced, proceed as indicated below: 1. Clamp the cylinder body in a vice using soft jaws (taking care not to deform the liner). 2.

  • Page 53: Sideshift Cylinder Maintenance (Siss)

    7 DISASSEMBLY PROCEDURE 7.8 Sideshift Cylinder Maintenance (siss) CYLINDERS SISS 1. Release the pressure from the hydraulic system and disconnect the lines. 2. Remove the equipment from the forklift truck, as outlined in point Removing the Equipment from on page 37. the Forklift Truck 3.
  • Page 54 7 DISASSEMBLY PROCEDURE Figure 51 N.B. Although only type 474.160 with sis is shown, the procedure for removing and disassembling the sideshift cylinders is identical for the other versions (.190, WITH SISS). Page 53 of 58...

  • Page 55: Troubleshooting

    8 TROUBLESHOOTING 8 TROUBLESHOOTING 8.1 Probable Faults and Solutions FAULT CAUSE SOLUTION Calibration of the maximum pressure Increase the pressure without exceeding valve too low the maximum limit Insufficient pressure Contact the forklift truck manufacturer Insufficient force Worn pump Replace it Worn cylinder seals Replace them No oil in the tank...

  • Page 56: Lubrication

    8.2 Lubrication 1. Lubricate sliding components using grease nipples. 2. Grease gibs and bars/sliding surfaces (e.g. nylon bushes). N.B. Although only type 474.160 is shown, the lubrication procedure is identical for the other versions (.190). Figure 52 Page 55 of 58...
  • Page 57 8 TROUBLESHOOTING WITH SISS Figure 40 Figure 41 Page 56 of 58...
  • Page 58 8 TROUBLESHOOTING 180° ROTATING 1. Lubricate sliding components using grease nipples; 2. Lubricate sliding and rotating parts (e.g. racks, bushes, etc.); 3. For all procedures, see lubrication points inFigure 41; 4. All operations are to be carried out on both mounts. N.B.
  • Page 59 I-D02-01-86 - Rev.2...

This manual is also suitable for:

474.190

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