DOWNLOAD PDF :Cascade Layer Picker Service Manual

S

ERVICE MANUAL

Layer Picker

Manual Number 230444 R-1

cascade姞 corporation

Cascade is a Registered Trademark of Cascade Corporation

C

ONTENTS Layer Picker Page

INTRODUCTION, Section 1 Introduction, 1.1 Special Definitions, 1.2 PERIODIC MAINTENANCE, Section 2 100-Hour Maintenance, 2.1 500-Hour Maintenance, 2.2 1000-Hour Maintenance, 2.3 2000-Hour Maintenance, 2.4 TROUBLESHOOTING, Section 3 General Procedures, 3.1 Truck System Requirements, 3.1-1 Tools Required, 3.1-2 Troubleshooting Chart, 3.1-3 Load handling troubleshooting, 3.1-4 Plumbing, 3.2 Hosing Diagram–Clamp, Reach Circuits, 3.2-1 Hosing Diagram–Swing, Hoist Circuits, 3.2-2 Hydraulic Schematics, 3.2-3 Clamp Function, 3.3 Supply Circuit Test, 3.3-1 Clamp Circuit Test, 3.3-2 Reach Function, 3.4 Supply Circuit Test, 3.4-1 Reach Circuit Test, 3.4-2 Swing Function, 3.5 Supply Circuit Test, 3.5-1 Swing Circuit Test, 3.5-2 Hoist Function, 3.6 Supply Circuit Test, 3.6-1 Lower Carriage circuit Test, 3.6-2 Electrical Circuit, 3.7

i

Page

SERVICE, Section 4 Layer Picker Removal, 4.1 Clamp Assembly, 4.2 Clamp Removal, 4.2-1 2 Arms – Removal, Installation, 4.2-2 2 Contact Pad Rotation, Replacement, 4.2-3 3 Contact Pad Camber Adjustment, 4.2-4 3 Arm Bearing Replacement, 4.2-5 Clamp Valve Removal, Installation, 4.2-6 4 Valve Service, 4.2-7 4 Cylinders, 4.3 4 Cylinder Removal, Installation, 4.3-1 5 Cylinder Disassembly, 4.3-2 6 Cylinder Inspection, 4.3-3 7 Cylinder Reassembly, 4.3-4 7 Boom-Carriage Assembly, 4.4 8 Boom-Carriage Removal, Installation, 4.4-1 10 Boom Reeving Service, 4.4-2 12 Telescope Bars, Bearings, 4.4-3 12 Revolving Connection Removal, Installation, 4.4-4 12 Revolving Connection Service, 4.4-5 14 Swing Valve Removal, Installation, 4.4-6 14 Valve Service, 4.4-7 14 Boom Replacement, 4.4-8 15 Swing Drive Motor Removal, Installation, 4.4-9 15 Carriage Inspection, Service, 4.4-10, 4.4-11 15 Mast, 4.5 16 Inspection and Adjustments, 4.5-1 16 Chain Inspection, 4.5-2 16 Lift Chain Service, 4.5-3 17 Mast Reeving Service, 4.5-4 Hoist Cylinder Removal, Installation, 4.5-5 Hoist Cylinder Bleeding, 4.5-6 Hoist Cylinder Service, 4.5-7 Mast Valve Service, 4.5-8 Mast Upright Disassembly, 4.5-9 Mast Upright Inspection, 4.5-10 Mast Upright Assembly, 4.5-11 Solenoid Valve, 4.6 Coil Service, 4.6-1 Valve Service, 4.6-2 SPECIFICATIONS, Section 5 Specifications, 5.1 Hydraulics, 5.1-1 Auxiliary Valve Functions, 5.1-2 Torque Values, 5.1-3 1 1

18 20 20 21 21 22 22 24 24 25 25 26 26 27 28 28 30 30 31 31 32 32 33 34 35 37 37 38 39 40 41 41 42 43 44 44 45 46 46 46 47 47 47 48

230444 Rev. 1

I 1.1

NTRODUCTION

Introduction This Manual provides the Periodic Maintenance, Troubleshooting, Service and Specifications for the Cascade Layer Picker.

In any communication about the Layer Picker, refer to the product I.D. number stamped on the nameplate as shown.

If the nameplate is missing, the numbers can be found stamped on the mast.

IMPORTANT: All hoses, tubes and fittings on Layer Picker are JIC. NOTE: Specifications are shown in both U.S. and (Metric) units.

Nameplate

c cascade

姞

ATTACHMENT CAPACITY

LIFT TRUCK ATTACHMENT

SERIAL NUMBER

CATALOG NUMBER

POUNDS INCH LOAD AT CENTER CAPACITY OF TRUCK AND ATTACHMENT COMBINATION MAY BE LESS THAN ATTACHMENT CAPACITY SHOWN ABOVE. CONSULT TRUCK NAMEPLATE.

674870

WEIGHT LBS.

RECOMMENDED SYSTEM PRESSURE – 2000 PSI MAXIMUM SYSTEM PRESSURE – 2300 PSI

ADDITIONAL EQUIPMENT

cascade姞

ADDITIONAL EQUIPMENT

FOR TECHNICAL ASSISTANCE, PARTS AND SERVICE CONTACT: 1-800-227–2233 PORTLAND, OREGON USA

ADDITIONAL EQUIPMENT

70 48 7 6 R O

01

-0 -LP

A

30 LP0074.ill

1.2

Special Definitions The statements shown appear throughout this Manual where special emphasis is required. Read all WARNINGS and CAUTIONS before proceeding with any work.

Statements labeled IMPORTANT and NOTE are provided as additional information of special significance or to make the job easier.

WARNING - A statement preceded by WARNING is information that should be acted upon to prevent bodily injury. A WARNING is always inside a ruled box.

CAUTION - A statement preceded by CAUTION is information that should be acted upon to prevent machine damage.

IMPORTANT - A statement preceded by IMPORTANT is information that possesses special significance.

NOTE - A statement preceded by NOTE is information that is handy to know and may make the job easier.

230444 Rev. 1

1

P 2.1

ERIODIC MAINTENANCE

100-Hour Maintenance

Mast

Every time the lift truck is serviced or every 100 hours of truck operation, whichever comes first, complete the following maintenance on the Layer Picker:

Clamp Cylinder Anchors

• Check for loose or missing bolts, damaged or worn hoses and hydraulic leaks.

Swing Boom

Upper Carriage

Boom Stops

• Inspect contact pads, arms, and forks for damage or wear. Replace as necessary.

• Inspect clamp and boom cylinder anchor nuts for proper connection and tightness. If necessary tighten to 160 ft.-lbs. (220 Nm).

Clamp Arms

• Check swinging boom stops for damage. Replace as necessary.

• Check that mast is vertical and clamp assembly is level during normal operation. Adjust as necessary.

• Lubricate mast upright rails with roller mast channel lube (Cascade Part No. 599474).

2.2

Mast Upper Links Contact Pads

LP0037.ill

Lower Carriage with Forks (if equipped)

500-Hour Maintenance After each 500 hours of truck operation, in addition to the 100-hour maintenance, perform the following procedures.

• Inspect chains for proper tension and adjustment (see Section 4.5-1).

• Lubricate full length of mast chains with SAE 40 wt. oil or chain lube (Cascade Part No. 200867).

• Inspect and adjust (if necessary) side-to-side clearance in mast upright and carriage (see Section 4.5-1).

Lubricate areas indicated by heavy line full length of each mast upright every 100 hours.

Outer Upright

Load Rollers

Carriage

Inner Upright

LP0043.ill

• Check torque value on mast mounting hardware.

• Check torque value on swing boom-to-motor top capscrews (see illustration below). Use crosspattern and tighten to 160 ft.-lbs. (215 Nm).

Swing Boom -to-Motor Capscrews (12)

LP0162.ill

• Check torque value on motor-to-carriage capscrews (see illustration opposite). Use cross-pattern and double-torque capscrews to 450 ft.-lbs. (610 Nm).

2

LP0163.ill

Swing Drive Motor-toCarriage Capscrews (4)

230444 Re v. 1

P 2.3

ERIODIC MAINTENANCE

1000-Hour Maintenance

Arm and Boom Bearing Tubes (6)

After each 1000 hours of truck operation, in addition to the 100 and 500-hour maintenance, perform the following procedures.

• Inspect clamp arm, boom arm, and load spacer bearings for wear. Replace as necessary.

LP0038.ill

Cylinder Rod-End Anchors (5)

2.4

2000-Hour Maintenance

Center Load Spacer

Spacer Bearings (4 sides)

After each 2000 hours of truck operation, in addition to the 100, 500 and 1000-hour maintenance, perform the following procedures: • Replace center load spacer bearings (see illustration opposite).

• Replace clamp arm and boom arm bearings (see Sections 4.2-5 and 4.4-3).

• Replace load and thrust rollers in mast and carriage (see Section 4.5).

Boom Bearings (2)

Clamp Frame

LP0165.ill

Arm Bearings (4) Retaining Rings (8)

WARNING: After completing any service procedure, always test each function through five complete cycles. First test with no load, then test with a load to make sure the Layer Picker operates correctly before returning it to the job.

230444 Rev. 1

3

T

ROUBLESHOOTING

3.1

General Procedures

3.1-1

Truck System Requirements • Truck hydraulic pressure should be within the range shown in Specifications, Section 5.1. PRESSURE TO THE LAYER PICKER MUST NOT EXCEED 2300 psi (160 bar).

WARNING: Before servicing any hydraulic components, relieve pressure in the Attachment system. Turn the truck off and move the truck auxiliary control valve levers several times in both directions.

• Truck hydraulic flow should be within the range shown in Specifications, Section 5.1.

After completing any service procedure, always test the Layer Picker through several cycles. First test empty to bleed any air trapped in the system to the truck tank. Then test with a load to be sure the unit operates correctly before returning it to the job.

• Hydraulic fluid supplied to the Layer Picker must meet the requirements shown in Specifications, Section 5.1.

Stay clear of the load while testing. Do not raise the load more than 4 in. (10 cm) off the floor while testing.

Flow Meter Kits: 671476 (10 GPM - 37 L/min) 671477 (20 GPM - 75 L/min) (2) No. 8-12 JIC/ O-Ring

Flow Meter

GA0013.ill

(2) No. 6-8 JIC Reducer

3.1-2

Tools Required In addition to a normal selection of mechanic's hand tools, the following are required: • Inline Flow Meter Kit: 10 GPM (37 L/min) - Cascade Part No. 671476.

20 GPM (75 L/min.) - Cascade Part No. 671477.

Pressure Gauge Kit: 671212 Pressure Gauge*

No. 6 and No. 8 JIC Swivel Tee

No. 6-6 Hose*

• Pressure Gauge Kit: 5000 psi (345 bar) - Cascade Part No. 671212.

GA0014.ill

• Assortment of fittings and hose.

• Magnetic Protractor/Level for vertical and horizontal adjustments.

No. 4-6 Pipe/JIC*

No. 6-8 JIC Reducer

• Pallet hand truck to install Clamp on Mast.

No. 4, No. 6* and No. 8 JIC/O-Ring

• Overhead hoisting capability of 4000 lbs. (1815 kg).

• Metric hex key set to adjust pressure reliefs.

Quick-Disconnects Male Straight Thread O-Ring Coupler: No. 4 (Part No. 212282)* No. 5 (Part No. 210378) No. 6 (Part No. 678592) Female JIC Thread Coupler: No. 4 (Part No. 210385)* No. 6 (Part No. 678591)

AC0127.ill

* NOTE: Diagnostics Kit 394382 includes items marked.

4

230444 Rev. 1

T 3.1-3

ROUBLESHOOTING

Troubleshooting Chart Determine All The Facts – It is important to gather all the facts about the problem before beginning any service procedures. The first step is to talk to the equipment operator. Ask for a complete description of the malfunction. Guidelines below and on the following pages can then be used as a starting point to begin troubleshooting.

Clamp Circuit • Load slips after it has been picked up.

• Clamp will not carry load up to its rated capacity.

• Clamp arms move slowly or not at all.

To correct these problems, see Sections 3.1-4 and 3.3.

Reach Circuit • Clamp will not extend or retract.

• Clamp extends or retracts slowly or with jerky motion.

To correct these problems, see Section 3.4.

Swing Circuit • Boom will not swing in either direction.

• Boom swings in one direction only.

• Boom swings slowly or with jerky motion.

To correct these problems, see Section 3.5.

Hoist Circuit • Mast will not raise when loaded or unloaded.

• Mast has spongy or jerky action.

• Mast drifts down.

• Lower carriage will not raise or lower.

To correct these problems, see Section 3.6.

230444 Rev. 1

5

T 3.1-4

ROUBLESHOOTING

Layer Picker Loads IF LOWER TIER OF LOAD BRIDGES DOWN OR SLIDES OUT:

4

Check for worn arm bearings

5

3 Check hydraulics for low supply pressure

Check for bent pads or arms, straighten or replace

Add or increase positive camber (See Section 4.2-4)

LP0020.ill

2

Check for worn contact pad surfaces, replace

IF LOWER TIER OF LOAD IS CREASED:

4

5

1

Re-clamp layer so bottom edge is even with bottom of pads

6

Check Center Spacer Bearings

3 Check hydraulics for high supply pressure

Check for bent pads or arms, straighten or replace LP0021.ill

2 6

Re-clamp load squarely between pads

Re-clamp load so bottom edge is even with bottom of pads

1 230444 Rev. 1

T

ROUBLESHOOTING

3.2

Plumbing

3.2-1

Hosing Diagrams – Clamp and Reach Circuits

Clamp Cylinders (4) Clamp Valve

Extend-Retract Cylinder CLAMP (1 Port)

OPEN (3 Port)

Revolving Connection

Internal Reeving Hose Terminal Truck Auxiliary Valves

RETRACT (2 Port)

LP0084.eps

EXTEND (4 Port)

CLAMP ARMS Pressure: Return:

RELEASE ARMS Internal Reeving Hose Terminal

Revolving Connection

Truck Auxiliary Valves

LP0085.ill

EXTEND

RETRACT

Pressure: Return:

230444 Rev. 1

7

T 3.2-2

ROUBLESHOOTING

Hosing Diagram – Swing Circuit SWING RIGHT Boom Swing Drive Motor Swing Valve

SWING LEFT

Hose Reel Carriage Hose Terminal

LP0083.ill

Truck Auxiliary Valve

SWING LEFT

SWING RIGHT

Pressure: Return:

8

230444 Rev. 1

T 3.2-2

ROUBLESHOOTING

Hosing Diagram – Hoist Circuit

Hoist Cylinders

LOWER CARRIAGE SOLENOID ADAPTION

Mast Lowering Control Valve

Solenoid LP0082.ill

Truck Main Valve

Lower Carriage Cylinders LP0093.ill

HOIST UP

HOIST DOWN

Pressure: Return:

230444 Rev. 1

9

T 3.2-3

ROUBLESHOOTING

Hydraulic Schematic (without flow/pressure control valve) Clamp Valve G

Clamp Cylinders (4) Check Cartridge (1) Extend-Retract Cylinder OPEN

CLAMP

Hoist Cylinders (2)

RETRACT

EXTEND Hydraulic Fuse/Cushion (in cylinder)

Hoist Lowering Control Valve

Optional Lower Carriage Cylinders (2)

Swing Revolving Connection

4

3

2

1 Ports

Swing Valve

2

1

4

3

Swing Drive Motor RIGHT

LEFT

Counterbalance Cartridges (2)

Relief Cartridges (2) 4-Position Pressure Relief Valve Hose Reel

Optional Solenoid Valves (2)

Mast IHR Connections

G P

HOIST

REACH

SWING

CLAMP

Truck Valves (4) T

Truck Pump

Truck Relief

Truck Tank LP0187.ill

10

230444 Rev. 1

T 3.2-3

ROUBLESHOOTING

Hydraulic Schematic (with flow/pressure control valve) Clamp Valve G

Clamp Cylinders (4) Check Cartridge (1) Extend-Retract Cylinder

OPEN

Hoist Cylinders (2)

CLAMP

Swing Drive Motor Swing Valve

RETRACT

Hydraulic Fuse/Cushion (in cylinder)

EXTEND

4

3

2

1

Counterbalance Cartridges (2)

Ports

Relief Cartridges (2) Hoist Lowering Control Valve

Optional Lower Carriage Cylinders (2)

Swing Revolving Connection

RIGHT

LEFT

2

1

4

3 End Block Mast IHR Connections

Hose Reel

4

3

2

1

Flow/Pressure Control Valve

TP

Adjustable Relief Cartridge (1) Multi-Position Pressure Relief Valve

T

Removable Orifices (4) 4

3

2

1 G

Optional Solenoid Valves (2)

P HOIST

SWING

REACH

CLAMP

Truck Valves (4) T

Truck Pump

Truck Relief

Truck Tank

Adjustable Relief Cartridges (3)

LP0223.ill

230444 Rev. 1

11

T 3.3

ROUBLESHOOTING

Clamp Function

WARNING: Before removing hydraulic lines or components, relieve pressure in the Attachment hydraulic system. Turn the truck off and move the auxiliary control lever several times in both directions.

There are five potential problems that could affect the CLAMP and REACH functions: • Incorrect load handling. Refer to Operator’s Guide for suggested procedures.

• Incorrect hydraulic pressure or flow from the lift truck.

• External leaks.

• Worn/defective cartridge valves or cylinder seals.

• Damaged or worn clamp arms or bearings

3.3-1

Supply Circuit Test 1 Check the pressure supplied by the truck at the Clamp Valve. Pressure must be within the range shown in Specifications, Section 5.1. PRESSURE TO THE CLAMP MUST NOT EXCEED 2300 PSI (160 bar).

Pressure gauge on valve test port

1

2

Flow Meter

CLAMP Port

2 Check the flow volume at the Clamp Valve. Flow must be within the range shown in Specifications, Section 5.1.

3 Clamp on a load, holding the lever in the CLAMP position for a few seconds. Release the lever and check for external leaks at fittings, hoses, valve, revolving connection and cylinder rods.

3.3-2

Clamp Circuit Test

Clamp Valve

Top of Clamp Frame

1 Position the arms to mid-stroke. Turn the truck off and relieve system pressure by moving the CLAMP lever back and forth several times. Connect a 3000 psi (200 bar) pressure gauge to the test port on top of the Clamp valve.

2 Start the truck and clamp on a load, holding the lever in

LP0090.ill

Front View

the CLAMP position for a few seconds.

3 Release the lever and watch the pressure gauge: • If the pressure drop is less than 150 psi (10 bar) initially, and additional drop does not exceed 25 psi (1.7 bar) per minute, the problem is not hydraulic (see Section 3.3).

• If the pressure drop is more than 150 psi (10 bar) initially, and additional drop exceeds 25 psi (1.7 bar) per minute, the Clamp check valve may be faulty.

Replace the cartridge. If the pressure still drops as above, one or more of the cylinders requires service.

2 LP0092.ill

12

230444 Rev. 1

T 3.3-2

ROUBLESHOOTING

Clamp Circuit Test (Continued)

WARNING: Before removing hydraulic lines or components, relieve pressure in the Attachment hydraulic system. Turn the truck off and move the auxiliary control lever several times in both directions.

4 To test a single cylinder, isolate the other three by disconnecting the hoses to the cylinder rod ends (see illustration below). CAUTION: Plug the hose ends and cap the cylinder fittings before starting the truck.

5 Start the truck and clamp on a load, holding the lever in the CLAMP position for a few seconds.

6 Release the lever and watch the pressure gauge: • If the pressure drop is more than 150 psi (10 bar) initially, and additional drop exceeds 25 psi (1.7 bar) per minute, the cylinder under test is faulty and requires service (see Section 4.3).

• If the pressure drop is less than 150 psi (10 bar) initially, and additional drop does not exceed 25 psi (1.7 bar) per minute, one or more of the other cylinders is faulty and requires service.

Re-seal all cylinders (see Section 4.3), or pressurecheck the other cylinders as described above to isolate the faulty cylinder.

ISOLATING A SINGLE CYLINDER

Clamp cylinder under test (hoses connected)

CAUTION: Plug all disconnected hoses and cap corresponding cylinder fittings before starting truck.

6

Pressure gauge on valve test port

4 4 4

LP0108.ill

Front View

230444 Rev. 1

13

T 3.4

ROUBLESHOOTING

Reach Function

WARNING: Before removing hydraulic lines or components, relieve pressure in the Attachment hydraulic system. Turn the truck off and move the auxiliary control levers several times in both directions.

There are five potential problems that could affect the REACH function: • Incorrect load handling. Refer to Operator’s Guide for suggested procedures.

• Incorrect hydraulic pressure or flow from the lift truck.

• External leaks.

• Worn/defective cylinder seals.

• Damaged or worn boom arms or bearings.

3.4-1

Pressure Gauge

4

2

Flow Meter

Supply Circuit Test 1 Check the pressure supplied by the truck at the Reach cylinder. Pressure must be within the range shown in Specifications, Section 5.1. PRESSURE TO THE REACH CYLINDER MUST NOT EXCEED 2300 PSI (160 bar).

2 Check the flow volume at the reach cylinder. Flow must

'Tee' Fitting on cylinder rod end port

LP0107.ill

be within the range shown in Specifications, Section 5.1.

3 Actuate the REACH lever and extend or retract the

Reach Cylinder

boom fully, holding the lever in position for a few seconds. Release the lever and check for external leaks at fittings, hoses, revolving connection and cylinder rod. Correct any problems.

3.4-2

Reach Circuit Test

1

1 Retract the boom fully. Turn the truck off and relieve system pressure by moving the REACH control lever back and forth several times.

2 Disconnect the cylinder headend (EXTEND) hose and cap the end. Connect a drain hose to the cylinder headend fitting and route the hose to a drain bucket.

3 Start the truck and actuate the RETRACT control lever for 5 seconds: • If there is substantial hydraulic flow out of the drain hose, the reach cylinder is faulty and requires service (see Section 4.3).

• If there is no hydraulic flow out of the drain hose, the problem is not hydraulic (see Section 3.4 above)

LP0109.ill

14

230444 Rev. 1

T 3.5

ROUBLESHOOTING

Swing Function

WARNING: Before removing hydraulic lines or components, relieve pressure in the Attachment hydraulic system. Turn the truck off and move the auxiliary control levers several times in both directions.

There are five potential problems that could affect the swing function: • Incorrect load handling. Refer to the Operator’s Guide for suggested procedures.

• Incorrect hydraulic pressure or flow from the lift truck.

• External leaks.

• Worn or defective cartridge valves or drive motor.

• Damaged boom.

3.5-1

Supply Circuit Test Remove either of the tubing supply lines to the swing drive motor valve. Connect a pressure gauge and flowmeter by using a 'tee' fitting connected to the supply terminal.

1

Pressure Gauge

2

Flow Meter

Counterbalance Valve Cartridge (2)

1 Check the pressure supplied by the truck at the swing drive motor valve. Pressure must be within the range shown in Specifications, Section 5.1. PRESSURE TO THE SWING DRIVE CIRCUIT MUST NOT EXCEED 2300 PSI (160 bar).

2 Check the flow volume into the swing drive motor valve.

Flow must be within the range shown in Specifications, Section 5.1.

Swing Valve

Swing left and right fully, holding the lever in position for a few seconds. Release the lever and check for external leaks at fittings, hoses, valve and swing drive motor.

Correct any problems.

3.5-2

Relief Valve Cartridge (2)

Swing Circuit Test NOTE: The swing drive motor functions hydraulically similar to a hydraulic cylinder. An internal piston is forced up and down on a curved-spline shaft, causing boom rotation left or right.

3

Front View

3 Clamp and raise a maximum load and actuate the SWING LEFT control lever: • If the boom swings slowly or not at all, the SWING LEFT relief valve cartridge may be faulty (perform a similar test for the SWING RIGHT relief valve cartridge). Replace the cartridges as required. If the boom still swings slowly or not at all, the drive motor may be faulty.

Swing Drive Motor

4 Disconnect the SWING RIGHT tubing from the drive motor and cap the tubing end. Connect a drain hose to the drive motor fitting and route the hose to a drain bucket.

4

5 Start the truck and actuate the SWING LEFT control lever for 5 seconds: • If there is substantial hydraulic flow out of the drain hose, the drive motor is faulty and requires replacement (see Section 4.4-9).

• If there is no hydraulic flow out of the drain hose, the problem is not hydraulic (see Section 3.5 above)

230444 Rev. 1

Supply Tubing to Motor

LP0230.eps

15

T 3.6

ROUBLESHOOTING

Hoist Function There are five potential problems that could affect the hoist function on the mast: • Incorrect load handling. Refer to the Operator’s Guide for suggested procedures.

• Incorrect hydraulic pressure or flow from the lift truck.

• External leaks.

• Worn or defective mast control valve or cylinder seals.

Mast Lowering Control Valve

• Damaged or worn mast uprights, rollers, carriage.

3.6-1

Supply Circuit Test

4

1 Check the pressure supplied by the truck at the mast lowering control valve. Pressure must be within the range shown in Specifications, Section 5.1.

PRESSURE TO THE MAST MUST NOT EXCEED 2600 PSI (180 bar).

Cartridge

LP0123.ill

Hoist supply from truck main valve.

2 Check the flow volume into the mast lowering control valve. Flow must be within the range shown in Specifications, Section 5.1.

3 Raise the mast fully and hold the hoist control lever in the RAISE position for a few seconds. Release the lever and check for external leaks at fittings, hoses, valve and cylinder rods or retainers. Correct any problems.

Pressure Gauge

4 Lower the mast. If the mast exhibits problems during lowering, replace the lowering control valve cartridge. If the mast still exhibits problems, mast service is required (see Section 4.5).

3.6-2

Lower Carriage Circuit Test

Dual Solenoid Valve

1 Accomplish a mast supply circuit test as described in Section 3.6.1. Correct any problems.

2 Check the lower carriage solenoids for proper operation (see Section 3.7). For solenoid valve service, see Section 4.6. Correct any problems.

3 Raise a fully-loaded lower carriage (press button on HOIST control lever). If the carriage raises slowly or not at all, the cylinders are faulty and require service (see Section 4.3.)

Lower Carriage Cylinders

Hoist supply from truck main valve.

LP0186.ill

16

230444 Rev. 1

T S 3.7

ERVICE ROUBLESHOOTING

Electrical Circuit (Solenoid-equipped lower carriage) Lower carriage dual solenoid valves must work together.

The dual valve arrangement provides a positive lockout of the carriage not selected. Use the electrical schematic and diagram shown below and follow the steps:

4 Test for solenoid coil continuity by placing the ohmme-

1 Check the circuit fuses. NOTE: If equipped with a

ter test leads across the solenoid coil terminals (ohmmeter on Rx1 scale).

Power Bus/Relay, fuses and diodes are contained within the unit. Replace fuses if necessary.

2 Check for loose electrical connections at the control knob pushbutton, Power Bus/Relay (if equipped), truck fuse block power source, and solenoid coil terminal connections.

3 Disconnect the connections from the solenoid coil terminals. Use a voltmeter to determine if voltage is present at the electrical leads when the pushbutton is depressed.

• If there is an ohmmeter reading, the coil is good.

• If the coil is good, but the solenoid valve does not 'click' when the control knob button is depressed, the solenoid cartridge may be jammed. Service or replace the solenoid valve (see Section 4.6-1).

• If there is no ohmmeter reading, the coil is defective.

Replace the coil (See Section 4.6-2).

• If there is no current to the solenoid coil, troubleshoot the electrical circuit for opens or shorts.

• Check for current flow into and out of the Power Bus/ Relay. Replace the Power Bus/Relay if necessary.

• If there is current to the solenoid coils, test for coil continuity.

ELECTRICAL HOOKUP WITH POWER BUS/RELAY (recommended) Normally-Open Pushbutton

Dual Solenoid Valves

NOTE: Power Bus contains supply fuse (20A) and solenoid circuit power fuse (7.5A).

Switch Cable

Power Bus/ Relay –+

Dual Solenoid Valves HOIST Control Lever

PWR/KEY

–++–

Part No. 6020665

LP0202.ill

Pushbutton Switch

POWER BUS/ RELAY OUTPUT

INPUT

7.5A

7.5A

7.5A

7.5A

20A

4

3

2

1

PWR/KEY

Switched Unswitched

Truck Fuse Block Key Ground

Ground

230444 Rev. 1

12V Truck Battery

IC Trucks – Use chassis ground.

Electric Trucks – Use battery ground.

Recommended Wire Sizes (user-supplied): Power –12 AWG Key, Pushbutton – 18 AWG

LP0203.ill

17

S 4.1

ERVICE

Layer Picker Removal IMPORTANT: It is recommended that the Clamp Assembly be removed before removing the Mast/Boom Assembly.

1 Remove the Layer Picker Clamp Assembly as described in Section 4.2-1.

WARNING: Before removing hydraulic lines, relieve pressure in the truck hydraulic system. Turn the truck off and move the auxiliary control valve levers several times in both directions.

2 Disconnect the truck supply hoses to the hose reel. Tag hoses for reassembly. Plug the hoses and cap the hose reel fittings.

3 Disconnect the truck supply hoses to the mast internal reeving. Tag hoses for reassembly. Plug the hoses and cap the reeving hose terminals.

4 Disconnect the truck hoist supply hose. Plug the hose and cap the fitting.

2 Swing Right (CW) - lever back or down Swing Left (CCW) - lever forward or up

Solenoid adaption for lower carriage.

Solenoid Valves (2)

Front View

Hoist

3

3

Clamp

Extend

Open

Retract

4

4

Hoist

LP0185.ill

LP0079.ill

(To Truck Main Valve)

18

Back (Driver's) View

(To Truck Main Valve)

230444 Rev. 1

S 4.1

ERVICE

Layer Picker Removal (Continued)

5

5 Remove the counterweights (shown bottom of page), or remove the forks and lower carriage if equipped (shown opposite). NOTE: To remove the lower carriage, the truck may need to be driven onto ramps or blocked up to provide clearance: A) Disconnect the lower carriage cylinders supply hose at the 'tee' fitting. Plug the hose and cap the fitting.

B) Attach a hoist to the lift handles on the lower carriage counterweight and take up the slack.

C) Disconnect the cylinder headend anchor nuts (bottom of mast) from their mounts.

D) Remove the capscrews and remove the cylinder mounts from the mast. For reassembly, tighten the capscrews to 60 ft.-lbs. (80 Nm). Tighten the cylinder anchor nuts to 165 ft.-lbs. (225 Nm).

Headend Anchor Nuts (2) Cylinder Mounts (2)

LP0168.ill

Lower Carriage, Counterweight

E) Lower the carriage assembly out through the bottom of the mast.

For reassembly, reverse the above procedures with the following exceptions:

6

• Service cylinders if required (see Section 4.3).

• Inspect, lubricate and shim the lower carriage rollers using the same procedures as for the upper carriage (see Section 4.4, Step 10).

WARNING: Make sure overhead hoist and sling have a rated capacity of at least 4500 lbs. (2040 kg).

Mast

6 Attach an overhead hoist to the top of the mast as shown and take up the slack.

7 Disconnect the mast tilt cylinders or links. For reassembly, tighten the capscrews using the truck manufacturers torque specifications.

8 Disconnect the mast mounts and lift the mast/boom assembly away from the truck. Place the mast into a vertical mast stand, or lay the unit down on its back on a pallet. For reassembly, tighten the mast mount capscrews using the truck manufacturer's torque specifications.

Modified Tilt Cylinders or Links

Swing Boom

7

9 For reassembly, reverse the above procedures with the following exceptions: • Inspect the mast mount bearings or pin mounts for wear or damage. Replace or repair as necessary.

• Adjust the mast tilt cylinders or links so the mast is in vertical plumb during normal operation.

LP0078.ill

5 230444 Rev. 1

8

Mast Mounts, Capscrews

Counterweights

19

S

ERVICE

4.2

Clamp Assembly

4.2-1

Removal 4 Remove the two (2) mounting pin retainers and

1 Lower the Layer Picker Clamp Assembly onto a pallet.

mounting pins connecting the boom telescoping bars to the Clamp assembly. For reassembly, tighten the pin retainer capscrews to 20 ft.-lbs. (30 Nm).

WARNING: Before removing hydraulic lines, relieve pressure in the Attachment hydraulic system. Turn the truck off and move the auxiliary control valve several times in both directions.

OR

5 Disengage the boom assembly with bars still attached by backing the truck away from the Clamp assembly.

2 Disconnect the CLAMP function hoses (2) from the valve.

6 For reassembly, reverse the above procedures with the following exceptions:

or bulkhead fittings. Tag hoses for reassembly. Plug the hoses and cap the valve fittings.

• Inspect the boom telescoping bars and bearings for damage or wear (see Section 4.4-2).

3 Disconnect the boom cylinder rod end from the Clamp

• Inspect the mounting pins for wear and replace if necessary.

assembly bulkhead. For reassembly, tighten spherical retainer against hex washer, to a torque of 165 ft.-lbs.

(225 Nm). NOTE: Joint operates with a loose clearance.

3

Adjustable Stops (4)

• Apply chassis grease to the boom cylinder rod end spherical joints and to the Clamp mounting pins.

Boom Cylinder Rod End

Mounting Pins, Retainers

4 LP0039.ill

Layer Picker Clamp Assembly LP0076.ill

5

Hose Clamp

2

CLAMP OPEN

OP

EN

2

OP EN

CL AM P

Clamp Valve LP0077.ill

20

230444 Rev. 1

S 4.2-2

ERVICE

Arms – Removal and Installation The following procedure can be performed without removing the Clamp Assembly.

2

Hex Washer

Spherical Nut

1 Lower the Layer Picker Clamp Assembly onto a pallet until it just touches the surface.

2 Disconnect the cylinder rod end from the arm to be

3

removed. For reassembly, assemble the parts as shown. Tighten the spherical nut against the hex washer to 160 ft.-lbs. (220 Nm). NOTE: Rod end joint operates with a loose operating clearance. Secure locking cap with a new cotter pin.

WARNING: Keep hands and feet out from under contact pads and arms.

3 Slide the arm out of the Clamp frame. Do not damage the bearings when removing the arm.

4 For reassembly, reverse the above procedures with the following exceptions: • Inspect the arm bearings for wear and replace if necessary (see Section 4.2-5).

• Apply chassis grease to the cylinder rod end joint.

LP0091.ill

Locking Cap

Cylinder Rod End

Cotter Pin

LP0116.ill

Spherical Nut

4.2-3

Contact Pad – Rotation or Replacement

3

Hex Washer. NOTE: Beveled side faces arm lug

Contact Pad

NOTE: Contact pad surfaces that are worn or damaged over the entire pad area will require pad replacement. If only the lower surface is worn, the pads can be rotated 180 degrees and reinstalled.

1 Extend the arms fully.

2 Remove the capscrews and nuts fastening the contact pad to the arm base. For reassembly, tighten the capscrews to 65 ft.-lbs. (90 Nm).

NOTE: Reinstall any shims in original position to maintain same pad camber setting (see Section 4.2-4 to determine pad camber).

Pad capscrews, washers, nuts

2

3 Remove the contact pad. Rotate the pad 180 degrees or install a new pad.

4 For reassembly, reverse the above procedures.

LP0086.ill

230444 Rev. 1

21

S 4.2-4

ERVICE

Contact Pad Camber Adjustment The following procedures can be performed with the Layer Picker mounted on the truck.

1 Extend the arms to midstroke. Assure that the Clamp is not resting directly on the floor or pallet.

2 Measure the distance between the pads at the top and bottom. The difference between the two measurements is the pad camber.

3 Determine the camber adjustment required. (See recommended starting points in Table below).

Position arms to midstroke

1

4 Loosen the capscrews and nuts fastening the contact pad to the arm base. For reassembly, tighten the capscrews to 65 ft.-lbs. (90 Nm).

Positive Camber (top of pads lean out)

NOTE: It is not necessary to remove the capscrews and nuts to insert the shims.

3

5 Install shims as required. Installing shims at the bottom of the pad provides positive camber (top of pad leans out).

CAUTION: Use an equal number of shims on each contact pad. Pad camber must be the same on all pads for proper load handling.

Load

2

FOR MINIMUM POSITIVE CAMBER:

Opposite Pads - Lower Tier

CANNED / BOTTLED / DENSE CASE GOODS

Neutral-to-Positive

BOXED LIGHT CASE GOODS

Neutral

LP0139.ill

Measure from pad centers

LP0136.ill

No shims

Arm Contact Pad

FOR MAXIMUM POSITIVE CAMBER:

4

1/8-in. (3.2 mm) Bottom Shim(s)

5

LP0086.ill

Shims (if used) Front View

22

Pad Capscrews and Nuts (4 per arm)

LP0137.ill

IMPORTANT: Shim all four (4) pads equally.

230444 Rev. 1

S 4.2-5

ERVICE

Arm Bearing Replacement NOTE: Replace all arm bearings if wear is found in one arm bearing.

1 Remove the four (4) clamp arms as described in Section 4.2-2.

2 Remove the internal Teflon retaining rings from the clamp frame. NOTE: Use Cascade brass tool 674424 (or a thin blade screwdriver) to remove the rings.

Avoid damaging the grooves in the frame.

3 Pull the bearings out of the frame.

4 For reassembly, reverse the above procedures with the following exception: • Use new bearing retaining rings when installing the new bearings.

Clamp Frame

Arm Bearings (4)

Retaining Rings (8)

3

2 LP0127.ill

Front View

Bearing Retainer Ring

2 Cascade Tool Part No. 674424

LP0134.ill

230444 Rev. 1

23

S 4.2-6

ERVICE

Clamp Valve Removal, Installation WARNING: Before removing hydraulic lines, relieve pressure in the Attachment hydraulic system. Turn the truck off and move the auxiliary control valve several times in both directions.

Clamp Valve

1

CLAMP Hoses or Tubes (2)

1 Disconnect the two CLAMP function hoses or tubes from the valve. Plug the hose or tube ends and tag for reassembly.

2 Disconnect the eight (8) cylinder supply hoses from the valve. Plug the hose ends and tag for reassembly.

3 Remove the capscrews fastening the valve to the top of the boom. For reassembly, tighten the capscrews to 65 ft.-lbs. (90 Nm).

4 Service the valve as described in Section 4.2-7.

5 For reassembly, reverse the above procedures.

IMPORTANT: Assure that hoses are connected as shown (see hydraulic schematic, Section 3.2-3).

2

Front View

4.2-7

LP0126.ill

Cylinder Supply Hoses (8)

Clamp Valve Service IMPORTANT: Service the valve in a clean work area.

1 Remove the valve from the Clamp as described in Clamp Check Valve Cartridge

Section 4.2-6.

2 Remove the check valve cartridge from the valve and remove the O-rings and back-up rings.

3 Remove the fittings from the valve.

4 Clean all parts with solvent.

5 For reassembly, reverse the above procedures with the

3

2

following exceptions: • Replace O-rings and back-up rings on check valve cartridge as shown.

OP

EN

CL

AM

P

Body

O-Rings (3)

LP0094.ill

RC0311.ill

Back-Up Rings (3)

CLAMP CHECK VALVE CARTRIDGE

24

230444 Rev. 1

S 4.3 4.3-1

ERVICE

Cylinders – Clamp & Reach

Reach Cylinder (1) Clamp Cylinders (4)

Cylinder Removal and Installation NOTE: The following procedure can be performed with the Layer Picker mounted on the truck and the clamp arms remaining on the Attachment.

1 Close the arms fully.

WARNING: Before removing hydraulic lines, relieve pressure in the Attachment hydraulic system. Turn the truck off and move the auxiliary control valves several times in both directions.

2 Disconnect the hydraulic hoses from the cylinder to be removed. Plug the hoses and cap the cylinder ports.

Tag hoses for reassembly.

3 Disconnect the cylinder head end from the boom or clamp frame by removing the cotter pin, locking cap and spherical nut. IMPORTANT: Make sure that the inner and outer roll pin is in place when reinstalling to keep the cylinder shell from rotating while tightening.

4 Disconnect the cylinder rod end from the clamp frame or arm lug by removing the cotter pin, locking cap, spherical nut and hex washer.

LP0081.ill

5 Slowly slide the Clamp arms or Clamp frame outward 3 LP0089.ill

in. (75 mm) to remove the cylinder.

CAUTION: Use care not to disengage the clamp arms from the clamp frame, or the boom arms from the boom when removing the cylinders.

6 Service the cylinder as described in Section 4.3-2.

7 For reassembly, reverse the above procedures with the following exceptions for the cylinder anchors: • Lubricate threads with chassis grease and assemble cylinder anchors as shown.

REACH CYLINDER Clamp Frame

Cylinder

4

• Install hex beveled washer on cylinder rod end.

NOTE: Assure beveled side of washer faces mount (see illustration).

• Tighten spherical nut against hex washer to 160 ft.lbs. (220 Nm). NOTE: Joints function with a loose operating clearance. Lubricate with chassis grease.

Roll Pins

• Install locking cap and secure with new cotter pin.

Locking Cap

7 LP0164.ill

Spherical Nut

230444 Rev. 1

Hex Washer (NOTE: beveled side faces arm lug)

3

3

Clamp Frame

Boom Frame

Cylinder

Arm Lug

4

Cylinder Rod End

Cotter Pin

LP0087.ill

CLAMP CYLINDER (Typical) Arm LP0088.ill

25

S 4.3-2

ERVICE

Cylinder Disassembly

1

1 Clamp the cylinder in a soft-jawed vise at the extreme head end only. Do not clamp on the shell.

2

2 Unscrew and remove the retainer using a claw-type spanner wrench as shown. (Cascade Part No. 678598)

3 Remove the rod/piston assembly from the cylinder.

4 To remove the piston, clamp the rod assembly in a vise on the wrench flats as shown. CAUTION: Do not clamp on the cylinder rod sealing surface.

5 Remove the piston nut and remove the piston from the

4

cylinder rod.

6 Place the piston or retainer in a soft-jawed vise to remove the seals. Pry the seals or O-rings up with a brass seal removal tool (Cascade Part No. 674424) and cut the seals to remove them. CAUTION: Do not scratch seal grooves.

CL1072.ill

5

CL1073.ill

4.3-3

Cylinder Inspection • Inspect the rod, piston and retainer for nicks or burrs.

Minor nicks or burrs may be removed with 400-grit emery cloth. If they cannot be removed, replace the parts.

• Inspect the cylinder bore and remove any minor nicks or burrs with a butterfly. If they cannot be removed, replace the part.

• Inspect the outside of the shell for any deformities or cuts that could impair performance or cause leaks under pressure. If necessary, replace the part.

6

• Inspect the spherical nuts and hex washer for wear

SS0062.ill

and replace as necessary.

Piston Nut Spherical Nut, Locking Cap

Rod Piston

Shell

Rod End Hex Washer Spherical Nut, Retainer Locking Cap

CL1305.ill

26

230444 Rev. 1

S 4.3-4

ERVICE

4

Cylinder Reassembly 1 Lubricate all new seals and O-rings with petroleum jelly.

2 Note the direction of the U-cup seals. Pressure seals must be installed with the lip toward the high pressure side of the cylinder.

3

Chamfer angle CL1070.ill

3 Polish the piston and retainer chamfer angles with 400grit emery cloth to ease seal installation.

4 Install a new seal and O-ring on the piston. Install the piston seal from the rod end side of the piston by hooking one side into the groove and carefully working the seal over the piston as shown.

5 Install a new rod seal, back-up ring, and exclusion seal in the retainer I.D., and a new O-ring and back-up ring on the retainer O.D. as shown. NOTE: Use internal seal installation tool (Cascade Part No. 599512) to ease seal installation. If installing by hand, form the seal into a 'kidney' shape and position into the internal groove. Use finger pressure to smooth the seal into the groove.

Stop Fins Cylinder Shell IMPORTANT: Loader must not contact thread relief chamfer

RC0320.ill

7

Piston/Seal Loader

6 Apply petroleum jelly to the piston internal O-ring and install the piston on the rod. Tighten the nut to 65 ft.-lbs.

(85 Nm).

7 Place the piston loader into the cylinder shell.

IMPORTANT: The loader must cover all of the shell threads but not contact the thread relief chamfer. If necessary, trim the stop fins for a correct fit. The piston will not enter the shell if the loader contacts the thread relief chamfer.

Piston/Rod Assembly

8

8 Apply a thick film of petroleum jelly to the piston, shell and loader. Using a rubber mallet, tap the piston/rod assembly into the cylinder shell.

9 Place the retainer loader over the rod end threads.

Apply petroleum jelly to the retainer I.D. and slide the retainer onto the rod. Remove the loader and screw the retainer into the shell. Tighten the retainer to 75–125 ft.lbs. (100–170 Nm).

9 Retainer Seal Loader Retainer CL1074.ill

6

4

Piston U-Cup Pressure Seal Note seal direction Back-Up Ring (2) O-Ring

Rod U-Cup Pressure Seal Note seal direction Back-Up Ring O-Ring

5

Back-Up Ring Exclusion Seal

CL1304.ill

230444 Rev. 1

27

S 4.4

4.4-1

ERVICE

Boom/Carriage Assembly

5

Removal

6

IHR Hoses (4)

Hose Reel Hoses (2)

NOTE: The Boom/Carriage Assembly may be removed through the bottom of the mast as a complete unit, to perform carriage inspection and service.

1 Remove the Layer Picker Clamp Assembly as described in Section 4.2-1.

2 Remove the Lower Carriage (if equipped) as described in Section 4.1

3 Raise the mast until the inner upright extends approximately 8 in. (20 cm) out the top of the mast.

4 Position blocks between the inner and outer upright, or chain the mast uprights together at the top of the mast.

Lower the mast until the inner upright is securely blocked in position.

WARNING: Before removing hydraulic lines, relieve pressure in the Attachment hydraulic system. Turn the truck off and move the auxiliary control valves levers several times in both directions.

8

Lift Chain Anchors (2) IHR Hose Terminals

Hose Reel Terminal Up-Connection

5 Disconnect the four (4) internal reeving hoses at the carriage hose terminals. Tag hoses for reassembly.

Plug hoses and cap terminal fittings.

LP0111.ill

6 Disconnect the two (2) hose reel hoses at the upconnection hose terminals. Tag hoses for reassembly.

Plug hoses and cap terminal fittings.

Back (Driver's) View

28

230444 Rev. 1

S 4.4-1

ERVICE

Removal (Continued) WARNING: Make sure overhead hoist has a rated capacity of at least 2500 lbs. (1125 kg).

7 Attach an overhead hoist to the boom-carriage assembly as shown and take up the slack. Assure that the chains or straps are positioned properly.

8 Disconnect the mast lift chains from the carriage by removing the snap rings and sliding the chain anchors out from the rear of the carriage.

7

9 Lower the overhead hoist until the boom-carriage assembly clears the bottom of the mast inner upright.

10 For reassembly, reverse the above procedures with the following exceptions: • Inspect carriage as described in Section 4.4-10.

• Lubricate upright rails with general-purpose chassis lube (Cascade Part Number 599474) as shown.

• Assemble shims and load rollers on carriage stub shafts. Shims should be installed to provide a total side-to-side clearance of 1/16 in. (1.5 mm) maximum at the tightest point throughout the travel of the carriage. Use an equal number of shims per side.

• Adjust the carriage side thrust rollers for unrestricted clearance along the travel of the carriage. Turn the eccentric base of the thrust roller toward the upright rail to decrease the clearance (see illustration).

Tighten the capscrews to 75 ft.-lbs. (100 Nm).

• Check and adjust the lift chains as described in Section 4.5-1.

LP0110.ill

9

Boom-Carriage Assembly

CARRIAGE SIDE THRUST ROLLERS

IMPORTANT: Adjust side-thrust roller base toward rail in direction shown.

10

CARRIAGE & MAST LOAD ROLLERS Lubricate areas indicated by heavy line full length of each mast upright.

Carriage Inner Upright

230444 Rev. 1

Outer Upright Load Rollers

MA0622.ill

29

S 4.4-2

ERVICE

Boom Reeving Service

1

WARNING: Before removing hydraulic lines, relieve pressure in the Attachment hydraulic system. Turn the truck off and move the auxiliary control valves several times in both directions.

4 1

Hose Clamps

Loop

NOTE: Boom may be equipped with tubing in place of hoses.

1 Remove the hose clamps that secure the hoses to the clamp frame and boom. For reassembly, tighten the hose clamp capscrews to 8 ft.-lbs. (10 Nm).

2

Boom reeving hoses

2 Remove and replace the hoses one at a time. Tag ends for reassembly.

3 Inspect the hose sheaves and bearings for damage. If necessary, remove the snap rings and washers and remove and replace the hose sheaves.

4 For reassembly, reverse the above procedures with the following exceptions: • Form a loop in the CLAMP/OPEN circuit hoses as shown to allow for extension and retraction of the boom.

3

• Refer to Hydraulic Schematic, Section 3.2-3, to assure correct hose/tubing hookup.

4.4-3

Hose Sheeves

Telescope Bars, Bearings NOTE: The following procedures require that the Clamp Assembly be removed from the boom.

LP00115.ill

1 Remove the Layer Picker Clamp Assembly as described in Section 4.2-1.

2 Slide the telescope bars (2) out of the boom. Inspect the bars for straightness, and for nicks or protrusions that could damage the bearings. Replace if necessary.

3 Remove the bearing retaining rings from the clamp frame and pull the bearing tubes out of the boom. Replace the bearings if worn or damaged.

Bearing (2)

3 2

Telescope Bar (2)

4 For reassembly, reverse the above procedures with the following exceptions: • Lubricate bearings if required.

3

Bearing Retainer Ring

LP0114.ill

Cascade Tool 674424

30

LP0135.ill

230444 Rev. 1

S 4.4-4

ERVICE

Revolving Connection – Removal, Installation

Retainer Bracket

2

NOTE: The following procedures can be performed with the Layer Picker mounted on the truck.

WARNING: Before removing hydraulic lines, relieve pressure in the Attachment hydraulic system. Turn the truck off and move the auxiliary control valves several times in both directions.

Revolving Connection

Boom Hoses/ Tubing

3

Mounting Capscrews (2)

1

1 Disconnect the hoses and tubing from the revolving connection. Tag hoses and tubes for reassembly.

2 Remove the retainer bracket for the shaft end block. For reassembly, tighten the capscrews to 15 ft.-lbs. (20 Nm).

3 Remove the two (2) capscrews and remove the revolving

1

connection from the top of the boom as shown. For reassembly, tighten the capscrews to 20 ft.-lbs. (30 Nm).

LP0096.ill

4 Service the revolving connection as described in Section 4.4-6.

5 For reassembly, reverse the above procedures with the following exceptions: • Position Revolving Connection shaft so stamped port numbers on end block are on same side as similar port numbers on body (see illustration in 4.4-5).

Back (Driver's) View

Revolving Connection Service

Shaft/End Block

1

4

2

4.4-5

Top of Boom

3

IMPORTANT: Service the revolving connection in a clean work area.

1 Remove the revolving connection from the top of the boom as described in Section 4.4-5.

2 Remove the snap ring from the shaft end and withdraw the shaft from the body.

CAUTION: Remove all burrs and paint from exposed shaft surface prior to removal from body. Burrs or paint chips pulled through bore will permanently damage valve body.

O-Rings, Back-Up Rings

3

3 Remove the O-rings and back-up rings from the shaft.

4 Remove the fittings from the body and shaft.

5 Clean all parts with solvent and air-blow dry.

6 Inspect the body and shaft for grooves and scratches.

Body

If worn, replace the parts.

2

7 For reassembly, reverse the above procedures with the

1

following exceptions: • Install new O-rings and back-up rings on the shaft as shown.

• Apply a thick film of petroleum jelly to the seals, shaft and body ID.

4

• Use a seal/shaft loader when installing the shaft into the body. Rotate the body to ease installation.

LP0097.ill

Snap Ring

Front View

230444 Rev. 1

3

2 31

S 4.4-6

ERVICE

Swing Valve – Removal, Installation

SWING supply hoses from hose reel

NOTE: The following procedures can be performed with the Layer Picker mounted on the truck.

WARNING: Before removing hydraulic lines, relieve pressure in the Attachment hydraulic system. Turn the truck off and move the auxiliary control valve handles several times in both directions.

2

Tubing to Swing Drive Motor

SWING Valve

1 Disconnect the tubing between the hose terminal upconnection and the swing valve.

2 Remove the two (2) bolts fastening the valve and hose terminal clamp to the carriage. Remove the valve. For reassembly, tighten the bolts to 15 ft.-lbs. (20 Nm).

3 Service the Swing Valve as described in Section 4.4-7.

4 For reassembly, reverse the above procedures.

4.4-7

Hose Terminal Clamp

2

Swing Valve Service IMPORTANT: Service the Valve in a clean work area.

1 Remove the Valve from the side of the mast carriage as described in Section 4.4-6.

2 Remove the cross-over relief cartridges (2).

3 Remove the counterbalancecartridges (2).

4 Remove the fittings from the valve.

5 Clean all parts with solvent and air-blow dry.

6 For reassembly, reverse the above procedures with the

LP0101.ill

Up-Connection Tubing, Bracket

Tubing to Valve

1

Back (Driver's) View

following exceptions:

3

• Replace the cartridges or O-rings as shown.

O-Rings (2)

Counterbalance Cartridges (2)

Valve Body RC0456.ill

Back-Up Rings (2) CROSSOVER RELIEF CARTRIDGE Adjustment Screw

O-Rings (3)

4

LP0232.ill

2

RC0802.ill

Back-Up Rings (3)

Cross-over Relief Cartridges (2)

COUNTERBALANCE CARTRIDGE

32

230444 Rev. 1

S 4.4-8

ERVICE

Boom Replacement

EARLY TYPE

NOTE: The following procedure requires that the Clamp Assembly be removed from the swing boom.

8

1 Remove the Clamp as described in Section 4.2-1.

2 Remove the hose clamps, hoses/tubing, hose sheaves

Boom Top Mount Capscrews (12) Swing Drive Motor

6

(if equipped) as described in Section 4.4-2.

3 Remove the telescope bars and bearings as described in Section 4.4-3.

4 Remove the swing revolving connection as described in Section 4.4-4.

5 Disconnect the shock absorber rod (if equipped) from the boom by removing the pivot pin.

6 Securely attach an overhead hoist to the boom

Boom

assembly and take up the slack.

7 Remove the six (early) or seven (later) capscrews that fasten the lower boom to the stubshaft (early) or swing drive motor(later). For reassembly, use a cross-pattern and tighten the capscrews to 80 ft.-lbs. (110 Nm).

8 Remove the twelve (12) capscrews that fasten the boom to the top of the swing drive motor. For reassembly, use a cross-pattern and tighten the capscrews to 160 ft.-lbs. (215 Nm).

7

9 Lift the boom assembly away from the swing drive motor.

10 For reassembly, reverse the above procedures.

Stubshaft Capscrews (6)

LP0104.ill

LATER TYPE

8

Boom Top Mount Capscrews (12) Swing Drive Motor

6 Boom

7 230444 Rev. 1

Bottom Mount Capscrews (7)

LP0259.eps

33

S 4.4-9

ERVICE

Swing Drive Motor Replacement

EARLY TYPE Mounting Capscrews (4)

CAUTION: There are no field-servicable components in the Swing Drive Motor. Replace as a complete assembly.

1 Remove the Clamp as described in Section 4.2-1.

2 Remove the Boom as described in Section 4.4-8.

3 Disconnect and remove the tubing between the swing valve and the swing drive motor.

4 Remove the four (4) large capscrews that secure the

SWING Valve

4

Mast Carriage

Spacer Blocks

5

Swing Drive Motor

drive motor to the carriage. For reassembly, use a cross-pattern when tightening. Double-torque the capscrews by tightening to the final torque value of 450 ft.-lbs. (610 Nm), backing off 1/2 turn, and immediately retightening to 450 ft.-lbs. (610 Nm).

5 Remove the swing drive motor.

6 For reassembly, reverse the above procedures.

3

Drive Motor Tubing

LP0105.ill

LATER TYPE Swing Drive Motor

Drive Motor Tubing

5

SWING Valve

Mast Carriage

3

Mounting Capscrews (4)

34

4

LP0260.eps

230444 Rev. 1

S

ERVICE

4.4-10 Carriage with all Roller Bearings –

Inspection, Service NOTE: Carriage service requires removal of the Clamp Assembly and Boom-Carriage Assembly.

1 Remove the Clamp Assembly as described in Section 4.2-1.

2 Remove the Boom-Carriage Assembly as described in Section 4.4.1.

3 Inspect all thrust roller bearings for excessive wear, flat spots, cracks, or bearing roughness. Replace rollers if required. Keep track of shim locations.

4 Inspect all load roller bearings for excessive wear, flat

6 Inspect the roller stubshafts. Replace the carriage if cracks are found on any of the stubshaft bases, or if the roller bearing bores are loose on the stubshafts.

CAUTION: Reparing cracks by welding must be approved by Cascade. Contact Cascade Service for approval and recommended welding procedures.

7 For reassembly, reverse the above procedures with the following exceptions: • Measure and adjust (if required) side-to-side clearance within the mast (see Section 4.4-1).

spots, cracks, or bearing roughness. Replace rollers if required. Keep track of shim locations.

5 Inspect all welds on the carriage including sideplates, horizontal bars, thrust roller mounts and chain anchor mounts. Repair any damaged welds, or replace the carriage (see CAUTION statement).

Thrust Rollers (8)

3

6 Weld Areas

Roller Stubshafts (6)

5

4

Load Rollers (2) with Retainer

Retainer

Shims

4 Additional Thrust Rollers (4) on heavy-duty carriage

230444 Rev. 1

3

Load Rollers (4) without Retainer

LP0102.ill

Back (Driver's) View

35

S

ERVICE

4.4-11 Carriage with Sliding and

Roller Bearings – Inspection, Service NOTE: Sliding thrust bearings, stubshafts and shims may be replaced with the carriage in place. Load roller bearings and shim replacement require that the carriage be removed from the mast.

1 Remove the Clamp Assembly (if necessary) as described in Section 4.2-1.

2 Remove the Boom-Carriage Assembly (if necessary) as described in Section 4.4.1.

3 Inspect all sliding thrust bearings for excessive wear or

6 Inspect all stubshafts for wear. Replace the sliding bearing stubshafts if new sliding bearing blocks are loose on the stubshafts. Tighten the stubshaft capscrews to 75 ft. lbs (85 Nm). If cracks are found on any of the other roller stubshaft bases repair any damaged welds, or replace the carriage (see CAUTION statement).

CAUTION: Reparing cracks by welding must be approved by Cascade. Contact Cascade Service for approval and recommended welding procedures.

flat spots. Replace sliding bearings if required. Keep track of shim locations.

7 For reassembly, reverse the above procedures with

4 Inspect all roller load bearings for excessive wear, flat

• Measure and adjust (if required) side-to-side clearance within the mast (see Section 4.4-1).

spots, cracks, or bearing roughness. Replace rollers if required. Keep track of shim locations.

the following exceptions:

5 Inspect all welds on the carriage including sideplates, horizontal bars or tubes, and chain anchor mounts.

Repair any damaged welds, or replace the carriage (see CAUTION statement).

Stubshaft Capscrews (4)

3

Thrust Bearing Shims, Retaining Capscrew

Load Roller Stubshafts (6)

6

Thrust Bearing Stubshafts (4)

Weld Areas

4

Sliding Thrust Bearings (4)

5

LP0237.ill

Back (Driver's) View

36

Load Roller Shims

4

Load Rollers (6)

230444 Rev. 1

S 4.5

ERVICE

Layer Picker Mast WARNING: Never work on the mast with a load on the forks or attachment. Use supports or blocking when working with the mast raised. Do not allow anyone near the truck control handles per ANSI B56.1

4.5-1

Inspection and Adjustments NOTE: The following procedures can be performed with the Layer Picker mounted on the truck.

Pry here to check side-to-side clearance of mast uprights.

Carriage Load Roller

NOTE: Use a similar procedure to check carriage.

1/16 in.

(1.5 mm) Max.

Mast Upright, Roller Inspection Extend the mast to its full height and assure that the uprights and carriage extend freely and smoothly without binding. If problems are encountered, first check for proper lubrication (see Periodic Maintenance, Section 2). Next check the side-to-side clearance of the inner upright and the carriage as follows:

Mast Load Roller

Mast Side-Thrust Rollers

• Pry between the upright or carriage and its corresponding load roller so that the opposite load roller is tight against the upright.

LP0119.ill

• Measure the clearance for the pair of rollers at 'XXX' as shown. If the clearance is not correct, the mast or carriage requires service (see Section 4.5-9).

NOTE: Make sure that the mast thrust plugs and sidethrust rollers do not interfere with the measurement when checking the side-to-side clearance.

RECOMMENDED CLAMP UNDERCLEARANCE

Chain Tension Chains must be under equal tension to ensure proper load distribution and mast operation. Inspect the lift chains for equal tension as follows: Raise the unloaded mast to put the chains under tension. Press the center of a strand of chain with the thumb, then press at the same place on the other chain of the pair. Each chain in a pair should have equal 'give'. If they do not, adjust the chains as described below.

Inspect the chains for wear or defects as described in Section 4.5-2.

Adjust until Clamp just touches floor or ground.

LP0118.ill

Chain Adjustment The lift chains should be adjusted for the clamp clearance required above the floor for your specific application.

Adjust chains as follows:

• Adjust one chain to achieve the specified contact pad height above the floor as shown.

• Adjust the other chain to achieve equal chain tension (see above). Tighten the chain anchor jam nuts together to 60 ft.-lbs. (80 Nm).

• Raise and lower the mast several times to confirm the adjustments. Assure carriage is not hitting stops.

230444 Rev. 1

Chain Anchors, Double Jam Nuts

LP0117.ill

37

S 4.5-2

ERVICE

Chain Inspection NOTE: The following procedures can be performed with the Layer Picker mounted on the truck.

Wear or Damage Inspect the chains for wear or defects as listed below (see illustration). If wear or defects are found in either chain, replace both strands of chain.

• Check for severe rust and corrosion.

CRACKED SIDE PLATES

• Check for cracked side plates.

• Check for tight joints. NOTE: If suspected cause is rust or corrosion, joints may be loosened with penetrating oil followed by SAE 40 wt. oil. If tightness is caused by bent pins, bent side plates or peened plate edges, replace both chains.

• Check for protruding or turned pins.

• Check for excessive chain side wear. NOTE: Excessive side wear may be caused by misaligned sheaves or other mast components. Correct any misalignment found.

TIGHT PIN JOINTS

• Check for worn, broken or misaligned chain anchors.

Replace or adjust as required.

Lubrication Clean and lubricate the chains with SAE 40 wt. oil or heavy duty load grease (Cascade Part No. 200867). Refer to Periodic Maintenance, Section 2.

Chain Stretch

PEENED PLATE EDGES

A

A

Use a Chain Wear Scale (Cascade Part No. 661923) to check for excessive chain stretch. Raise the Layer Picker without a load about 1 ft. (30 cm) to put tension on the chains. Use the instructions printed on the scale and measure the chains as shown. If either chain is beyond the wear limit, replace both chains. Adjust as required.

Chain Wear Scale (Part No. 661923)

PROTRUDING PINS

MA0065.ill

A

A

TURNED PINS LP0120.ill

New Chain

38

Stretched Chain

230444 Rev. 1

S 4.5-3

ERVICE

Lift Chain Service 1 Lower the Layer Picker completely, then raise approximately 6 in. (15 cm) off the floor. Place blocking under the boom-carriage assembly as shown, or use a safety chain to secure the carriage within the mast.

WARNING: To avoid possible injury, assure that the boom-carriage assembly is properly supported before disconnecting the mast lift chains. Use blocking or chains as necessary.

2 Lower the carriage until the mast lift chains are slack.

Assure that the carriage is properly supported.

3 Remove the pins that fasten the chains to the lower chain anchors on the carriage.

4 Remove the pins that fasten the chains to the upper

Mast

chain anchors on the mast outer upright. Roll the chains out of the sheaves to remove. NOTE: New chains are pressure-lubricated at the factory. Do not wash, sand blast, etch, steam clean, or paint the chains.

5 For reassembly, reverse the above procedures with the following exceptions: • Inspect chain anchors and mounts for wear or damage and replace if necessary.

Chain Sheaves (on inner upright)

4

Upper Chain Anchor

3

Lower Chain Anchor

• Inspect chain sheaves/bearings for wear or damage and replace if necessary.

• Use new pivot pins and cotter pins when installing new chains.

• Adjust chains as described in Section 4.5-1.

Carriage

NOTE: Boom Assembly not shown for clarity

Wood or Metal Blocking

LP0121.ill

230444 Rev. 1

39

S 4.5-4

ERVICE

Mast Reeving Service

4

NOTE: The following procedures can be performed with the Layer Picker mounted on the truck.

Internal Reeving Hose sheeves

1 Lower the Layer Picker fully.

WARNING: Before removing hydraulic lines, relieve pressure in the Attachment hydraulic system. Turn the truck off and move the auxiliary control valve levers several times in both directions.

2 Disconnect the internal reeving hoses from the hose terminals on the back of the mast.

3 Disconnect the hoses from the carriage and cap the fittings. Remove the hoses by pulling them through the sheaves.

4 Remove the capscrews and remove the hose sheaves (2) from the chain sheave mounting pin shafts. Keep track of any spacer washers between the sheaves. For reassembly, tighten capscrews to 65 ft.-lbs. (88 Nm).

5 For reassembly, reverse the above procedures with the following exceptions: • Inspect the hoses and sheeves for wear or damage.

Replace the parts as required.

• Adjust mast hose terminal brackets (if necessary) to remove any slack in hoses. Tighten capscrews to 38 ft.-lbs. (50 Nm). Tighten all hose fittings.

• Raise and lower Layer Picker several times to assure proper hose tracking. Use white tracer line on hoses to detect twisting and adjust hose ends if necessary.

3

2

Carriage IHR connection

NOTE: RH reeving only shown for clarity. Use same procedures to service LH reeving.

Mast IHR connection

5

Adjustable Hose Terminal Mounting

LP0131.ill

Front View

40

230444 Rev. 1

S 4.5-5

ERVICE

Hoist Cylinder Removal

2

NOTE: The following procedures can be performed with the Layer Picker mounted on the truck.

Snap Ring

Mast Inner Upright

WARNING: To avoid possible injury, assure that the mast inner upright is properly supported before disconnecting hoses. Use wood blocking or safety chains as necessary.

Shim(s)

1 Raise the Layer Picker until the mast inner upright is about 2 ft. (50 cm) above the outer upright. Block or chain the inner upright securely to prevent it from moving.

2 Remove the snap rings that fasten the hoist cylinder rods to the inner upright. Lower the cylinder rods to disengage them from the inner upright.

IMPORTANT: Keep track of shims on the cylinder rod.

Shims must be installed in their original location to assure that the mast extends without skewing.

1

Wood Blocking

3 Disconnect the cylinder supply hoses at the cylinder ports. Remove the special long fittings from the cylinder ports. Plug the hoses and cylinder ports.

4 Lift the cylinders from their base mounts and angle inward. Remove the cylinders through the gap at the top of the mast uprights as shown. Service the cylinders as described in Section 4.5-5.

5 For reassembly, reverse the above procedures with the following exceptions: • Bleed the cylinders before lifting a load (see Section 4.5-6 below).

4.5-6

Hoist Cylinder Bleeding WARNING: Air trapped in the cylinders can compress on the first extension which could rupture the cylinder shell and cause serious bodily injury or property damage.

3

Hoist Cylinder Hydraulic Connections

1 Extend the mast without a load to 90 percent of full stroke, then lower completely. Repeat three times.

2 Extend the mast without a load using 50 percent of full engine speed, then build full system pressure at the end of the stroke. For electric trucks, limit control valve movement to achieve 50 percent extension.

Lower the mast completely. Repeat four times.

3 Cycle the mast with a half load (50 percent of mast rated capacity) through full cylinder extension. Repeat two times while checking for smoothness. Repeat the steps if cylinder extension is not smooth.

LP0132.ill

230444 Rev. 1

41

S 4.5-7

ERVICE

Hoist Cylinder Service

Shell

Claw-Type Spanner

1 Remove the cylinder as described in Section 4.5-5.

2 Unscrew and remove the retainer using a claw-type

2

spanner wrench as shown. (Cascade Part No. 678598)

3 Remove the plunger/piston assembly from the shell.

4 Remove the hydraulic fuse / lowering cushion valve

Strap MA0814.ill Wrench

components from the cylinder port.

5 Inspect all components as follows: • Inspect the plunger, piston and retainer for nicks or

Retainer Plunger

burrs. Minor nicks or burrs may be removed with 400-grit emery cloth. If they cannot be removed, replace the parts.

3 Snap Ring

• Inspect the cylinder bore and remove any minor Plunger

nicks or burrs with a butterfly. If they cannot be removed, replace the part.

• Inspect the outside of the shell for any deformities or

Plunger Wiper Retainer

cuts that could impair performance or cause leaks under pressure. If necessary, replace the part.

9 6 Remove the piston (if necessary) by using a strap-type wrench on the plunger while turning the piston with a pin-type spanner wrench (Cascade Part No. 679917).

See illustration. CAUTION: Do not clamp on the plunger surface.

Plunger Seal Back-Up Ring

Retainer O-Ring

Shell

7 Turn the piston until the snap wire end is visible through the hole. Use a screwdriver to start the wire end out the hole. Turn the piston to feed the wire out.

8 Pull the piston from the plunger.

9 Replace the retainer and piston seals, back-up rings, O-rings, and bearing. Lubricate the new seals with petroleum jelly prior to installation. Note the direction of the seals. Pressure seals must always be installed with the lip toward the high pressure side of the cylinder.

10 Install the retainer on the plunger. Install the plunger/ piston assembly into the cylinder shell. Tighten the retainer to 240 ft.-lbs. (320 Nm).

Spacer

9

Snap Wire Retainer

Back-Up Ring

Piston

Plunger U-Cup Pressure Seal

Piston Strap Wrench

7

Snap Wire Retainer

MA0815.ill

Hydraulic Fuse / Cushion Valve

6

Pin-Type Spanner MA0813.ill

42

Wear Ring

4 230444 Rev. 1

S 4.5-8

ERVICE

Mast Valve Service NOTE: The only serviceable part on the mast valve is the lowering control valve cartridge. Replace if symptoms are encountered as described in Troubleshooting, Section 3.1-3.

1 Completely lower the Layer Picker mast.

2 Disconnect the supply hose at the mast valve cartridge.

3 Remove the cartridge from the valve. Note stamped part

Mast Valve

number on cartridge.

WARNING: Assure that the correct valve cartridge is used. Replacing the cartridge with a different part number cartridge may cause the mast to malfunction.

4 For reassembly, reverse the above procedures.

230444 Rev. 1

Cartridge

3

LP0123.ill

2

Hoist Supply Hose

43

S 4.5-9

ERVICE

Mast Upright Disassembly NOTE: The mast may be serviced on the truck, or removed and serviced horizontally on a pallet. To perform service on the truck, all Layer Picker components and hoist cylinders must be removed.

1 Remove the Clamp Assembly as described in Section

Thrust Plugs

4.2-1.

2 Remove the Boom-Carriage Assembly as described in Section 4.4-1.

3 Remove the Lift Chains as described in Section 4.5-2.

4 Remove the Internal Reeving Hoses as described in Section 4.5-4.

Upper Load Rollers, Shims

5 Remove the Hoist Cylinders as described in Section

6

4.5-5.

Side-Thrust Rollers

WARNING: Make sure overhead hoist has a rated capacity of at least 2000 lbs. (900 kg).

6 Using an overhead hoist, lower the inner upright to expose the upper and lower load rollers. Remove the load rollers. Keep track of shims.

7 Lift the inner upright out through the top of the mast.

Mast Inner Upright

4.5-10 Mast Upright Inspection Inspect the following areas of the mast upright: •

Inspect the side-thrust rollers on the side of the outer upright for excessive wear, flat spots, cracks, or bearing roughness. Replace and adjust rollers if required.

•

Inspect the thrust plugs in the outer upright for wear.

Replace the plugs if the wear surface is worn to less than 1/16 in. (1.5 mm) thickness.

•

Inspect all load rollers for excessive wear, flat spots, cracks, or bearing roughness. Replace and adjust rollers if required. Keep track of shim locations.

•

Inspect the chain and hose sheaves (if attached), bearings, mounting pins for wear. Replace the parts as required.

•

•

Inspect all welds on the mast including crossbars, side-thrust roller mounts, chain anchor mounts.

Replace or repair the uprights.

LP0122.ill

Inspect the roller stubshafts. Replace the upright if cracks are found on any of the stubshaft bases, or if the roller bearing bores are loose on the stubshafts.

CAUTION: Reparing cracks by welding must be approved by Cascade. Contact Cascade Service for approval and recommended welding procedures.

44

Check for Cracks on Stubshafts

Lower Load Rollers, Shims

230444 Rev. 1

S

ERVICE

4.5-11 Mast Upright Reassembly 1 Lubricate the mast upright rails with general-purpose chassis lube (Cascade Part Number 599474).

2 Attach an overhead hoist to the inner upright and install through the top of the outer upright (see illustration on previous page).

1

Lubricate areas indicated by heavy line full length of each mast upright every 100 hours.

Outer Upright

Carriage

Load Rollers Inner Upright

LP0043.ill

3 Assemble the load rollers on the stub shafts using the appropriate number of shims for proper clearance. The shims should be installed to provide a total side-to-side clearance of 1/16 in. (1.5 mm) maximum at the tightest point throughout the travel of the upright. Use an equal number of shims on each side. NOTE: Make sure the mast thrust plugs and side-thrust rollers do not interfere with the measurement when checking the side-to-side clearance.

Pry here to check side-toside clearance of mast upright.

Mast Load Roller

Carriage Load Roller

NOTE: Use similar procedure to check carriage.

3

1/16 in.

(1.5 mm) Max.

Mast Side-Thrust Rollers

LP0119.ill

4 Adjust the side-thrust rollers on the outer upright for unrestricted clearance along the full travel of the inner upright.

5 Install the Hoist Cylinders as described in Section 4.5-5.

6 Install the Internal Hose Reeving as described in Section 4.5-4.

7 Install the Lift Chains as described in Section 4.5-2.

8 Install the Boom-Carriage Assembly as described in Section 4.4-1.

9 Install the Clamp Assembly as described in Section

4 IMPORTANT: Adjust side-thrust roller base toward inner rail in direction shown.

MA0871.ill

4.2-1.

230444 Rev. 1

45

S 4.6

4.6-1

ERVICE PECIFICATIONS

Lower Carriage Solenoid Valve Coil Service 1 Disconnect the wires from the coil terminals and remove

Coils (2)

the coils from the valves.

2 Install new coils. Assure that the terminals are connected correctly. Refer to the electrical schematic in Section 3.7 for correct hookup.

Crossover Tubing

3 For reassembly, reverse the above procedures.

WARNING: Never work on the mast with a load on the forks or attachment. Use supports or blocking when working with the mast raised. Do not allow anyone near the truck control handles per ANSI B56.1

4.6-2

Solenoid Valves (2)

Adapter Bracket

Valve Service 1 Disconnect the hoses to the solenoid valves. Plug the hoses and tag for reassembly.

LP0188.ill

2 Remove the caspcrews that fasten the solenoid valves to the adapter bracket and remove the valves. Replace the solenoid valves as complete assemblies. For reassembly, tighten the capscrews to 18 ft.-lbs. (25 Nm).

3 For reassembly, reverse the above procedures.

46

230444 Rev. 1

S

PECIFICATIONS

5.1

Specifications

5.1-1

Hydraulics Truck Relief Settings Reach, 2000 psi (138 bar) Recommended, 2300 psi Max. Clamp, Swing Hoist

2600 psi (180 bar) Recommended

Truck Flow Volume ➀ Min. ➁

Recommended

Max. ➂

Reach, Clamp

5 GPM (19 L/min.)

7.5 GPM (28 L/min.)

10 GPM (38 L/min.)

Swing

3 GPM (11 L/min.)

3.5 GPM (13 L/min.)

3.5 GPM (13 L/min.)

30A

➀ The Cascade Layer Picker is compatible with SAE 10W petroleum base hydraulic fluid meeting Mil. Spec. MIL-0-5606 or MIL-0-2104B. Use of synthetic or aqueous base hydraulic fluid is not recommended. If fire resistant hydraulic fluid is required, special seals must be used. Contact Cascade. ➁ Flow less than recommended will result in slower than normal operating speed. ➂ Flow greater than maximum can result in excessive heating, reduced system performance and reduced hydraulic system life.

Hoses and Fittings • Hoist Function – Hoses and fittings for the HOIST function should be No. 8 with .400 in. (10 mm) minimum I.D. • Clamp, Reach, Swing Functions – Hoses and fittings for the CLAMP, REACH and SWING functions should be No. 6 with .250 in. (7 mm) minimum I.D.

GA0144.ill

Upper Mast Mounts (tilt cylinders) No tilt function on the Layer Picker. Mast tilt cylinders are replaced with adjustable links to provide a fixed, mast-vertical configuration for all operations. If adjustable links are not provided, contact OEM for cylinder lockout/immobilization.

5.1-2

NOTE: Swing function replaces Tilt function (second control lever) on Layer Picker.

Clean truck axle or pin mounts and inspect for damage.

Repair as necessary.

Swing Left

Truck Valve Functions Check that lever movement is in compliance with ANSI standards (B56.1):

Lower Mast Mounts

Hoist Down

GA0082.ill

Hoist Up Swing Right

230444 Rev. 1

Clamp Open/Release

Reach Extend

Reach Retract

Clamp Close

47

S 5.1-3

PECIFICATIONS

Torque Values Ref.

Fastener

Size

Ft.-lbs.

Nm

1

Contact pad-to-arm base (4)

M-12

65

90

2

load guard-to-arm (All)

M-12

65

90

3

Valve-to-frame (2)

M-8

18

25

4

Cylinder rod anchor nut (All)

3/4 UNF

165

225

5

Adjustable stop jam nuts (4)

M-12

60

80

6

Hose clamp

M-6

8

10

7

Sheave pin retainers (4)

M-10

40

50

8

Mast sidethrust roller (4)

M-12

60

80 ▲

9

Chain anchor jam nuts (2)

5/8 x 18UNF 60

80

10 Mast tilt cylinder or link (2)

(see truck mfgs. specs.)

11 Mast valve and mount (4)

M-10

40

50

12 Counterweight carriage-to-mast (8)

M-12

60

80

13 Mast lower mount (4)

(see truck mfgs. specs.)

14 Pin retainers (2)

M-8

20

30

15 Revolving Connection-to-boom (2)

M-8

20

30

16 Counterweight retainer (2)

M-16

165

225

▲ Double-torque (tighten, loosen 1/2-turn, retighten)

3 2 1 48

5 14

Fastener torque values for the Layer Picker are shown in the table below in both U.S. and Metric units. All torque values are also called out in each specific service procedure section throughout the Manual.

8

7

27 9 15 6 10 11

4 16

LP0099.ill

12

13

230444 Rev. 1

S 5.1-3

PECIFICATIONS

Torque Values (Continued) Ref.

Fastener

Size

Ft.-lbs.

Nm

17 Boom-to-swing drive motor (12)

5/8 UNC

165

225

18 End-block bracket-to-carriage (2)

M-10

15

20

19 Carriage thrust rollers (4)

M-12

65

90 ■

20 HD carriage thrust rollers (4)

M-12

65

90 ■

21 Swing drive motor-to-carriage (4)

7/8 UNC

450

610 ▲

22 Mounting bracket, IHR terminal (4)

M-8

15

20

23 Stubshaft-to-swing drive motor (6)

1/2 UNC

80

110

24 Cylinder rod anchor nut (All)

3/4 UNF

165

225

25 Swing valve/hose terminal bracket (3) 3/8 UNC

15

20

26 Clamp cylinder piston nut

5/8 UNF

65

85

27 Hoist cylinder retainer

–

240

320

17 18

20

19 21 25

22

LP0103.ill

■ Use Loctite 242 (blue) ▲ Double-torque (tighten, loosen 1/2-turn, retighten)

23

24 Carriage Back (Driver's) View

26

230444 Rev. 1

49

Do you have questions you need answered right now? Call your nearest Cascade Service Department.

Visit us online at www.cascorp.com Cascade Corporation U.S. Headquarters 2201 NE 201st Fairview, OR 97024-9718 Tel: 800-CASCADE (227-2233) FAX: 888-329-8207

Cascade Canada Inc. 5570 Timberlea Blvd.

Mississauga, Ontario Canada L4W-4M6 Tel: 905-629-7777 FAX: 905-629-7785

Cascade GmbH Dahlener Strasse 570 41239 Mönchengladbach Germany Tel: 02166-68230 FAX: 02166-682323

Cascade Finland A. Petreliuksenkatu 3 01370 Vantaa Finland Tel: 09-8361925 FAX: 09-8361935

Cascade N.V. Benelux Sales and Service Damsluisweg 56 PO Box 3009 1300 El Almere The Netherlands Tel: 036-5492950 FAX: 036-5492974

Cascade (UK) Ltd. Unit 4, 12 O'Clock Court Attercliffe Road Sheffield, S4 7WW England Tel: 0870-850-8756 FAX: 0870-850-8757

Sales Scotland Macade Systems Ltd. 18 Melford Road Righead Ind. Estate Bellshill ML4 3LR Scotland Tel: 01698-845777 FAX: 01698-845888

Cascade (Africa) Pty. Ltd. PO Box 625, Isando 1600 60A Steel Road Sparton, Kempton Park South Africa Tel: 27-11-975-9240 FAX: 27-11-394-1147

Cascade Scandinavia AB Hammarvägen 10 PO Box 124 S-56723 Vaggeryd Sweden Tel: 039-336950 FAX: 039-336959

Cascade France S.A.R.L. MHP 1D Rue De Charaintru BP 18, 91360 Epinay-Sur-Orge France Tel: 01-6454-7500 FAX: 01-6454-7501

Cascade Hispania S.A. Carrer 5, Sector C Zona Franca Duanera Poligono de la Zona Franca 08040 Barcelona Spain Tel: 93-264-07-30 FAX: 93-264-07-31

Cascade Roncari S.R.L. Via Dell'Artigianato 1 37050 Vago di Lavagno (VR) Italy Tel: 39-045-8989111 FAX: 39-045-8989160

Sales Portugal FAG Santos Lda Rua do Mercado Lte 6, Loja 2-Tires 2785-630 S. Domingos De Rana Portugal Tel: 214-448-083 FAX: 214-458-098

Sales Switzerland Fahrzeugbedarf 8810, Horgen Switzerland Tel: 01-7279797 FAX: 01-7279798

Sales Poland Targowa 35/61 03-728 Warszawa Tel: 022-619 00 49 FAX: 022-619 00 49 Mobile Phone: 0501-27 29 55

Sales Russia EMCG Material Handling Equipment Moscow Tel: 095-795-2400 FAX: 095-795-2475 Email: emcg@sovintel.ru

Cascade Japan Ltd. 5-5-41, Torikai Kami Settsu, Osaka Japan, 566 Tel: 81-726-53-3490 FAX: 81-726-53-3497

Cascade Korea 121B 9L Namdong Ind. Complex, 691-8 Gojan-Dong Namdong-Ku Inchon, 405-310 Korea Tel: 82-32-821-2051 FAX: 82-32-821-2055

Cascade Australia 1445 Ipswich Road Rocklea, QLD 4107 Australia Tel: 1-800-227-223 FAX: 617-3373-7333

Cascade New Zealand 15 Ra Ora Drive East Tamaki, Auckland New Zealand Tel: 64-9-273-9136 FAX: 64-9-273-9137

Cascade-Xiamen No. 668 Yangguang Rd. Xinyang Industrial Zone Haicang, Xiamen City Fujian Province P.R. China 361026 Tel: 86-592-651-2500 FAX: 86-592-651-2571

Sunstream Industries Pte Ltd. No. 3 Tuas Link 1 2263 Singapore Tel: 65-6863-3488 FAX: 65-6863-1368

c

䊚 Cascade Corporation 2006

1-2006

Part Number 230444 Rev. 1