6853927R1 Magnetic Layer Picker User Manual (Mast)
Contents
1. LP0625 eps G Using The Magnetic Assembly Function G amp H 1 Lower the attachment until the stripper pan contacts the cans to be handled 2 G Engage Lower Magnetic Head 3 Raise the load and transport to desired area 4 H Release Raise Magnetic Head 5 Raise the attachment 16 WARNING Truck control handle and A attachment function activation shown here conforms to ASME ANSI B56 1 recommended practices Failure to follow these practices may lead to serious bodily injury or property damage End user dealer and OEMs should review any deviation from the practices for safe operation QO Tim Og O G gt Lower Magnetic Assembly Raise Magnetic Assembly Swing Left Swing Right Extend Retract Engage Lower Magnetic Head Release Raise Magnetic Head CAUTION Sliding the magnetic assembly on the floor will cause extensive wear to the stripper pan Avoid this action 6853927 R1 E P ERIODIC MAINTENANCE 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 e Check for loose or missing fasteners worn or damaged returning it to the job hoses and hydraulic leaks e Inspect the stripper pan for damage or wear Replace Mast as necessary Every time the li2. WARNING The safe operation and maintenance of industrial trucks is regulated by Occupational Safety and Health OSHA regulations 1910 178 and American National Standards Institute ANSI Safety ndard for Powered Industrial Trucks ANSI B56 1 When operating and maintaining industrial trucks equipped with attachments you should pay particular attention to the following sections of these regulations You should be familiar with all sections of these regulations Ask your employer for the complete regulations a General Requirement 4 Modifications and additions which affect capacity and safe operation shall not be performed by the customer or user without manufacturers prior written approval Capacity operation and maintenance instruction plates tags or decals shall be changed accordingly If the truck is equipped with front end attachments other than factory installed attachments the user shall request that the truck be marked to identify the attachments and show the appropriate weight of the truck and attachment combination at maximum elevation with load laterally centered 6 The user shall see that all nameplates and markings are in place e Safety Guards 2 If the type of and maintained in a legible condition oad presents a hazard the user shall equip fork trucks with a vertical load backrest extension in accordance with a 2 following a 2 All new powered industrial trucks acquire
3. D PRESSURE ADJUSTMENTS if equipped Adjust the pressure reliefs in the following valves in the order shown Truck Valves Adjust main HOIST valve relief on truck to 2600 psi 180 bar Adjust Auxiliary control valve reliefs to 2300 psi 158 bar Pressure Flow Control Valve Adjust the valve relief to 2000 psi 138 bar Flow control is fixed with internal orifices Multi Position Pressure Selection Valve Adjust the relief cartridges to 750 psi 52 bar for low setting 1000 psi 69 bar for medium setting and 1200 psi 83 bar for high setting Position the stops to block the lever from reaching the X valve block out position see illustration IMPORTANT Pressure settings are a starting point only Verify by testing with actual loads Test by picking up a single layer tier of the load to be handled and look for slippage or creasing Adjust the low setting if required Pick up multiple layers tiers and look for slippage or creasing Adjust the medium setting if required Pick up a maximum number of layers tiers and look for slippage or creasing Adjust the high setting if required RECOMMENDED MAGNETIC ASSEMBLY UNDERCLEARANCE LP0630 eps t 3 Selectable Relief Positions Driver s Top View AC0844 eps PRESSURE FLOW MULTI POSITION PRESSURE D CONTROL VALVE SELECTION 2 VALVE Adjustable Relief Cartridge Adjustable
4. J SE manva JOB Magnetic Layer Picker Swing Model Manual Number 6853927 R1 cascade Corporation Cascade is a Registered Trademark of Cascade Corporation C ONTENTS Page INTRODUCTION What The System Does Special Definitions 1 OPERATION Safety Rules 2 Industrial Lift Trucks 2 Handling Loads 3 Auxiliary Valve Functions Operation 3 Safe Operation and Maintenance 4 OSHA Regulations 4 INSTALLATION Truck Requirements 5 Truck Preparation 6 Installation 9 PERIODIC MAINTENANCE 100 Hour Maintenance 17 500 Hour Maintenance 17 1000 Hour Maintenance 18 2000 Hour Maintenance 18 EN NTRODUCTION This user manual is for the 30B Magnetizer Layer Picker Contents include an Operator s Guide Installation Mast Instructions Troubleshooting and Periodic Maintenance NOTE All specifications are shown in U S and Metric units where applicable All fasteners have a torque value range of 10 of stated value IMPORTANT The attachment fittings are JIC Supply fittings adapted as required for application I Upper m f f What The System Does carriage U swing rive The Magnetic Layer Picker is designed to remove an entire layer of cans at one time from a multi layer stack of steel cans The entire layer can be transferred to a take away belt a retort or any other area The magnet can also be used in reverse order to deposit a layer on a pallet The operation can be repeate
5. capacity shall be adjusted 4 Trucks equipped with attachments shall be operated as partially loaded trucks when not handling a load 5 Aload engaging means shall be placed under the load as far as possible the mast shall be carefully tilted backward to stabilize the load 6 Extreme care shall be used when tilting the load forward or backward particularly when high tiering Tilting forward with load engaging means elevated shall be prohibited except to pick up a load An elevated load shall not be tilted forward except when the load is in a deposit position over a rack or stack When stacking or tiering only enough backward tilt to stabilize the load shall be used p Operation of the Truck 1 If at any time a powered industrial truck is found to be in need of repair defective or in any way unsafe the truck shall be taken out of service until it has been restored to safe operating condition q Maintenance of Industrial Trucks 1 Any power operated industrial truck not in safe operating condition shall be removed from service All repairs shall be made by authorized personnel All parts of any such industrial truck requiring replacement shall be replaced only by parts equivalent as to safety with those used n the original design ndustrial trucks shall not be altered so that the relative positions of the various parts are different from what they were when originally received from the manufacturer nor shall
6. level on the clamp frame or arm as shown Unscrew the four stops until the clamp hangs freely Screw the stops down until they contact the boom tubes then back off each 1 2 turn Tighten locknuts CAUTION Boom cylinder and rod end anchor will be damaged if stops are not adjusted properly Stops must prevent the magnetic assembly from rocking too far forward and backward during load handling Magnetic Assembly Frame Adjustable Stops Locknuts Pivot Pins Side View Magnetic Protractor on Magnetic Assembly 6853927 R1 IMPORTANT Final adjustments must be completed at time of delivery to end user in the location where the Layer Picker will be used and with actual product loads Magnetic ka Protractor on Mast Upright Adjustable Solid Links Retainer LP0629 eps 13 14 NSTALLATION Adjustments Continued C MAGNETIC ASSEMBLY HEIGHT ABOVE FLOOR Adjust the mast chain anchors equally to provide a recommended clearance of 1 5 in 38 mm above the floor with the Layer Picker fully lowered IMPORTANT When making this adjustment make sure that the mast inner upright does not contact the upper stops on the mast outer upright arrows Chain Anchors Double Jam Nuts LP0117 eps
7. reach cylinder s rod end B Engage magnetic assembly with boom Lubricate reach arm bearings with general purpose chassis lube C Connect reach cylinder rod end to magnetic assembly bulkhead Hold hex washer and tighten spherical nut to a torque of 165 ft Ibs 225 Nm NOTE Joint operates with a loose clearance Oylinder Rod End Anchor see detail below A C Adjustable Pallet Hand Truck Magnetic Assembly D Check that pivot pins and eyepin retainers are in place Tighten eyepin capscrews to 20 ft lbs 30 Nm E Connect ENGAGE RELEASE function hoses to valve Make sure hoses form a loop to allow for boom telescoping movement CAUTION Do not twist hoses F Adjust stops so that magnetic assembly can hang in a level attitude during tier pickup Refer to Step 6 Spherical Nut Retainer NI Cotter Pin 10 LP0225 eps Cylinder Rod Hex Washer Rod End Anchor 6853927 R1 m f NSTALLATION Prepare and connect supply hoses Determine hose lengths required for A B C and D below NOTE For HOIST circuit use No 8 hose and fittings with a minimum ID of 400 in 10 mm For MAGNETIZE REACH and CLAMP circuits use No 6 hose and fittings with a minimum ID of 250 in 7 mm Cut hoses to length and install hose fittings A Hoist Mast hoist valve to truck main valve 1st control lever B Swing RH Hose reel to flow pressu
8. 7 kg l 8 30 in 211 mm 4 5 Ib 2 kg 3 lb 1 4 kg 15 74 in 400 mm 7 Ib 3 2 kg 5 Ib 2 3 kg 15 80 in 403 mm 7 Ib 3 2 kg 5 Ib 2 3 kg 23 74 in 9 to 9 5 Ib i 603 mm 12 Ib 5 5 kg 4 1 to 4 3 kg I a Maximum can weight is based on approximately 3 4 of the I LOAD maximum holding power WEIGHT LP0624 eps Rawaq Auxiliary Valve Functions WARNING Truck control handle and A attachment function activation shown here conforms to ASME ANSI B56 1 recommended practices Failure to follow these practices may lead to serious bodily injury or property damage End user dealer and OEMs should review any deviation from the practices for safe operation LP0027 eps LP0625 eps G Using The Magnetic Assembly Function G amp H 1 Lower the attachment until the stripper pan contacts the cans to be handled 2 AEngage Lower Magnetic Head 3 Raise the load and transport to desired area 4 B Release Raise Magnetic Head 5 Raise the attachment CAUTION Sliding the magnetic assembly on the floor will cause extensive wear to the stripper pan Avoid this action 6853927 R1 QO Tim g O G gt Swing Left Swing Right Extend Retract Lower Magnetic Assembly Raise Magnetic Assembly Engage Lower Magnetic Head Release Raise Magnetic Head AFE OPERATION AND MAINTENANCE OSHA Regulations Industrial Trucks and Attachments Specitic Regulations from OSHA 1910 178 Sta
9. 9136 Fax 64 9 273 9137 Cascade do Brasil Rua Joao Guerra 134 Macuco Santos SP Brasil 11015 130 Tel 55 13 2105 8800 Fax 55 13 2105 8899 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 18 Tuas South Street 5 Singapore 637796 Tel 465 6795 7555 Fax 65 6863 1368 06 2014 Cascade India Material Handling Private Limited No 34 Global Trade Centre 1 1 Rambaugh Colony Lal Bahadur Shastri Road Navi Peth Pune 411 030 Maharashtra India Phone 91 020 2432 5490 Fax 491 020 2433 0881 Part Number 6853927 H1
10. Flow greater than maximum can result in excessive heating reduced system performance and short 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 ID Palletize Reach Swing Functions Hoses and fittings for the CLAMP REACH and SWING functions should be No 6 with 250 in 7 mm minimum ID WARNING Rated capacity of the A truck attachment combination is a responsibility of the original truck manufacturer and may be less than that shown on the attachment nameplate Consult the truck nameplate 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 Auxiliary Valve Functions Check that lever movement is in compliance with ANSI standards B56 1 Swing ae Extend Hoist P m Hed 3 d E eps mE Hoist 7 Engage T Right NOTE Swing function replaces Tilt function second control lever 6853927 R1 GA0144 eps Lower Mast Mounts Clean truck axle or pin mounts and inspect for damage Repair as necessary T RUCK PREPARATION Tools Required Pressure Gauge Kit 671212 In addition to a normal selection of mechanic s hand tools Pressure No 6
11. ION 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 _ O PERATION This section contains operating instructions for the Cascade Magnetic Layer Picker It will help you avoid common errors which often cause damage to the equipment or product being handled This information is intended to simplify operator understanding about effective and safe Magnetic Layer Picker use and operation Read this information thoroughly before operating the attachment Be sure you know and understand all operating procedures and safety precautions If you have any questions or don t understand a procedure ask your supervisor Swing Drive Carriage Emphasize Safety Most accidents are caused by operator carelessness or misjudgment You must watch for poorly maintained equipment and hazardous situations and correct them Magnetic Actuator Oylinder iV Magnetic Head CAUTION Sliding the magnetic assembly on the floor will cause extensive wear to the stripper pan Avoid this action Telescoping Boom Stripper Pan Strong Magnetic Field Heart Pacemaker or Medical Device may malfunct
12. Relief Cartridges Front View LPO215 eps 6853927 R1 J NSTALLATION Adjustments Continued E ELECTRONIC STOP POSITION ADJUSTMENT if equipped 1 When swinging the attachment boom should stop at the left middle and right positions some units are left and right positions only Wait 3 seconds to swing after stopping OR press the swing override button to continue swinging NOTE A full swing should be 7 to 8 seconds e f boom stops at middle position continue with step 2 f boom stops momentarily and then continues at the middle position A Reduce the hydraulic input pressure for the Swing function OR B Adjust both swing valve side counterbalance cartridges CCW in 1 2 turn increments until boom stops at the middle position e f boom does not stop at the middle position A Inspect the wiring Look for loose connection or pinched cables B The limit switch end rollers are not fully engaging the deceleration ramp in the middle position Adjust the limit switch actuators to engage the ramp The ramp can also be adjusted for precision of the stop position NOTE The limit switch plungers must be fully depressed 2 To continue swing wait 3 seconds after stopping or press the swing override button to continue Swinging the boom To swing boom without stopping in the middle position press the override button e f the boom does not move off the ramp switch the positive and negative wire connectio
13. and No 8 the following are required Gauge No 6 6 Hose JIC Swivel Tee e Inline Flow Meter Kit 10 GPM 87 L min Cascade Part No 671476 20 GPM 75 L min Cascade Part No 671477 BD O 02 SF GA0014 eps e Pressure Gauge Kit 5000 psi 345 bar Cascade Part No 671212 No 4 6 Pipe JIC deus JIC bared WA eaucer an 0 e Assortment of fittings and hose JIC O Ring Magnetic Protractor Level for vertical and horizontal adjustments Pallet hand truck to install clamp assembly on mast Overhead hoisting capability of 4000 Ibs 1815 kg Quick Disconnects Male Straight Thread Metric allen wrench set to adjust pressure reliefs O Ring Coupler No 4 Part No 212282 Flow Meter Kit 671476 10 GPM 37 L min T o Ma ds d 1477 20 GPM 75 L mi AQ 67 min w 2 No 8 12 JIC Female JIC Thread _ RUS O Ring Flow Meter Coupler X P No 4 Part No 210385 AC0127 eps No 6 Part No 678591 di T B E 3 GA0013 eps NOTE Diagnostics Kit 394382 2 No 6 8 JIC Reducer includes items marked Prepare truck for Layer Picker mast A Raise and block the front end of the truck 12 in 30 cm per ANSI B56 1 or drive the truck over a service pit If required remove existing mast Clean and
14. d and used by an employer after February 15 1972 shall meet the design and construction requirements for powered industrial trucks established in the American National Standard for Powered Industrial Trucks Part Il ANSI B56 1 except for vehicles intended primarily for earth moving or over the road hauling Operator Training Only trained and authorized operators shall be permitted to operate a powered industrial truck Methods shall be devised to train operators in he safe operation of powered industrial trucks m Truck Operations 1 5i Sii ii Trucks shall not be driven up to anyone standing in front of a bench or other fixed object No person shall be allowed to stand or pass under the elevated portion of any truck whether loaded or empty Unauthorized personnel shall not be permitted to ride on powered industrial trucks A safe place to ride shall be provided where riding of trucks is authorized The employer shall prohibit arms or legs from being placed between the uprights of the mast or outside the running lines of the truck When a powered industrial truck is left unattended load engaging means shall be fully lowered controls shall be neutralized power shall be shut off and brakes set Wheels shall be blocked if the truck is parked on an incline A powered industrial truck is unattended when the operator is 25 feet or more away from the vehicle which remains in his view or whenever t
15. d to form a multi layer stack The cans may be full or empty The magnetic head when in the pick up position rests on the stripper pan The cylinder with 1 5 in 37 mm stroke is actuated to raise the magnetic head when the cans are to be released as shown Telescoping The stripper pan should extend over the edges Boom of the can layer by approximately 1 in 25 mm minimum on all four sides This will establish adequate holding power on the outside can edges as shown Magnetic Actuator Oylinder Magnetic Head Stripper Pan Counterweight LP0621 eps i 6853927 R1 J NTRODUCTION 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 Rated capacity of the truck attachment combination is a responsibility of the original truck manufacturer and may be less than shown on the attachment nameplate Consult the truck nameplate WARNING Do not operate this attachment unless you are a trained and authorized lift WARNING A statement preceded by WARNING is information that should be truck driver acted upon to prevent bodily injury A WARNING is always inside a ruled box CAUT
16. e uprights A properly may result in flaking material that can get into the operator s eyes and cause personal injury Swing Boom Drive Lubricate areas Capscrews indicated by heavy line full length of each Outer mast upright every 100 hours H v Upright IT WA HE Load 4 Swing Drive Motor Carriage Rollers LP0520 eps Capscrews YA Inner Upright m LP0043 eps Check torque value on swing drive motor capscrews Refer to illustration opposite Use cross pattern and double torque to 450 ft Ibs 610 Nm 6853927 R1 17 E P ERIODIC MAINTENANCE 18 500 Hour Maintenance Continued e Inspect and adjust if necessary the thrust bearing side to side clearance in mast upright and carriage Check carriage alignment and verify that the total side to side clearance is 1 16 in 1 5 mm maximum at the tightest point throughout the travel of the carriage Shim behind the thrust bearings for required side to side clearance 1000 Hour Maintenance After each 1000 hours of truck operation in addition to the 100 and 500 hour maintenance perform the following procedures e Inspect boom arm bearings for wear Replace as necessary 2000 Hour Maintenance After each 2000 hours of truck operation in addition to the 100 500 and 1000 hour maintenance perform the following procedures f equipped replace thrust bearings in mast and carriage WARNING After comp
17. ft truck is serviced of every 100 hours of truck operation whichever comes first complete the following maintenance on the attachment 1 00 Hour Mai ntenance WARNING After completing any service e Inspect boom cylinder anchor nut for proper connection and tightness If necessary tighten to 160 ft Ibs 220 Nm DILE R e Check that mast is vertical and magnetic assembly is 1 level during normal operation Adjust as necessary e Lubricate mast upright rails Cascade approved d lubricants are as follows Cascade Lube Part No 599474 Aerosol W Swing Boom Chevron Open Gear Grease Aerosol Carriage Castrol Molub Alloy 936 Cartridge Bx IMPORTANT Regular application of Cascade MN Magnetic approved lube will prevent premature mast rail roller N Assembly if equipped and thrust block wear 500 Hour Maintenance After each 500 hours of truck operation in addition to the 100 hour maintenance perform the following procedures Stripper Inspect chains for proper tension and adjustment Lubricate full length of mast chains with chain lube Cascade Part No 200867 Check torque value on mast lower mounts and adjustable solid links Check torque value on swing boom drive top capscrews Refer to illustration below Use cross pattern and tighten to 160 ft Ibs 215 Nm LP0633 eps WARNING Failure to lubricat
18. he operator leaves the vehicle and it is not in his view When the operator of an industrial truck is dismounted and within 25 feet of the truck still in his view the load engaging means shall be fully lowered controls neutralized and the brakes set to prevent movement 6 10 A safe distance shall be maintained from the edge of ramps or platforms while on any elevated dock or platform or freight car Trucks shall not be used for opening or closing freight doors A load backrest extension shall be used whenever necessary to minimize the possibility of the load or part of it from falling rearward n Traveling 4 The driver shall be required to slow down and sound the horn at cross isles and other locations where vision is obstructed If the load being carried obstructs forward view the driver shall be required to travel with the load trailing 7i When ascending or descending grades in excess of 10 percent loaded trucks shall be driven with the load upgrade 7i On all grades the load and load engaging means shall be tilted back if applicable and raised only as far as necessary to clear the road surface o Loading 1 Only stable or safely arranged loads shall be handled Caution shall be exercised when handling off center loads which cannot be centered 2 Only loads within the rated capacity of the truck shall be handled 3 The long or high including multiple tiered loads which may affect
19. inspect mounting areas B Remove the existing tilt cylinders Remove existin NOTE No tilt function is used with the Layer t M Picker Existing tilt cylinders must be replaced PEY with solid adjustable links Refer to step 4 C C Remove the existing tilt cylinder supply hoses NOTE Longer hoses are required to connect between the original TILT control section on the 7 truck main valve and if applicable the SWING D function hose reel on the Layer Picker mast pD Remove tilt SD cylinders B WARNING Cap all open hydraulic A supply ports and secure the truck against operation 6 6853927 R1 T RUCK PREPARATION Install pressure selection and flow control valves if equipped A Multi Position Pressure Selection Valve Locate valve within safe reach and view of driver For adjustments see Step 6 Section Step D B Flow Pressure Control Valve Determine location to mount valve Preferred location is on mast crossmember to enable use of straight fittings and short hose lengths For adjustments see Step 6 Section Step D INSTALLATION ON MAST Preferred INSTALLATION ON COWL B Flow Pressure T Control Valve SE PALLETIZE bs IHR Circuit reul F ressure x uez Circuit B i Flow Pressure Control Valve Multi Position Pressure Selection Valve Multi Position Pressure Selection Valve LP0197 eps LP0198 eps y t Fro
20. ion Hand and foot pinch danger by Counterweight objects attracted to magnet Credit Cards Computer Disks Storage Devices may be damaged LP0621 eps Label 6854621 LP0645 eps 6853927 R1 1 PERATION Safety Rules Industrial Lift Trucks No standing under load No riders No reaching through mast or magnetic assembly LP0622 eps No traveling loaded on ramps Traveling emply Overhead cg iai uu ili Swinging D Loads miil PEH gi Lp lE E Watch clearances TRAFFIC e c c9 4 E k p Observe Workers Stops J L e is n 7 1 a aa gt my gum Wet fl B Di Slow for Sound horn slow Sound horn slow SE moans umps IpS two way traffic at intersection at corner 2 6853927 R1 PERATION Handling Loads RECOMMENDED CAN SIZE HOLDING MAXIMUM CAN LOAD WEIGHT Diameter POWER WEIGHT Load weight must not exceed the can are ge H H k In specifications shown in the chart 202 mm 2 25 Ib 1 kg 1 5 Ib 0
21. is grease Install the mast on the truck Tighten mounting capscrews using the truck manufacturer s torque specifications Install upper mount adjustable links Using a magnetic protractor level adjust the mast for O degree tilt during normal operation Check that ballast carriage retainer capscrews are tightened to 165 ft Ibs 225 Nm Check mast anchor chains for proper tension NOTE Chains are factory adjusted for correct tension and carriage position If adjustment is necessary refer to Step 6 WARNING Mast modifications and additions which affect mast capacity and safe operation shall not be performed by the dealer customer or user without manufacturer s prior written approval Capacity operation and maintenance instruction plates tags or decals shall be changed accordingly per OSHA regulations 1910 178 WARNING Verify that the overhead hoist and chains or straps are rated for the weight of the attachment Refer to nameplate for attachment weight Upper Mount see illustration lower right Lower Mount Axle mount shown SPA LP0438 eps Upper Mast Mounts Go i Adjustable Solid link LP0179 eps E NSTALLATION Install Magnetic Assembly IMPORTANT Keep magnetic assembly banded on pallet until securely mounted on Layer Picker boom A Remove cotter pin lock tab and spherical retainer nut from
22. leting any service A 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 Shim to adjust side clearance LP0632 eps Shim Adjustment 6853927 R1 BLANK AMERICAS Cascade Corporation U S Headquarters 2201 NE 201st Fairview OR 97024 9718 Tel 800 CASCADE 227 2233 Fax 888 329 8207 EUROPE AFRICA Cascade Italia S R L European Headquarters Via Dell Artigianato 1 37030 Vago di Lavagno VR Italy Tel 39 045 89891 11 Fax 39 045 8989160 ASIA PACIFIC Cascade Japan Ltd 2 23 2 Chome Kukuchi Nishimachi Amagasaki Hyogo Japan 661 0978 Tel 81 6 6420 9771 Fax 81 6 6420 9777 Cascade Australia Pty Ltd 1445 Ipswich Road Rocklea QLD 4107 Australia Tel 1 800 227 223 Fax 61 7 3373 7333 cascade C73 TM Cascade Corporation 2014 Cascade Canada Inc 5570 Timberlea Blvd Mississauga Ontario Canada LAW 4M6 Tel 905 629 7777 Fax 905 629 7785 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 Korea 121B 9L Namdong Ind Complex 691 8 Gojan Dong Namdong Ku Inchon Korea Tel 82 32 821 2051 Fax 82 32 821 2055 Cascade New Zealand 15 Ra Ora Drive East Tamaki Auckland New Zealand Tel 64 9 273
23. m Truck Return to From Truck Return to Auxiliary Valves Tank Auxiliary Valves Tank No 8 Hoses No 8 Hoses Recommended Recommended Flow Pressure Control Valve Ports OPEN SWING R CLAMP SWING L 2 Pp7YOUTI ETS 4 p9 LH Side Top View RH Side INLETS Bottom View LP0220 eps 6853927 R1 7 JT Hydraulic Connections RUCK PREPARATION LAYER PICKER WITH MAGNETIC ASSEMBLY Swing Circuit if equipped SWING SWING LEFT RierHT Magnetic Assembly 2 Reach Actuat lind i Extend Retract ottiating Cylindel Cylinder ENGAGE W STOP Valve P EET EXTEND RETRACT Swi Ww DECEL Valve wing RELEASE i Valve Electronic Swing Control if equipped Hois Cylinders O O Mast IHR Connections u y RH Hose Reel 4 Multi Position Pressure Selection Valve Flow Pressure Control Valve 6036088 M HOIST SWING REACH PALLETIZE Peu AMIE ER WEI x Valves 4 Wy z W WI ro Truck Relief Truck Pump A a RANERI Truck Tank LP0627 eps 8 6853927 R1 J Ballast Carriage D Retainer Capscrews 6853927 R1 NSTALLATION Install Layer Picker Mast Assembly A Install the bearings in the mast lower axle or pin mounts Lubricate the bearing surfaces with chass
24. ns to the truck power The timer is polarity sensitive not the solenoids e f boom swings too fast adjust the restrictor on the STOP Solenoid Valve Adjust the screw until three threads show past the jam nut Swing the boom and back out the screw 1 4 turn Repeat backing the screw 1 4 turn with each swing until the boom slows The swing boom should gently come to a rest against the mast Counterbalance Cartridge Adjust 6853927 R1 Middle Position 90 LPO631 eps Boom swings to left middle and right positions some units are left and right positions only 1809 Pressing the override switch allows continuous swing Wait 3 seconds or press the override button to continue swinging Limit Switches Normally Open LP0390 eps Deceleration Ramp STOP Solenoid Valve Adjust restrictor if the boom swings too fast LP0553 eps 15 E NSTALLATION Cycle Layer Picker functions e Check for leaks at fittings valves and cylinders e With no load cycle through all Layer Picker functions several times Check for control lever function in accordance with ANSI standards Ref ANSI B56 1 Lever or Handle Type Controls e Pick up and cycle a maximum load check for proper speeds and smoothness of operation Auxiliary Valve Functions LP0027 eps
25. re control valve ports 3 and 4 3 5 GPM NOTE Swing function does not apply to Stationary Side Mount models C Reach RH internal hose reeving to truck auxiliary valve 3rd control lever D Magnetize LH internal hose reeving to flow pressure control valve ports 1 and 2 7 5 GPM Multi Position gt Pressure Selection C M Valve oe Flow Pressure Control Valve Ports RELEASE SWING R ENGAGE SWING L 2 P7zYOUTI ETS 4 P9 LH Side INLETS Bottom View LPO209 eps 6853927 R1 IMPORTANT Use straight or 45 degree fittings wherever possible Avoid sharp bends or pinch points Use as few fittings as possible and keep hose lengths to a minimum If 90 degree connections are required use tubing type hose end fittings see illustration for least flow restriction Tubing type 90 degree fittings LPO200 eps B Swing Flow Pressure Control Valve TH p Magnetize C Reach A Hoist LP0207 eps 11 NSTALLATION Flush supply hoses A Install hoses to truck auxiliary valves Temporarily connect the other ends together using union Palletize Swing fittings B Operate auxiliary valves for 30 sec Reach C Remove union fittings GA0124 eps Electronic Swing Control if equipped Use the illustration shown to connect the electrical components to the truck power supply Refer
26. they be tered either by the addition of extra parts not provided by the manufacturer or by the elimination of any parts Additional counter weighting of fork trucks shall not be done unless approved by the truck manufacturer fed Industrial trucks shall be examined before being placed in service and shall not be placed in service if the examination shows any condition adversely affecting the safety of the vehicle Such examinations shall be made at least daily When industrial trucks are used on a round the clock basis they shall be examined after each shift Defects when found shall be immediately reported and corrected 6853927 R1 I RUCK REQUIREMENTS Truck Relief Settings Reach Palletize 2000 psi 138 bar Recommended Swing 2300 psi 160 bar Maximum Hoist Truck Flow Volume o 30A amp 30B Min Recommended Max G Reach 5 GPM 7 GPM 10 GPM Palletize 18 L min 37 L min 56 L min Swing 2 GPM 3 5 GPM 5 GPM 18 L min 13 L min 13 L min 7 GPM 11 GPM 15 GPM 26 L min 42 L min 57 L min Hoist Cascade Layer Pickers are 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 Q Flow less than recommended will result in slower than normal operating speed G
27. to Installation Instructions 6158507 for operation and adjustment NOTE All cables should be 2 conductor with Deutsch type connectors ESC Control Box NOTE Factory adjusted time delay relay inside If necessary see STOP DECEL Valve Valve STOP Service manual to change setting Limit Switch Mast Normally Open N X O 2 852 3 2 Coil Cord DECEL cocHuHs LONE Supply Limit Switch PPiuus Communications Normally Open nnaa a Group OR Cable SWING ooo d H Reel Control Knob Override Pushbutton IMPORTANT Normally Open Pushbuttons that are 180 and E normally closed are Center Stop used only on swing units with center stop LT t 90 position mm Em PI Ld bal 5 Carriage 12V Truck Battery LP0513 eps IC Trucks Use chassis ground Electric Trucks Use battery ground 12 6853927 R1 E f NSTALLATION Adjustments Accomplish the following adjustments in the order listed below A MAST AT ZERO DEGREES TILT Place a magnetic protractor level on the front or rear of the mast outer upright Adjust the adjustable links to provide 0 degrees of tilt Install retainers and tighten capscrew to 20 ft Ibs 30 Nm IMPORTANT Make sure the solid adjustable link connections to the mast are tightened properly using truck manufacturer s torque specifications B LEVEL MAGNETIC ASSEMBLY Swing the magnetic assembly straight ahead Place a magnetic protractor
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