2 - Cascade Corporation
Contents
1. 344 Circuit Schematics D TM Hydraulic Sheet Sav g Gripper Cylinders i ee S j E Push Pull n WW GC Oylinders PR GB GR PB rw 1 Junction Block x TM H SE ES B Sheet Sav Cylinders GB PR GR Tir B en i PB te O vi Eis Valve HE rs 4 1 i ee CNW i Stomp In Pullin Pushin E poem l e oe Hose Ke L MI IX Push Pull Auxiliary Valve Auxiliary Valve 74 Truck Truck Hydraulic Relief Pump Valve E T ROUBLESHOOTING 3 5 3 5 1 22 Push Pull Circuit There are seven potential problems that could affect push pull operation e Incorrect hydraulic pressure volume from truck e Physically jammed mechanism e External leaks e Worn or defective cylinder seals e Valve assembly malfunction e Kinked supply hoses e Incorrect adjustment on gripper sequence control valves WARNING Before removing any hoses A relieve pressure in the hydraulic system With the truck off open the truck auxiliary control valve s several times in both directions 1 Check the pressure delivered by the truck Refer to the truck service manual The pressure must be within 100 psi 7 bar of specified truck pressure TRUCK PRESSURE MUST NOT EXCEED 2300 PSI 160 BAR measured at the truc2. GB PR LBr m 7 Sp E Independent Gripper LB Control Solenoid Optional E M 7 ne M LR Hh Cu M l Sheet Sav Cylinders aa Sheet Sav Solenoid am Sideshift Cylinder Valve im E Hose Terminals Hose Hose Reel Wa Reel Truck Relief Valve Sideshift R Q Sheet Sav amp Push Pull Auxiliary N N Ze Valve Ur Truck Hydraulic Pump PP0424 eps 686455 R3 19 E T ROUBLESHOOTING 343 Hosing Diagram Hydraulic Sheet Sav FACEPLATE RETRACT PRESSURE EE Junction RETURN C Block NOTE For faceplate EXTEND reverse the colors shown Gripper Cylinders Push Pull J Cylinders Valve Hose Reel Stomp In Push Pull QS Auxiliary d lt lt lt q Valve LV SS SR o Sheet hb Hose Sav Terminal Auxiliary Valve PP1586 eps SHEET SAV LIFT PRESSURE EE RETURN E a NS NOTE For Sheet Sav STOMP reverse the colors shown Valve d LN 7 gt Sheet Sav 2 SES Ly Stomp In LB LR To Push Pull Auxiliary Valve LB Hose Reel Sheet Sav Auxiliary Valve Sheet Sav Cylinder Zeen 20 686455 R3 _ T ROUBLESHOOTING
3. 3 3 6 Circuit Schematics Gane a Load Push Sideshifting Ig M Hose Terminal Hose Hose Reel 5N L Reel 1 3 Truck Xm Klee Auxiliary Valves Truck Relief Valve TT a Truck Hydraulic 4 Pump is dE PP0417 eps 686455 R3 15 T ROUBLESHOOTING 3 3 7 Hosing Diagram Load Push with Pressure Relief Sideshifting FACEPLATE RETRACT and SIDESHIFT RIGHT PRESSURE ins RETURN NOTE For faceplate EXTEND and SIDESHIFT LEFT reverse the colors shown Hose Terminal Sideshift Hose Cylinder Reel Valve Hose Reel Hose Terminal IN Push Pull Oylinders Sideshift Auxiliary Valve Push Oylinders PP0418 eps Sideshift 3 3 8 Circuit Schematics Cylinder Load Push with Pressure Relief Sideshifting Te Hose m sii 16 Sideshift Auxiliary Valves Truck Relief Valve a uir l Truck Pump Hose Reel Load Push X M Auxiliary Valves Hydraulic PP0360 eps 686455 R3 _ T ROUBLESHOOTING 3 3 9 Hosing Diagram Wide Load Push FACEPLATE RETRACT and SIDESHIFT RIGHT PRESSURE BEEN RETURN P NOTE For faceplate EXTEND and SIDESHIFT LEFT rever
4. procedures always test the attachment CAUTION For push pulls used in extreme conditions refer through five complete cycles First test to TB 297 in place of this periodic maintenance Failure to the attachment empty then test with a load follow this schedule may result in push pull failure and void to make sure the attachment operates warranty correctly before returning it to the job 21 1 100 Hour Maintenance Every time the lift truck is serviced or every 100 hours of truck operation whichever comes first complete the following maintenance on the attachment Faceplate 2 1 Dedicated Push Pulls A WARNING After completing maintenance Frame n Push Pull Check for loose or missing bolts worn or damaged Oylinders hoses and hydraulic leaks NOTE Nylon protection sleeves are available to prevent hoses from rubbing Cascade part number 6086044 and 6088062 e Inspect faceplate and frame sliding bearing blocks for lubrication Lubricate as necessary with Dubois FGG 2 food industry grease Cascade Part No 669306 Gripper Cylinders 21 2 500 Hour Maintenance W After each 500 hours of truck operation in addition to the 100 hour maintenance perform the following procedures Inspect all mechanism pivot point bushings and pins for excessive wear and replace as necessary See the service section of this manual PP0665 eps e Tighten the mecha
5. 4 For reassembly reverse the above procedures including the following items Read the General Service procedures for Inspection and Reassembly in Section 4 4 5 Note the position of the seals See the illustration for correct seal placement 3 VRE PP1048 eps 686455 R3 ERVICE 44 10 Sideshift Cylinder Service Read the General Oylinder Service Procedures for Oylinder Disassembly in Section 4 4 5 1 N Remove the snap ring from the retainer Tap the retainer into the cylinder bore Use a screwdriver to tap on the retaining ring and turn it sideways Pull the rod assembly from the shell Remove the nut fastening the piston to the rod Remove the retainer from the rod For reassembly tighten the piston nut to a torque of 45 ft lbs 60 Nm Remove all seals For reassembly reverse the above procedures including the following items e Read the General Service procedures for Inspection and Reassembly in Section 4 4 5 e Note the position of the seals See the illustration for correct seal placement Retainer Retainer Ring Tap in ES d Tap Screwariver PP1063 eps 686455 R3 SS0540 eps 49 S ERVICE 44 11 Sheet Sav Cylinder Service Read the General Cylinder Service Proced
6. AC1434 eps 686455 R3 _ S ERVICE 44 8 Gripper Cylinder Service Read the General Cylinder Service Procedures for Cylinder Tap Screwdriver Disassembly in Section 4 4 5 Retainer Ring 1 Remove the snap ring from the retainer Tap the retainer into the cylinder bore Use a screwdriver to tap on the retaining ring and turn it sideways 2 Pull the rod assembly from the shell 3 Remove the nut fastening the piston to the rod Remove Tap in e the retainer from the rod For reassembly tighten the Retainer piston nut to a torque of 45 ft lbs 60 Nm PP1063 eps A Remove all seals 5 For reassembly reverse the above procedures including the following items e Read the General Service procedures for Inspection and Reassembly in Section 4 4 5 e Note the direction of the U cup seals If installed backwards the seal will not work properly See the illustration for correct seal placement Use the piston seal loader to install the piston rod assembly into the shell BN e a WAN Ss Uu EE RIE Te a N PP1047 eps BZ 686455 R3 47 S ERVICE 44 9 Hydraulic Positioned Platen V 48 Cylinder Service Read the General Cylinder Service Procedures for Cylinder Disassembly in Section 4 4 5 1 Unthread the retainers For reassembly tighten the retainers to a torque of 65 ft lbs 90 Nm 2 Pull the rod assemblies from the shell 3 Remove all seals
7. Valve with one cartridge three cartridges NOSE Solenoid Valve Terminal Truck Q Auxiliary j CD Valve Truck I Relief Truck Val SR Hydraulic Pump PP0367 eps 686455 R3 T ROUBLESHOOTING 3 2 7 Hosing Diagram 10 Push Pull Solenoid Sideshift and Hydraulically Positioned Platens FACEPLATE RETRACT AND POSITION PLATENS PRESSURE i RETURN hs NOTE For faceplate EXTEND reverse the colors shown Hose Valve Reel Hose Terminal Truck Auxiliary Gripper Valve Cylinders Push Pull Cylinders Solenoid l SINA Additional Solenoid Valve ie Ke if equipped PP0368 eps Position Platen Oylinder SIDESHIFT RIGHT PRESSURE Pen RETURN Pen NOTE For sideshift LEFT reverse the colors shown Hose Reel Hose Truck Terminal Auxiliary Valve Solenoid Valves Sideshift Cyclinder PP0369 eps 686455 R3 _ T ROUBLESHOOTING 32 8 Circuit Schematic Push Pull Solenoid Sideshift and Hydraulically Positioned Platens Push Pul Oylinders Gripper Cylinders Valve with three cartridges Sideshift Oylinder RET EXT RET i l EZ V
8. Ibs 170 Nm 5 For reassembly reverse the above procedures 686455 R3 PP1058 eps 2 PP1042 eps 29 S ERVICE 42 3 Arm Mechanism Disassembly 30 WARNING Before removing any hoses A relieve pressure in the hydraulic system With the truck off open the truck auxiliary control valve s several times in both directions 10 11 Remove the faceplate from the arm mechanism as described in Section 4 2 1 Remove the push pull cylinders from the mechanism arms as described in Section 4 4 2 Disconnect plug and tag the four hoses from the valve Remove the valve from the inner primary arm For reassembly tighten the capscrews to a torque of 15 ft lbs 20 Nm Remove the bearing blocks roller pin spacer tube and shims from the outer secondary arms Note the location of the shims for reassembly Remove the capscrews and eyepins from the outer secondary arm pivot pins points Remove the pivot pins to remove the arms For reassembly clean and dry capscrews Apply Loctite 242 blue to capscrews and tighten to a torque of 10 ft lbs 13 Nm Remove the capscrew and eyepins or retainers form the R H Inner Secondary Arm upper pivot point Drive out the pivot pin to remove the inner secondary arms Note the location of the shims for reassembly For reassembly clean and dry capscrews Apply Loctit
9. R3 PUSH PULL One Cartridge Valve 2 Faceplate Retracts 1 Gripper Bar g Fully Down Turn CW to lower sooner CCW to lower later PP1531 eps 41 S ERVICE 44 Cylinders 4 4 1 Gripper Cylinder Removal 1 Remove the gripper assembly from the faceplate as described in Section 4 2 2 Lay the assembly on the floor with the cylinders exposed Disconnect the tubes or hoses from the cylinder fittings 2 3 4 Drive out the anchor pins from the cylinder base and rod 5 For reassembly reverse the above procedures except as follows e Check tube or hose clearances with tips of arms Gripper Cylinders with Tubes 3 S A WARNING Before removing any hoses relieve pressure in the hydraulic system With the truck off open the truck auxiliary control valve s several times in both directions Three Cartridge PP1562 eps Gripper Cylinders with Hoses PP1045 eps 4 One Cartridge Valve One Cartridge Valve Current Models Early Models B A b PP2159 eps 42 Three Cartridge Valve 686455 R3 S 4 4 2 4 4 3 ERVICE Push Pull Cylinder Removal 1 Fully extend the faceplate WARNING Before removing any hoses relieve pressure in the
10. hydraulic system With the truck off open the truck auxiliary control valve s several times in both directions A 2 Disconnect the hose ends from the cylinder fittings Tag and plug the hoses for reassembly o Remove the crossover tubes from the cylinder fittings 4 Remove the capscrews fastening the cylinder anchor pins to the arms For reassembly clean and dry capscrews Apply Loctite 242 blue and tighten to a torque of Eyepin Capscrews 10 ft lbs 13 Nm Retainer Capscrews 21 ft lbs 28 Nm 5 Drive out anchor pins 6 For reassembly reverse the above procedures except as follows Make sure the cylinder tubes do not interfere with the secondary arms when they close Sideshift Cylinder Removal 1 Fully extend the faceplate WARNING Before removing any hoses relieve pressure in the hydraulic system With the truck off open the truck auxiliary control valve s several times in both directions A 2 Remove the attachment from the truck as described in Section 4 1 NOTE Units with hose hook up to the sideshift cylinder have the cylinder base attached to the stationary anchor plate 3 Disconnect the hoses and or tubes from the cylinder fittings Tag hoses or tubes for reassembly 4 Remove the cotter pins from the cylinder anchor pins Remove the anchor pins 5 For reassembly reverse the above procedures 686455 R3 LH Cylinder RH Cylinder A Base Por
11. in the table below in both US and Metric units All torque values are also called out in each specific service procedure throughout this manual 58 PECIFICATIONS Ref Fastener Location Size Ft Ibs Nm 1 Gripper Assembly Socket Capscrews M16 125 1708 2 Gripper Assembly Hex Capscrew M16 165 22 W Inner Secondary Arm Pin Capscrews 3 Eye Pin Type 8 10 13 Retainer Type 8 21 28 W Push Pull Cylinder Capscrews 4 Eye Pin Type 8 10 13 Retainer Type amp Retainer Pin Type 8 21 208 5 Valve Capscrews 8 15 20 6 Outer Secondary Arm Pin Capscrews 8 10 13m 7 Inner Primary Arm Pin Capscews 8 10 13m 8 Quick Disconnect Lower Hook Capscrews M16 125 170 Q Bolt On Lower Hook Capscrews M16 125 170 10 Platen Stop Capscrew M12 52 70 11 Platen Hook Capscrews M16 170 230 12 QFM Bolt On Platen Capscrews M12 52 70 W Use Loctite 242 Blue 3 Retainer Pin Type PP2160 eps NOTE All fasteners have a torque value range of 10 of stated value Eye Pin Type Retainer Type E 686455 R3 BLANK Do you have questions you need answered right now Call your nearest Cascade Service Department Visit us online at www cascorp com 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 It
12. the truck carriage and back away from the attachment o o P Oo For installation reverse the above procedures excepts the following items e For complete installation procedures refer to Installation Manual 684944 PP1049 eps BOLT ON HOOKS 2 Carriage Bar vi MM L Non Sideshifting Units E Tight against lower carriage bar Sideshifting Units Clearance of 0 09 0 18 in 2 5 5 0 mm Ges Carriage Bar RCO368 eps A Lower Hook GA0451 eps 686455 R3 QUICK CHANGE HOOKS RC0367 eps LH Lower Hook Unlocked Locking Pin 27 S ERVICE 4 12 QFM Push Pulls 28 1 Extend the faceplate 2 Raise the platens 2 ft 60 cm off the floor directions WARNING Before removing any hoses A relieve pressure in the hydraulic system With the truck off open the truck auxiliary control valve s several times in both 3 Disengage the hooks from the lower carriage bar 4 Disconnect tag and plug the hoses at the carriage hose terminals 5 Lower the attachment to the floor and back away 6 For reassembly reverse the above procedures excepts the following items e For complete installation procedures refer to Installation Manual 684948 PP1043 eps PP1500 eps PP0883 e ps a Ad
13. 3 A Not included in Pressure Gauge Kit 671212 Sideshift Circuit e Attachment will not sideshift e Attachment sideshifts slowly To correct this problem see Section 3 4 Hydraulically Positioned Platen Circuit e Attachment will not position platens To correct this problem see Section 3 5 686455 R3 5 E T ROUBLESHOOTING 32 Push Pull Plumbing 3231 Hosing Diagram Push Pull Non Sideshifting Hose Reel Gripper Cylinders Hose Terminal Truck Auxiliary Valve Push Pull Cylinders FACEPLATE RETRACT PRESSURE HS RETURN NOTE For faceplate EXTEND reverse the colors shown PP0409 eps 32 2 Circuit Schematics Push Pull Non Sideshifting Push Pull Oylinders Gripper Cylinders EXT Valve with three cartridges Valve with one cartridge Hose Terminal Hose Reel Truck Auxiliary Valve Truck Hydraulic Pump Un Es C T PP1495 eps 686455 R3 _ T ROUBLESHOOTING 32 3 Hosing Diagram Push Pull Sideshifting Hose Reel Hose Terminal Sideshift Cylinder Hose Reel Hose Terminal Gripper Cylinders Push Pull Cylinders Valve Sideshift Push Pull Auxiliary a Valve FACEPLATE RETRACT and alve SIDESHIFT RIGHT PRESSURE _ RETU
14. 60 ft Ibs 80 Nm Accumulator 5 22 3 1000 Hour Maintenance After each 1000 hours of truck operation in addition to the 100 and 500 hour maintenance perform the following procedures e Check accumulator pre charge and adjust to truck 2 relief pressure if required Use Charging Kit 228235 J and refer to Accumulator User Guide 227196 for J procedures Upper Hook Setscrews Platen Mounting Capscrews PP0895 eps Lower Mounting Hook Capscrews 4 686455 R3 _ T ROUBLESHOOTING hydraulic component relieve pressure in 3 1 General Proced u res A WARNING Before servicing any 3 1 1 Truck System Requirements mM d EE m i i th directions e Truck hydraulic pressure should be within the range Wieso BONG GGNOH shown in Specifications Section 5 1 PRESSURE TO After completing any service procedure test the THE ATTACHMENT MUST NOT EXCEED 2300 PSI attachment through several cycles First test the 160 BAR attachment empty to bleed any air trapped in the system to the truck tank Then test the attachment with a load to be sure it operates correctly before returning to the job e Hydraulic flow should be within volume range as shown in Specifications Section 5 1 e Hydraulic fluid supplied to the attachment must meet AA t f the hil ing D ise th the requirement shown in Specifications Section 5 1 Stay clear of the load while testin
15. 686455 R3 _ S ERVICE as Solenoid Valve 4 8 1 Solenoid Valve Service IMPORTANT Service the valve in a clean work area 1 Disconnect the wires and diode from the coil terminals 2 Remove the coil end cover from the valve assembly Remove the coil Note the position of the coil terminals in relation to the valve ports for reassembly 3 Install the new coil and end cover making sure the terminals are positioned correctly 4 For reassembly reverse the above procedures except as follows e See the electrical schematic in Section 3 6 for correct wire and diode installation 686455 R3 RC0686 eps 55 S s1 Specifications 5 1 1 Hydraulics PECIFICATIONS A WARNING Rated Capacity of the 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 Truck Relief Setting 2000 psi 140 bar Recommended 2300 psi 160 bar Maximum Truck Flow Volume Min Recommended Max 4 GPM 7 GPM 10 GPM 33E 49E 15 L min 26 L min 38 L min Cascade E Series Push Pull and Load Push 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 Flow less than reco
16. B S ERVICE MANUAL E Series Dedicated Push Pull amp Load Push QFM Quick Fork Mount Push Pull amp Load Push Manual Number 686455 R3 Cascade Corporation Cascade is a Registered Trademark of Cascade Corporation u C ONTENTS Page INTRODUCTION Section 1 Introduction 1 Special Definitions 1 PERIODIC MAINTENANCE Section 2 Dedicated Push Pulls 100 Hour Maintenance 500 Hour Maintenance 1000 Hour Maintenance 2000 Hour Maintenance QFM Push Pulls 100 Hour Maintenance 500 Hour Maintenance 1000 Hour Maintenance BIB IA IA IO Ino Ino IN Ino TROUBLESHOOTING Section 3 General Procedures 5 Truck System Requirements 5 Tool Requirements 5 Troubleshooting Chart 5 Push Pull Plumbing 6 Push Pull Non Sideshifting 6 Push Pull Sideshifting 7 Push Pull Sideshifting with Solenoid 8 Push Pull Solenoid Sideshift and Hydraulically Positioned Platens 10 Wide Push Pull 12 Load Push Plumbing 13 Load Push Non Sideshiftin 13 Load Push with Pressure Relief Non Sideshiftin 14 Load Push Sideshiftin 15 Load Push with Pressure Relief Sideshiftin 16 Wide Load Push 17 Sheet Sav Plumbing 18 Sheet Sav with Solenoids 18 Hydraulic Sheet Sav 20 Push Pull Circuit 22 Push Function 22 Pull Function 23 Sideshift Circuit 24 Hydraulically Positioned Circuit 25 Electrical Circuit 26 SERVICE Section 4 Attachment Removal 27 Dedicated Push Pull 27 QFM Push Pull 28 Faceplate and Arm Mechanism 29 Facepl
17. Base Port T LH Oylinder Base Port Gripper Block RH Port Center Cylinder Base Port RH Oylinder RH Oylinder GP enHippad Base Port Base Port Center Cylinder Base Port if eguipped l PP1514 eps Frame Fittings 686455 R3 35 S ERVICE 43 3 Valve Service IMPORTANT Service that valve in a clean work area 1 Remove the valve from the attachment as described in Section 4 3 1 2 Remove fittings plugs and cartridges 3 Clean all parts with clean solvent Remove any burrs or sharp edges with emery cloth 4 For reassembly reverse the above procedures except as follows e Install new O rings and back up rings on the cartridges e Lubricate the cartridges with petroleum jelly prior to reassembly e Tighten all fittings and cartridges to a torque of Rellef Valve Cartridge 15 ft lbs 19 Nm Load Push Valve Relief Valve Cartridge AC0686 eps Backup Rings Valve Body PP1510 eps 36 686455 R3 ERVICE S Valve Body PP1509 eps Push Pull Valve One Cartridge Relief Valve Cartridge 3 Check Valve Cartridge Backup Rings PP0716 eps Backup Rings Relief Valve Cartridges 686455 R3 CL2687 eps Backup Rings Relief Valve Cartridge Relief Valve Cartridge Valve Body PP0722 eps Push Pull Valve Three Cartridg
18. RN L NOTE For faceplate EXTEND and 3 2 4 Circuit Schematics E IGAT ene Push Pull Sideshifting PP0363 eps Push Pull Gripper Cylinders Cylinders leede PR Sideshift i Cylinder Valve with three cartridges RET Valve with one cartridge e ee Hose Terminals Hose Le Reels NNI Sideshift a Push Pull Auxiliary IX X M Auxiliary Valve Valve Truck us Tuck Hydraulic PP0364 686455 R3 i Pump 7 E T ROUBLESHOOTING 3 2 5 Hosing Diagram Push Pull Sideshift with Solenoid FACEPLATE RETRACT PRESSURE EE RETURN NOTE For faceplate EXTEND reverse the colors shown Valve Hose Reel Hose Terminal Truck Auxiliry Valve Push Pull Cylinders Solenoid Valve PP0365 eps SIDESHIFT RIGHT PRESSURE i RETURN NOTE For sideshift LEFT reverse the colors shown Hose Reel Truck Auxiliary Valve Solenoid Valve PP0366 eps Sideshift Cylinder 686455 R3 _ T ROUBLESHOOTING 32 6 Circuit Schematics Push Pull Sideshift with Solenoid Push Pull Cylinders Gripper Cylinders Sideshift Cylinder nib Ter 4 Valve with
19. aceplate reaches full extension Faceplate Retract Gripper bar fully down before the faceplate retracts 1 Loosena cartridge adjustment locknut Operate the truck at half throttle 2 Adjust the screw so the gripper bar is fully retracted when the faceplate reaches full extension Operate the faceplate through several cycles to confirm the setting Tighten the locknut 2 Faceplate Fully Extended 1 Gripper Bar Fully Up Turn CW to raise sooner CCW to raise later PUSH PULL Three Cartridge Valve 2 y CCW to lower later WITH SHEET SAV With Solenoids P La D 2 4 Turn CW to raise sooner CCW to raise later r LC 1 Gripper Bar lr Fully Down Ee 2 Faceplate Retracts ia Turn CW to lower sooner 4 CCW to lower later 40 Turn CW to lower sooner O a eB NV AX VAX Faceplate Retracts Gripper Bar Fully Down PP0333 eps VA Y A n KH S d Faceplate Extended Gripper Bar Fully Up PP0332 eps 686455 R3 _ S ERVICE One Cartridge Valve Faceplate Retract Gripper bar fully down before the faceplate retracts 1 Loosen the valve cartridge adjustment locknut Operate the truck at half throttle 2 Adjust the screw for the gripper bar to be fully lowered before the faceplate retracts Operate the faceplate through several cycles to confirm the setting Tighten the locknut 686455
20. alia 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 ot cc TM Cascade Corporation 2013 Cascade Canada Inc 5570 Timberlea Blvd Mississauga Ontario Canada L4W 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 482 32 821 2051 Fax 82 32 821 2055 Cascade New Zealand 15 Ra Ora Drive East Tamaki Auckland New Zealand Tel 64 9 273 9136 Fax 464 9 273 9137 Cascade do Brasil Rua Jo o 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 12 2013 Cascade India Material Handling Private Limited No 34 G
21. all new bushings using the bushing driver CAUTION The bushings may be damaged if installed without a bushing driver 4 33 in 110 mm 59 in Eg M 15 mm 82 in 22 mm DIA Bushing Driver PP0713 eps 686455 R3 Bushing Driver i PP0712 eps 51 S ERVICE 4s Bearings 4531 Bearing Lubrication The upper bearings will require lubrication with chassis grease every 500 hours of operation Apply waterproof chassis grease Whitmore Onmi Task EP2 or NLGI grade 2 at the zerk fitting lube points shown Sideshift to expose the upper fittings 45 2 Bearing Service 52 1 Remove the attachment from the truck as described in Section 4 1 2 Disconnect the sideshift cylinder anchor pins from the frame and anchor bracket 3 Screw out the setscrews to remove the anchor bracket from the frame 4 Remove the upper bearing segments Replace both bearing segments if either one is worn to less than 1 16 in 1 5 mm thick on the black surface 5 Measure the exposed thickness of the lower bearings If the thickness is less than 1 16 in 1 5 mm replace both bearings NOTE The bearings have a tight press fit into the bearing pockets and must be driven in 6 For reassembly reverse the above procedures except for the following special instructions Clean the frame upper hook and lower bearing pockets of any built up grease e After the attachment is mounted on the truck apply grease to t
22. alve with 8 one cartridge Hydraulic Solenoid Positioned Additional E Valves Platen Solenoid Hose Cylinder Valve Terminal if equipped e Hose Truck pe gn l Truck Hydraulic Pump _ ae C T PP0370 eps 686455 R3 11 E T ROUBLESHOOTING 329 Hosing Diagram Wide Push Pull Optional Third FACEPLATE RETRACT Cylinder PRESSURE ii RETURN Pen P uu NOTE For faceplate EXTEND Junction LU reverse the colors shown Block GB 4 Y Hose Reel Gripper Cylinders Truck Auxiliary Valve M d f Push Pull Valve Cylinders AA Optional Third Cylinder PP0361 eps Hose Terminal 32 10 Circuit Schematics Push Wide Push Pull SE Gripper Cylinders Units with Non Solenoid Activated Sideshifting See Sideshift hosing and circuit schematics in Sections 4 2 3 and 4 2 4 TEC Units with Solenoid EI Activated Sideshifting See Sideshift hosing and BEER Mei with circuit schematics in ze cn die Sections 4 2 5 and 4 2 6 E Valve with oe one cartridge Hose Terminal Truck Meg Hose Relief Q Reel Valve Truck XI CN zu Truck e Hydraulic ae Pump pee C T 12 Geng 686455 R3 _ T ROUBLESHOOTING 33 Load Push Plumbing 3331 Hosi
23. assembly reverse the above procedures PP1050 eps Cotter Pin 4 Clevis Pin PP1557 eps 686455 R3 _ S ERVICE 44 6 General Cylinder Service Procedures Cylinder Disassembly Clamp the cylinder in a soft jawed vise Clamp at the extreme base end only Never clamp at the middle of the cylinder shell or on the rod sealing area Place the piston and retainer in a soft jawed vise to remove the seals Pry the seals up with a blunt screwdriver Cut the seal to remove CAUTION Do not scratch the seal grooves PP1066 eps Cylinder Inspection e Inspect the rod piston and retainer for nicks or burrs Minor nicks and burrs can be removed with emery cloth If they cannot be remove with emery cloth replace the part Inspect the cylinder shell bore Remove any minor icks and burrs with a butterfly hone If they cannot e removed with the butterfly hone the shell must be replaced nspect the outside of the shell for any defects that could weaken its performance when under pressure Replace if necessary C 3 Cylinder Reassembly Lubricate all new seals with petroleum jelly before installing Install new seal on a piston or retainer by hooking one ide of the seal in the groove and pushing it over the iston or retainer OTE Polishing the chamfer angle will allow the seal to ide into the groove much easier Use 400 grit emery oth to polish ote the direction of the U cup seal
24. ate Push Pull e Inspect faceplate and frame sliding bearing blocks for Cylinders Frame lubrication Lubricate as necessary with Dubois FGG 2 food industry grease Cascade Part No 669306 22 2 500 Hour Maintenance After each 500 hours of truck operation in addition to the Gripper 100 hour maintenance perform the following procedures Cylinders e Inspect all mechanism pivot point bushings and pins for excessive wear and replace as necessary See the T om Ez E NN E WA IX service section of this manual e Tighten the mechanism pivot pin retainer capscrews to 10 ft Ibs 13 Nm e Tighten the gripper assembly capscrews to 120 ft Ibs 165 Nm e Tighten the platen mounting capscrews to 40 ft Ibs PP0892 eps o 60 Nm Gripper Jaw Linkage Platens Mechanism p 4 v WARNING Platen capscrews must be Gripper Bar tightened regularly to prevent equipment damage or personnel injury Check for 125 in 3 2 mm maximum clearance Faceplate Roller between lower mounting hooks and truck carriage Bearings Frame Roller bar Refer to Step 5 in this manual if adjustment is Boone necessary e Check for 06 in 1 6 mm maximum clearance Mechanism Culinitiar i Pivot Pins ides between upper hook setscrews and truck carriage Pivot Pins bar Refer to Section 4 1 2 Step 6 in this manual if Bushings Retainers adjustment is necessary e Tighten lower hook capscrews to
25. ate Removal 29 Gripper Assembly Removal 29 Arm Mechanism Disassembly 30 Frame and Faceplate Bearing Service 32 Arm and Faceplate Bushing Service 33 Gripper Bar Bearing Strip Service 33 Page SERVICE Section 4 continued Valve 34 Push Pull Valve Removal Three Cartridges 34 Push Pull Valve Removal One Cartridge 35 Valve Service 36 Load Push Pull Valve Sequence Adjustment 40 Cylinders 42 Gripper Cylinder Removal 42 Push Pull Cylinder Removal 43 Sideshift Cylinder Removal 43 Hydraulically Positioned Platen Cylinder Removal 44 Sheet Sav Cylinder Removal 44 General Cylinder Service Procedures 45 Push Pull Cylinder Service 46 Gripper Cylinder Service 47 Hydraulically Positioned Platen Cylinder Service 48 Sideshift Cylinder Service 49 Sheet Sav Cylinder Service 50 Push Pull Cylinder Bushing Service 51 Bearings 52 Bearing Lubrication 52 Bearing Service 52 Hydraulic Faceplate Stop 53 Adjustment 53 Stop Valve Service 53 Platens 54 Platen Width Adjustment 54 Platen Tip Adjustment 54 Solenoid Valve 55 Solenoid Valve Service 55 SPECIFICATIONS Section 5 Specifications 56 Hydraulics 56 Truck Carriage 56 Auxiliary Dedicated Push Pulls 57 Auxiliary QFM Push Pulls 57 Torque Values 58 686455 R3 u f NTRODUCTION 11 Introduction This manual provides the Periodic Maintenance Troubleshooting Service and Specifications for Cascade E Series QFM and Dedicated Push Pulls In any communicatio
26. could affect sideshifting operation Insufficient hydraulic pressure volume from the truck External leaks Faulty electrical connection solenoid equipped attachments Defective solenoid valve solenoid equipped attachments Worn or defective cylinder seals WARNING Before removing any hoses relieve pressure in the hydraulic system With the truck off open the truck auxiliary control valve s several times in both directions A Check the pressure delivered by the truck Refer to the truck service manual The pressure must be within 100 psi 7 bar of specified truck pressure TRUCK PRESSURE MUST NOT EXCEED 2300 PSI 160 BAR measured at the carriage hose terminal Check the flow volume at he carriage hose terminal See Section 5 1 1 for recommended flow volumes If the truck pressure and flow are correct proceed with troubleshooting Press the control knob push pull button e f the solenoid valve clicks it is working correctly Continue the troubleshooting check list e fthe solenoid valve does not click the solenoid valve is faulty Troubleshoot the electrical circuit as described in Section 3 8 e f the solenoid still does not click the solenoid valve is faulty Service the solenoid valve as described in Section 4 8 1 Extend faceplate Positioned the platens outward and hold the control handle in this position for 5 seconds Check for external leaks at the cylinder fittings an
27. d hoses Disconnect and plug the cylinder rod side hose or tube Install a drain hose and place the hose end in a bucket Start the truck Actuate the control handle to pressure the base end of the cylinder for 5 seconds e If there is oil flowing out of the rod side of the cylinder the cylinder seals are defective and require service Refer to section 4 4 4 elf there is no oil flow out of the rod side of the cylinder the problem is not hydraulic 686455 R3 PP0421 eps 25 E T ROUBLESHOOTING 3 8 Electrical Circuit Solenoid eguipped attachments See the wire diagrams and schematic shown Use the proper schematic while following the steps below 1 Check the control knob circuit fuse Replace as necessary 2 Check the solenoid coil to make sure it matches the truck voltage The coil voltage is marked at the terminals Verify by checking the resistance across the terminal with wired disconnected Coil Voltage Ohms Resistance 12V 2 24V 14 36V 36 48V 44 e f there is no ohmmeter reading shown the solenoid Coil is defective and requires replacing Refer to Section 4 8 1 3 Check for truck voltage at the solenoid coil terminals when the knob button is pushed 4 Check for loose electrical connection at the truck ignition switch control knob button s solenoid valve terminals and diodes 5 Remove the diode s from the solenoid valve terminals Test with an ohmmeter for hig
28. d actuator 5 Wash the components with cleaning solvent and blow 3 dry 6 Lubricate all internal components with petroleum jelly prior to reassembly 7 For reassembly reverse the above procedures 686455 R3 53 S ERVICE 4 Platens 471 Platen Width Adjustment QFM Push Pulls The platens are adjustable to provide 4 in 10 cm or 10 in 25 cm spacing between the platens Remove the platen capscrews and align the platens with the alternate set of holes Tighten the capscrews to a torque of 52 ft lbs 70 Nm Dedicated Push Pulls The platen are adjustable to provide 4 in 10 cm to 12 in 30 cm spacing between the platens Pull up the spring lock on the top of the platen Adjust the platen to the desired position Engage the spring lock in the bar notch Dedicated Push Pull 47 2 Platen Tip Adjustment Platen tips should align within 25 in 6 mm Add shims to raise the lower platen tip up even with the other tip 1 Remove the lower hook capscrews and hook on the platen the low tip For reassembly tighten the capscrews to a torque of 125 ft lbs 170 Nm 2 Raise the platen tip to insert shims between the back of the platen and frame lower hook bar Add shims as required to align the tips 3 For reassembly reverse the above procedure A tt Align Tips 54 PP1523 eps i in 10 cm OR 10 in 25 cm PP1054 eps
29. e 242 blue to capscrews and tighten to a torque of Eyepin Capscrews 10 ft lbs 13 Nm Retainer Capscrews 21 ft lbs 28 Nm Attach a hoist to the inner primary arm Remove the capscrews and eyepins from the outer primary arm center pivot points Remove the pivot pins Raise the primary arms out through the top of the frame guides Remove the bearing blocks pin spacer tube and shims from the outer primary arms Note the location of the shims for reassembly Remove the capscrews and eyepins from the inner primary arm lower pivot pins Note the location of the shim for reassembly Remove the pivot pins and lift away the arm For reassembly clean and dry capscrews Apply Loctite 242 blue to capscrews and tighten to a torque of 10 ft Ibs 13 Nm For reassembly reverse the above procedures except as follows Apply waterproof chassis grease Whitmore OmniTask EP2 NLGI grade 2 to the bearing blocks roller and faceplate and frame channels 686455 R3 _ S ERVICE a gt s QN M C Ea e ee A V PAS We 39 20 4 ED a d 31 686455 R3 S ERVICE 42 4 Frame and Faceplate Bearing Service 1 Extend the faceplate to the position shown 2 Support the upper arm pivot pin using one of the following methods e An overhead hoist hooked to the pin e f an overhead hoist is unavailable support th
30. e top pivot pin with a notched pipe see pipe illustration bottle jack and wood block placed on the platens Notched Pipe 3 Remove the outer secondary arm lower pins Tilt the faceplate forward to disengage the bearings from the channels 4 Install new faceplate bearings and reinstall to the faceplate channels Tilt the faceplate back to support while removing frame bearings 5 Remove the outer primary arm middle pivot pins Raise the arms out through the top of the frame channels 12 in 30 cm 6 Install new frame bearings and reinstall to the frame channels 7 Reinstall the pivot pins to the arms Clean and dry capscrews Apply Loctite 242 blue and tighten the retaining capscrews to a torque of 10 ft lbs 13 Nm PP0711 eps Faceplate Bearings Frame 5 v Bearings g o Platens A PP0663 eps Faceplate 32 686455 R3 _ S ERVICE 42 5 Arm and Faceplate Bushing Service 2 1 Remove the arms from the attachment as described in Section 4 2 3 l Bushing 2 Remove the bushings from the arms and faceplate Driver using a bushing driver e f you do not have a bushing driver a tool can be fabricated for bushing removal See the tool illustrated for bushing driver dimensions Ee K D 3 For reassembly reverse the above procedures except PPO714 eps as follows J e Install new bushings using the bushing driver CAUTION The bushings may be damaged if instal
31. es Check Valve Kickdown Relief Valve Cartridge 37 ERVICE S Sheet Sav Valve With Solenoids 3 2 Check Valve Cartridge Type Relief Valve e SOM Cartridge S O Lift Stomp Solenoid Valve Gripper Control Solenoid Valve if equipped LA Check Valve Cartridge 3 Type I Check Valve Cartridge Type II Valve Body Relief Valve Cartridge PP1511 eps Solenoid Valve Cartridge PP1529 eps Check Valve Cartridge Type Il Backup Ring O Rings PP1516 eps Backup Rings Check Valve Cartridge Type I Ri Backup Rings PP0716 eps Backup Rings 38 686455 R3 _ S ERVICE Check Valve Cartridge T Sheet Sav Valve Shack vale Type I Counterbalance Valve Without Solenoids Cartridge Se models Type II J Check Valve Type I Check Valve Cartridge Type I 3 Relief Valve amp Cartridge Valve Body PP1512 eps Relief Valve Cartridge Check Valve Cartridge Type I Check Valve Cartridge Type ll Backup Rings PP1517 eps Counterbalance Valve Cartridge PP0716 eps Backup Rings Backup Rings 686455 R3 39 S ERVICE 434 Load Push Pull Valve Sequence Adjustment The gripper bar should be adjusted to operate as follows Faceplate Extend Gripper bar fully retracted up when the f
32. g Do not raise the load more than 4 in 10 cm off the floor while testing 3 1 2 Tools Required In addition to a normal selection of hand tools the following will be required Flow Meter Kit 671477 e Inline Flow Meter Kit 20 GPM 75 L min Cascade Part No 671477 e Pressure Gauge Kit 2 No 8 12 JIC Flow Meter 5000 psi 345 bar Cascade Part No 671212 O ring Ba e J t 3 313 Troubleshooting Chart i He 2 No 6 8 JIC Reducer Determine All The Facts It is important that all the facts regarding the problem are gathered before beginning service procedures The first step is to talk to the equipment operator Ask for a complete description Pressure Gauge Kit 671212 of the malfunction The following guidelines can then be used as a starting point to begin troubleshooting Pressure No 6 and No 8 procedures Gauge No 6 6 Hose JIC Swivel Tee Push Pull Circuit y Attachment will not pull the load Faceplate will not extend or retract Dm ET emm c jd Faceplate operates slowly GA0014 eps D Gripper bar will not lower or raise Gripper bar is not sequenced with push pull function No 4 6 Pipe JIC No 6 8JIC No 6 JIC Gripper bar will not hold the slip sheet when pulling Reducer O Ring A load onto platens To correct one of these problems see Section 3
33. h resistance in one direction and no resistance in the other direction If there is no resistance in both directions replace the diode Two Function One Button Control Knob Knob 7 5 Amp White Button Black Fuse i ML ke t Gi Diode 18 Gauge Wire 1 4 in Terminals Solenoid Valve PP1041 eps 26 Three Function Two Button Control Knob 7 5 Amp Green Black White Fuse n d tt Fr s rt eo vis aan Diodes YW Solenoid Valves User Supplied Wire PP1040 eps 686455 R3 ERVICE S 41 Attachment Removal 4131 Dedicated Push Pulls 1 Fully extend the faceplate Lower the attachment onto a pallet 2 Disconnect the lower hooks Bolt On Hooks Remove the lower mounting hooks For reassembly tighten the capscrews to a torque of 125 ft lbs 170 Nm Quick Change Hooks Pull out the retaining pins slide the hooks down and reinstall the pins in the lower holes For reassembly slide the hooks up and install the pins in the top holes A Disconnect tag and plug the hoses at the carriage hose terminals WARNING Before removing any hoses relieve pressure in the hydraulic system With the truck off open the truck auxiliary control valve s several times in both directions Solenoid Equipped Attachments Disconnect the electrical connection at the truck carriage Lower
34. he zerk fittings as described in Section 4 5 1 PP1051 eps Class III Only PP1061 eps 1 16 in min 1 5 mm Bearing Segment 686455 R3 u S ERVICE ae Hydraulic Faceplate Select Stop 4 6 1 Adjustment 1 Extend the faceplate to expose the stop mechanism Pull outward on the selector and turn to the required stop position The selector should be turned so the corresponding adjusting capscrew will contact the lever Pull out to adjust on the stop valve 2 Adjust the faceplate position by loosing the selector locknut and turning the capscrew counterclockwise to decrease the distance to the platen tips or clockwise to increase the distance to the platen tips PP1064 eps 38 in PP1249 eps Maximum Setting 46 2 Stop Valve Service 1 Extend he faceplate to gain access to the stop valve a WARNING Before removing any hoses A relieve pressure in the hydraulic system With the truck off open the truck auxiliary E control valve s several times in both directions a tar 2 Disconnect tag and plug the hose or tube from the er valve fittings Remove the capscrews fastening the stop V valve to the arm a e 3 Remove the cartridge plunger and spacer Remove the small O ring and back up ring using an O ring removal tool CAUTION Do not damage the inner valve surfaces 4 Remove the plug an
35. ith troubleshooting Solenoid equipped attachments Press the control knob push pull button e fthe solenoid valve clicks it is working correctly Continue the troubleshooting check list e fthe solenoid valve does not click the solenoid valve is faulty Troubleshoot the electrical circuit as described in Section 3 8 e fthe solenoid still does not click the solenoid valve is faulty Service the solenoid valve as described in Section 4 8 1 Inspect the sideshift bearing blocks between the truck carriage and attachment frame for excessive wear Replace if necessary Refer to Section 4 5 2 Sideshift completely to the left and hold the control handle in this position for 5 seconds Check for external leaks at the cylinder fittings and hoses Disconnect and plug the cylinder rod end hose or tube Install a drain hose and place the hose end in a bucket Start the truck Actuate the control handle to pressure the base end of the cylinder for 5 seconds e If there is oil flowing out of the rod end of the cylinder the cylinder seals are defective and require service Refer to section 4 4 3 e f there is no oil flow out of the rod end of the cylinder the problem is not hydraulic PP0420 eps 686455 R3 T Hydraulically Positioned 3 7 ROUBLESHOOTING Platen Circuit There are five potential problems that
36. just clearance to 1 8 in 3 2 mm PP1515 eps 686455 R3 _ S ERVICE 4 2 4 2 1 4 2 2 Faceplate and Arm Mechanism Faceplate Removal 1 Fully extend the faceplate WARNING Before removing any hoses relieve pressure in the hydraulic system With the truck off open the truck auxiliary control valve s several times in both directions 2 Remove the gripper assembly from the faceplate as described in Section 4 2 2 3 Attach an overhead hoist to the top of the faceplate and take up slack 4 Remove the capscrews and eyepins from the inner secondary arm lower pivot pins Remove the pivot pins For reassembly tighten the capscrew to a torque of 10 ft Ibs 13 Nm 5 Remove the faceplate with the hoist Tilt the faceplate to disengage the outer secondary arm bearings from the faceplate channels Set the faceplate face down Gripper Assembly Removal 1 Fully extend the faceplate WARNING Before removing any hoses relieve pressure in the hydraulic system With the truck off open the truck auxiliary control valve s several times in both directions 2 Attach an overhead hoist to the gripper assembly lifting holes and take up slack 3 Disconnect tag and plug the hoses from the junction block 4 Remove the hex capscrews fastening the gripper assembly to the faceplate For reassembly clean and dry capscrews Apply Loctite 242 blue to capscrews and tighten to a torque of 125 ft
37. k carriage hose terminal 2 Check the flow volume at the carriage hose terminal See Section 5 1 1 for recommended flow volumes If the truck pressure and flow are correct proceed with troubleshooting Push Function Gripper bar will not raise e Kinked hoses e Physically jammed jaw assembly e Valve out of sequence Refer to Section 4 3 3 Gripper bar drifts down e Valve s check valve cartridge is stuck in open position due to contamination or damaged seals Refer to Section 4 3 3 e Damaged seal in gripper cylinder Refer to Section 4 4 1 Gripper bar raises but faceplate does not extend Valve is out of sequence Refer to Section 4 3 3 Valve s relief cartridge is struck in closed position due to contamination or damaged seals Refer to Section 4 4 1 Faceplate extends slowly e Worn seal in push pull or gripper cylinders Refer to Section 4 4 686455 R3 _ T ROUBLESHOOTING 3 5 2 Pull Function Faceplate retracts before gripper bar fully closes e Gripper sequence valve requires adjustment Refer to Section 4 3 3 e Check gripper hose size and length Hoses must be Parker Twinline 550 H 5 or equivalent 41 in 104 cm long with No 6 fittings Gripper bar will not lower e Physically jammed mechanism e Valve s check valve cartridge is stuck in closed position due to contamination or damaged seals Refer to Section 4 3 1 or 4 3 2 Gripper bar lowers but faceplate does n
38. led without a bushing driver 3 00 in 75 mm 2 16 in 55 mm 1 37 in 35 mm 59 in 15 mm F S i 94 in DIA A 144 in DIA 24 mm Y 29 mm i L_ 55 in DIA PP0710 eps 14 mm 75 in DIA 19 mm 42 6 Gripper Bar Bearing Service NOTE Early production units are not equipped with gripper bar bearing strips 1 Remove the gripper assembly from the faceplate as described in Section 4 2 2 2 Drive out the roll pins fastening the gripper bar to the 3 gripper cylinder rods Sal 3 Remove the bearings from the gripper jaw Gripper Jaw PPO715 eps Measure the thickness of the bearing surface If the thickness is less than 1 8 in 8 mm replace the bearings 4 For reassembly reverse the above procedures O O except as follows e Apply waterproof chassis grease Whitmore LET ia OmniTask EP2 or NLGI grade 2 to the gripper H H jaw and bearing contact surfaces during Gripper Bar assembly A m ae i O O O O PP1501 eps 686455 R3 33 S 4 3 ERVICE Valve 4331 Push Pull Valve Removal Three Cartridge Valve 1 Fully extend the faceplate A 2 Disconnect tag and plug the hoses from the valve fittings WARNING Before removing any hoses relieve pressure in the hydra
39. lobal 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 686455 R3
40. mmended will result in reduced mechanism speeds Flow greater than maximum can result in excessive heating reduced system performance and short hydraulic system life Hoses and Fittings All supply hoses should be No 6 All fittings should have a minimum orifices size of 9 32 in 7mm 5 1 2 Truck Carriage 56 Carriage Mount Dimension A ITA ISO Minimum Maximum Class II 14 94 in 380 0 mm 15 00 in 381 0 mm Class Ill 18 68 in 474 5 mm 18 74 in 476 0 mm if ll E al LE RR GA0090 eps GA0389 eps 686455 R3 _ S PECIFICATIONS 5 1 3 Auxiliary Dedicated Push Pulls Check for compliance with ANSI ISO standards Sideshift Left OR Tilt Platens Forward Out ii 2M Sheet Sav Release OR Hoist Down Gripper Down atte uf ote Pull Retract GA0082 eps y Hoist Up Tilt Sideshift Sheet Sav Back Rig ht Engage OR OR a Gripper Down 51 4 Auxiliary QFM Push Pulls Check for compliance with ANSI ISO standards Push Extend OR F Tilt d Sheet Sav orwan Release OR Hoist Down Gripper Down L FH Hoist Up Tilt Back Pull Retract Sheet Sav Engage OR Gripper Down 686455 R3 57 S 5 1 5 Torque Values Fastener torque values for the Standard and QFM Push Pulls are shown
41. n about the attachment refer to the product catalog and serial numbers stamped on the nameplate as shown If the nameplate is missing the numbers can be found stamped on the right front web of the baseplate IMPORTANT All hoses tubes and fittings on these attachments are JIC NOTE Specifications are shown in both US and metric units All fasteners have a torque value range of 10 of stated value e A2Z 35E PPS A001 wal K A 23 PTL 604920 1R0 ii SR KR 3 A EL E C Cascade Corporation www cascorp e NN Icons amp Patents www cascorp com support 6095754 Nameplate 12 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 A 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 686455 R3 1 P ERIODIC MAINTENANCE
42. ng Diagram Load Push Non Sideshifting FACEPLATE RETRACT PRESSURE RETURN BEES NOTE For faceplate EXTEND reverse the colors shown PP0410 eps 3 3 2 Circuit Schematics Load Push Non Sideshifting Push Cylinders Hose Terminal Hose ae Reel Truck m Relief Truck Valve Auxiliary V Gg ToT 686455 R3 Prost tens 13 T ROUBLESHOOTING 3 3 3 Hosing Diagram Load Push with Pressure Relief Non Sideshifting FACEPLATE RETRACT PRESSURE Pm RETURN en NOTE For faceplate EXTEND reverse the colors shown Hose Reel Terminal Truck Auxiliary Valve Push Oylinders 3 3 4 Circuit Schematics Load Push with Pressure Relief Push Non Sideshifting SC RS Valve i D i a Hose mU eg Reel Truck Truck Q Relief HN Valve Auxiliary Ed Valve Truck Hydraulic Pump Mc be 14 PP0413 eps 686455 R3 _ T ROUBLESHOOTING 3 3 5 Hosing Diagram Load Push Sideshifting FACEPLATE RETRACT and SIDESHIFT RIGHT PRESSURE Pen RETURN Bes NOTE For faceplate EXTEND and SIDESHIFT LEFT reverse the colors shown Hose Reel Hose Terminal Sideshift Cylinder C FN Th X f Push Cylinders A Truck Auxiliary Valves PP0416 eps
43. nism pivot pin retainer capscrews to Linkage 10 ft Ibs 13 Nm Platens Gripper Jaw Mechanism e Tighten the gripper assembly capscrews to 120 ft Ibs Gripper Bar PN F late Bearing Block aceplate bearin OCKS e Tighten the platen hook capscrews to 120 ft Ibs is ald 165 Nm Blocks Mechanism Pivot Pins Cylinder WARNING Platen capscrews must be Bushings f Pivot Pins tightened regularly to prevent equipment p Retainers damage or personnel injury wow Accumulator Gripper Assembly e Check the clearance between the lower mounting hooks Capscrews and the truck carriage bar Quick Change Hooks 3 16 in 5 mm maximum 2 Bolt on Hooks Tight against lower carriage bar if non sideshifting or 3 16 in 5 mm maximum if sideshifting e f hook adjustment is necessary refer Section 4 1 1 Step 6 Tighten the lower hook mounting capscrews to 120 ft lbs 165 Nm 21 3 1000 Hour Maintenance After each 1000 hours of truck operation in addition to the 100 and 500 hour maintenance perform the following procedures e Check accumulator pre charge and adjust to truck relief pressure if required Use Charging Kit 228235 and refer to Accumulator User Guide 227196 for procedures Lower Mounting Hook Capscrews PPO662 eps Platen Hook Capscrews 2 686455 R3 P ERIODIC MAINTENANCE 21 4 2000 Hour Maintenance After 2000 hours of truck operation in addition to the 100 500 and 1000 hou
44. ot retract e Valve s check valve cartridge is stuck in closed position due to contamination or damaged seals Refer to Section 4 3 1 or 4 3 2 e Worn seals in the push pull cylinders Refer to Section 4 4 Gripper bar does not hold slipsheet during faceplate retract e Damaged gripper pad or jaw e Worn seals in gripper cylinders Refer to Section 4 4 686455 R3 E T ROUBLESHOOTING 3 6 24 Sideshift Circuit There are seven potential problems that could affect sideshifting operation Insufficient hydraulic pressure volume from the truck External leaks Faulty electrical connection solenoid equipped attachments Defective solenoid valve solenoid equipped attachments Lower mounting hooks installed incorrectly See Section 4 1 1 Step 2 or 4 1 2 Step 3 Worn bearings See Section 4 5 2 Worn or defective cylinder seals WARNING Before removing any hoses A relieve pressure in the hydraulic system With the truck off open the truck auxiliary control valve s several times in both directions Check the pressure delivered by the truck Refer to the truck service manual The pressure must be within 100 psi 7 bar of specified truck pressure TRUCK PRESSURE MUST NOT EXCEED 2300 PSI 160 BAR measured at the carriage hose terminal Check the flow volume at the carriage hose terminal See Section 5 1 1 for recommended flow volumes If the truck pressure and flow are correct proceed w
45. r maintenance forks in use shall be inspected at intervals of not more than 12 months for single shift operations or whenever any defect or permanent deformation is detected Severe applications will require more frequent inspection Fork inspection shall be carried out by trained personnel to detect any damage that might impair safe use Any fork that is defective shall be removed from service Reference ANSI B56 1 2005 Inspect for the following defects Surface cracks Straightness of blade and shank Fork angle Difference in height of fork tips Positioning lock Wear on fork blade and shank Wear on fork hooks Legibility of marking NOTE Fork Safety Kit 3014162 contains wear calipers inspection sheets and safety poster Also available is fork hook amp carriage wear gauge 209560 Class II 209561 Class IIl and 6104118 Class IV 686455 R3 P ERIODIC MAINTENANCE procedures always test the attachment 2 2 Q FM Push Pu Is A WARNING After completing maintenance e through five complete cycles First test 2 2 1 1 00 Hou r Mai ntenance the attachment empty then test with a load to make sure the attachment operates Every time the lift truck is serviced or every 100 hours correctly before returning it to the job of truck operation whichever comes first complete the following maintenance on the attachment Check for loose or missing bolts worn or damaged hoses and hydraulic leaks Facepl
46. s If they are installed backwards the seals will not seal properly Refer to the illustration of the cylinder being serviced e Reassemble the rod assembly by sliding the retainer on first then the piston assembly Install and tighten the piston retaining nut before sliding the rod assembly into the shell e For ease of installment use petroleum jelly inside cylinder shell piston OD and retainer ID as needed oo e o o D z RC0319 eps 686455 R3 45 S ERVICE 447 Push Pull Cylinder Service 46 Read the General Cylinder Service Procedures for Cylinder Disassembly in Section 4 4 5 1 Usea claw type spanner wrench to remove the retainer For reassembly tighten the retainer to a torque of 275 ft lbs 372 Nm Pull the rod assembly from the shell N 3 Remove the nut fastening the piston to the rod Remove the retainer from the rod For reassembly tighten the piston nut to a torque of 130 ft Ibs 176 Nm A Remove all seals 5 For reassembly reverse the above procedures including the following items Read the General Service procedures for Inspection and Reassembly in Section 4 4 5 Note the direction of the U cup seals If installed backwards the seal will not work properly See the illustration for correct seal placement Use the piston seal loader to install the piston rod assembly into the shell Claw Type Spanner Wrench LS PP1065 eps
47. se the colors shown Optional Third Oylinder Junction Block Hose Reel Truck Auxiliary Valve Valve Oylinders A Optional Third Oylinder Hose PP0414 eps Terminal 3 3 10 Circuit Schematics Wide Load Push Push Cylinders Junction ad Block Valve Hose P ad Terminal Hose l Reel Truck Auxiliary Da Truck Valve Relief Valve a ae Truck Hydraulic Pump 5 C 686455 R3 PP0415 eps 17 T ROUBLESHOOTING 34 Sheet Save Plumbing 3 4 1 Hosing Diagram Sheet Sav with Solenoids FACEPLATE RETRACT PRESSURE RETURN ee NOTE For faceplate EXTEND reverse the colors shown Junction Gripper NOTE Units with Non Solenoid Oylinders activated sideshifter see sideshift hosing and circuit schematics in Sections 4 2 3 and 4 2 4 Push Pull Oylinders Hose Reel BN Hose Truck Terminal Auxiliary Valve PP1496 eps PRESSURE EE RETURN Sq NOTE For Sheet Sav STOMP reverse the colors shown Sheet Sav LB Cylinder S SH SHEET SAV LIFT SC L Sheet Sav Cylinder e J 686455 R3 Hose y m s Hose Truck Terminal Auxiliary Valve 18 _ T ROUBLESHOOTING 34 2 Circuit Schematics Sheet Sav with Solenoids Sideshifting C Le PF B i WW Push Pull pc d Cylinders
48. t Rod Port Gripper Block LH Port PP2161 eps Gripper Block RH Port Current Models EN IER Rod End Retainer Outside Stationary Anchor Plate PP1055 eps 43 S ERVICE 44 4 Hydraulically Positioned 44 5 Sheet Sav Cylinder Removal 44 Platen Cylinder Removal 1 Fully extend the faceplate WARNING Before removing any hoses A relieve pressure in the hydraulic system With the truck off open the truck auxiliary control valve s several times in both directions Remove the attachment from the truck as described in Section 4 1 Disconnect the hoses or tubes from the cylinder fittings Tag hoses or tubes for reassembly Remove the chain link cotter pins and pins from the cylinder rods a A o N Remove the capscrews fastening the cylinder to the frame For reassembly tighten the capscrews to a torque of 15 ft Ibs 20 Nm 6 For reassembly reverse the above procedures 1 Extend the faceplate to gain access to oylinder Oylinder WARNING Before removing any hoses A relieve pressure in the hydraulic system With the truck off open the truck auxiliary control valve s several times in both directions 2 Disconnect the hoses or tubes from the cylinder fittings Tag hoses or tubes for reassembly 3 Remove the cotter pins and clevis pins from the cylinder 4 For re
49. ulic system With the truck off open the truck auxiliary control valve s several times in both directions 3 Remove the capscrews securing the valve to the arm For reassembly tighten the capscrews to a torque of 15 ft lbs 20 Nm Gripper Block Gripper Block LH Port RH Port LH Cylinder RH Cylinder Base Por Rod Port 1 PP0709 eps Push Pull Frame Fittings 34 Wide Push Pull Center Oylinder LH Oylinder Base Port Base Tube Fitting 1 t if equipped Base Tube Fitting if equipped LH Cylinder 1 Base Port Center Cylinder Gripper Block Gripper Block LH Port RH Port RH Oylinder RH Oylinder Base Port Rod Port PP0708 eps Frame Fittings 686455 R3 ERVICE 43 2 Push Pull Valve Removal 2 BE SUEDE Monk One Cartridge Valve LH Oylinder RH Oylinder 1 Fully extend the faceplate Base Port Rod Port WARNING Before removing any hoses A relieve pressure in the hydraulic system With the truck off open the truck auxiliary control valve s several times in both directions 2 Disconnect tag and plug the hoses from the valve fittings 3 Remove the capscrews securing the valve to the arm 3 For reassembly tighten the capscrews to a torque of 15 ft Ibs 20 Nm Push Pull Frame Fittings PP1508 eps Wide Push Pull Gripper Block LH Port LH Cylinder
50. ures for Cylinder Tap Screwdriver Disassembly in Section 4 4 5 Retainer Ring 1 Remove the snap ring from the retainer Tap the retainer into the cylinder bore Use a screwdriver to tap on the retaining ring and turn it sideways CAUTION Do not scratch the cylinder bore Pull the rod assembly from the cylinder Tap in M a 3 To remove the piston clamp the rod assembly in a vise on Retainer PP1063 eps the clevis end as shown CAUTION Do not clamp on the cylinder rod sealing surface N 4 Remove the piston nut and remove the piston from the cylinder rod For reassembly tighten the piston nut to a torque of 75 ft lbs 100 Nm 5 For Reassembly reverse the above procedures including the following Read the General Service procedures for Inspection and Reassembly in Section 4 4 5 3 Note the position of the seals See the illustration for correct seal placement Piston Seal Loader SS0061 er Assembly SS0664 eps ya I A y SS0791 eps 50 686455 R3 _ S ERVICE 44 312 Push Pull Cylinder Bushing Service 1 Remove the cylinders from the attachment as described in Section 4 4 2 2 Remove the bushings from the cylinder using a bushing driver f you do not have a bushing driver a tool can be fabricated for bushing removal See the tool illustrated for bushing driver dimensions 3 For reassembly reverse the above procedures except as follows e Inst
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