Load Stabilizer - Cascade Corporation
Contents
1. ERVICE MANUAL E Series Load Stabilizer Manual Number 204312 Cascade Corporation Cascade is a Registered Trademark of Cascade Corporation u C ONTENTS Page INTRODUCTION Section 1 1 opecial Definitions 1 INSTALLATION Section 2 2 Truck Requirements 2 Recommended Hydraulic Supply 2 sideshifter Installation 3 Load Stabilizer Installation 4 Prior to Operation 8 PERIODIC MAINTENANCE Section 3 9 TROUBLESHOOTING Section 4 10 General Procedures 10 Plumbing 11 Hosing Diagrams 11 12 Circuit Schematics 11 12 Troubleshooting 13 Load Stabilizer Circuit 19 oideshift Circuit 14 Electrical Circuit 15 SERVICE Section 5 16 Attachment Removal 16 Load Stabilizer Removal 16 oideshifter Removal 16 Arm Assembly 18 Arm Assembly Removal 18 Arm Service 19 Load Stabilizer Cylinder 20 Cylinder Removal 20 Cylinder Disassembly 21 Cylinder Inspection 21 Cylinder Reassembly 22 oideshifter Cylinder 28 Cylinder Removal 23 Cylinder Disassembly 24 Cylinder Inspection 24 Cylinder Reassembly 20 Valve 26 Valve Removal 26 solenoid Valve Removal 26 Valve Service 27 oolenoid Valve Service 28 oideshifter Bearings 29 Bearing Lubrication 29 Bearing Service 29 SPECIFICATIONS Section 6 30 Hydraulics 30 Auxiliary Valve Functions 30 Truck Carriage 31 Torque Values e 204312 _ NTRODUCTION This manual provides the installation instructions periodic maintenance requirements troubleshooting procedures a2. Solenoid equipped units 25 i 7 6 mm Install wiring Solenoid equipped units 7 5 Amp Knob Fuse White Button m Black 18 Gauge wire 1 4 in Terminals Solenoid Valve User supplied wire DE Solenoid Valve LS0188 tif 204312 Cable assembly not shown Button toward driver Adapter Truck control valve handle Install solenoid control knob Solenoid equipped units Show correct knob cover side NSTALLATION 24 Load Stabilizer Installation Q Flush hydraulic supply hoses A Install hoses B Operate auxiliary valves both directions C Remove hoses 1 Install hoses LOAD STABILIZER NON SIDESHIFTING Using Installation Kit 202127 Stabilizer Down LOAD STABILIZER SIDESHIFTING Using Installation Kit 202126 Stabilizer Down Stabilizer Up LOAD STABILIZER SOLENOID ACTIVATED SIDESHIFTING Using Installation Kits 202126 and 202127 SSR BW 3 FOL op t 50129 Internal reeving hydraulic supply Stabilizer Up Hose reel hydraulic supply Allow length for 4 in sideshift in each direction Allow length for 4 in sideshift in each direction T TR 15 oy ea 204312 NSTALLATION 1 1 Auxiliary valve functions Tilt forward Lift down Jt d K p C ii m4 An o Nj Lift up Tilt back LOAD STABILIZER SIDESHIFTING A Sides
3. 204312 Check for truck voltage at the solenoid coil terminals when the knob button is pressed 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 lf there is no ohmmeter reading shown the solenoid coil is defective and requires replacing Check the control knob fuse Replace if necessary Check for loose electrical connections at the truck ignition switch control knob button s solenoid valve terminals and diodes Remove the diode from the solenoid valve terminal Test with an ohmmeter for high resistance in one direction and no resistance in the other direction If there is no resistance in both directions replace the diode 7 5 Amp Knob Fuse White Button 18 Gauge wire 1 4 in Terminals Solenoid User supplied wire Solenoid Valve LS0167 tif 15 S ERVICE s1 Attachment Removal 51 1 Load Stabilizer Removal WARNING Make sure the overhead hoist has a rated lifting capacity of at least 1000 los 450 kg 1 Attach an overhead hoist to the center frame crossmember Take up slack in the chain WARNING Before removing any hoses relieve pressure in the hydraulic system Turn the truck off then actuate the truck control valve s several times in both directions Disconnect hoses f
4. an GAO0014 eps 7 A No 4 6 Pipe JIC No 6 8 JIC 4 No 6 Reducer and No 8 JIC O Ring Not included in Pressure Gauge Kit part no 671212 204312 T ROUBLESHOOTING 4 2 Plumbing 4231 Non Solenoid Activated i Load Stabilizer STABILIZE LOAD and SIDESHIFT RIGHT Load Stabilizer Cylinder Hose Reel Pressure OR Return dis Reeving Sideshift Cylinder NOTE For RELEASE LOAD and SIDESHIFT LEFT reverse the colors Hose Reel OR shown Internal Reeving Truck Auxiliary Valves Load Stabilizer Cylinder 42 2 Circuit Schematic Non Solenoid Activated Load Stabilizer oideshift Cylinder Hose Heels OR Internal Heeving Truck Valves LP0163 eps Hydraulic Pump 204312 11 ROUBLESHOOTING 42 3 Hosing Diagram Solenoid Activated Load Stabilizer Load Stabilizer w Cylinder STABILIZE LOAD and SIDESHIFT RIGHT Pressure Return E Sideshift Cylinder NOTE For RELEASE LOAD and SIDESHIFT LEFT reverse the shades shown GS Solenoid Valve 6 N 1 Internal Cable Reeving Hose OR and Reel Cable Reel Load Stabilizer Cylinder 4 2 4 Circuit Schematic Solenoid Activated Load Stabilizer oideshift Cylinder _ _ 6 N 1 Internal Cable Heeving Hose OR and Heel Cable Reel Truck Relief Valve Truck LS0164 eps Hydraulic 12 Pump 204312 T ROUBLESHOOTING 4 3 Load Stabil
5. apply chassis grease to the bearing zerk fittings See Section 5 6 1 above Lubrication Points LS0181 tif 29 61 1 Hydraulics PECIFICATIONS Truck Relief Setting 2000 psi 140 bar Recommended 2300 psi 160 bar Maximum Truck Flow Volume 5 GPM 19 L min Minimum 8 GPM 30 L min Recommended 10 GPM 37 L min Maximum Hydraulic Oil Cascade attachments are compatible with SAE 10W petroleum base oil per Mil Soec MIL O 5606 or MIL 0 2104B Use of synthetic or aqueous base hydraulic oil is not recommended Contact Cascade if fire resistant hydraulic oil must be used 6 1 1 Auxiliary Valve Functions 30 A Stabilizer Up B Stabilizer Down LOAD STABILIZER NON SIDESHIFTING len B Sideshift Right C Stabilizer Up D Stabilizer Down Operate Attachment Functions If functions are backward switch hoses at hose terminal hose reel or auxiliary valve LOAD STABILIZER SIDESHIFTING Tilt forward Lift A iss hth Wee 5 5 Lift up Tilt back LOAD STABILIZER SOLENOID ACTIVATED SIDESHIFTING A Sideshift Left A Stabilizer Up press knob button B Sideshift Right B Stabilizer Down press knob button LS0182 tif 204312 6 PECIFICATIONS 6 1 3 Truck Carriage The truck carriage must conform to ISO dimensional standard 2328 equivalent to Industrial Truck Association ITA dimensions shown Make sure the truck carriage is clean a
6. 2055 Cascade New Zealand 15 Ra Ora Drive East Tamaki Auckland New Zealand Tel 64 9 273 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 65 6795 7555 Fax 65 6863 1368 4 1992 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 91 020 2433 0881 Part Number 204312
7. User supplied wire LSO178 tif 26 1 Stabilizer Down Stabilizer Up Valve Stabilizer T TU Stabilizer Down 7 5 Amp Knob Fuse White Button A Let 18 Gauge wire 1 4 in Terminals Black Solenoid Valve 204312 ERVICE 55 3 Valve Service IMPORTANT Service the valve in a clean work area 1 Remove the cartridge valves 2 Remove the remaining plugs and fittings 3 Remove the O rings and back up rings from the cartridge valves Relief Valve Adjustable 4 Clean all parts with kerosene or cleaning solvent 5 For reassembly reverse the above procedures except as follows e The cartridge valve back up rings and O rings must be installed as shown below for proper operation e Lubricate the cartridge and seals with hydraulic oil prior to reassembly Relief Valve Fixed SES Back up Rings Back up Ring Check Valve Relief Valve Fixed O Rings O Rings Back up Ring Flow Regulator Back up Ring Relief Valve Adjustable O Ring and Back up Ring Installation LS0179 tif 204312 27 S ERVICE 5 5 4 Solenoid Valve Service 28 IMPORTANT Service the valve in a clean work area Remove the cartridge valves Remove the remaining plugs and fittings Remove the O rings and back up rings from the cartridge valves Clean all parts with kerosene or cleaning solvent ah WN For reassembly r
8. not bypass oil under pressure If nicks cannot be removed with emery cloth replace the part Inspect the outside of the shell for deformities that could weaken the shell s performance when under pressure Heplace if necessary 2 Restrictor Washer S SEEN Ay LL DI SEAL SOLED mn Cm a 2 N Spe N O 7272 LLL L LE AL A TI ALAA E PL A ILE BEL PL I EZ SS0057 eps 204312 ERvicE 5 4 4 Sideshifter Cylinder Reassembly 1 2 6 7 8 9 204312 Lubricate all new seals and rings with petroleum jelly or equivalent Note the direction of the U cup seals If installed backwards the seals will not work properly For proper seal placement see the illustration below Polish the piston and retainer chamfer angle with emery cloth This allows the seals to slide over the chamfer easier Install the new seals on the piston and retainer Hook one side of the seal in the groove and push it over the piston or retainer as shown Install the retainer and piston on the rod and tighten the piston retaining nut Tighten the nut to a torque of 70 75 ft Ibs 95 102 Nm Apply a thick film of petroleum jelly to the inside of the cylinder shell piston seals and retainers Insert the rod assembly into the cylinder shell If resistance is encountered tap the rod end with a rubber mallet Tap the retainer into the shell far enough to install th
9. 1 8 bar continue troubleshooting e f the gauge reading is above or below1800 25 psi 124 1 8 bar adjust the clamp relief cartridge Hefer to Section 5 5 step 2 Turn the internal setscrew clockwise to increase pressure or counterclockwise to decrease pressure 204312 501651 13 T ROUBLESHOOTING 4 3 4 4 14 Load Stabilizer Circuit Continued 6 Start the truck Fully raise the stabilizer arm Place a load under the stabilizer arm that allows the arm to retract 6 in 150 mm minimum Retract the cylinder to clamp the load and build up pressure Note the gauge readings at 30 and 90 seconds after clamping e f the gauge reading initially shows no less than 1650 psi 114 bar and the pressure drop between 30 and 90 seconds does not exceed 500 psi 35 bar the problem is not hydraulic e f the gauge reading initially shows less than 1650 psi 114 bar or the pressure drops more than 500 psi 35 bar between 30 and 90 seconds the valve check valve is faulty Refer to Section 5 5 1 Sideshift Circuit There are seven potential problems that could affect the stabilizer operation Incorrect hydraulic pressure volume from truck Kinked supply hoses External leaks Lower mounting hooks installed incorrectly See Section 2 3 step 4 Worn bearings See Section 5 6 2 Worn or defective cylinder seals WARNING Before removing any hoses relieve pressure in the hydraulic system Wit
10. acement 34 2000 Hour Maintenance After each 2000 hours of lift truck operation in addition to the 100 500 and 1000 hour maintenance perform the following procedures e Replace the sideshifter upper and lower bearing sets section 5 6 2 e Replace the load stabilizer arm bearings Section 5 2 1 204312 9 T ROUBLESHOOTING 4 1 4 1 1 4 1 2 4 1 3 10 General Procedures A After completing any service procedure always test the function through several cycles First test the 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 WARNING Before servicing any hydraulic component relieve pressure in the system Turn the truck off then actuate the truck auxiliary control valve s several times in both directions stay clear of the load while testing Do not raise the load more than 3 in 75 mm off the floor while testing Truck System Requirements e The lift truck must supply sufficient hydraulic pressure to handle the heaviest load PRESSURE TO THE ATTACHMENT MUST NOT EXCEED 2300 psi 160 bar e Hydraulic flow should be within volume range shown e he truck hydraulic system must supply hydraulic oil to the attachment that meets the specifications shown Tools Required Metric In addition to a normal selection of metric hand tools you will need e A pressure gauge c
11. apable of measuring pressure to 2500 psi 175 bar Cascade part no 671212 e Aninline flow meter capable of measuring hydraulic flow to 20 GPM 80 L min Cascade Part No 671477 Get All The Facts It is important that you gather all the facts regarding the problem before you begin service procedures The best way is to talk to the operator Ask for a complete description of the malfunction The following guidelines will help you decide where to begin your troubleshooting procedures e Arm will not move e Arm moves slowly Normal speed is 4 in 100 mm per second For help with one of these problems see Section 4 3 e Arm will not sideshift e Attachment sideshifts slowly For help with one of these problems see Section 4 4 Truck Relief Setting 2000 psi 140 bar Recommended 2300 psi 160 bar Maximum Truck Flow Volume 3 GPM 11 L min Minimum 8 GPM 30 L min Recommended 10 GPM 37 L min Maximum Hydraulic Oil Cascade attachments are compatible with SAE 10W petroleum base hydraulic fluid per Mil Spec MIL 0 5606 or 0 2104 Use of synthetic or aqueous base hydraulic fluid is not recommended Contact Cascade if fire resistant hydraulic oil must be used Flow Meter Kit 671477 2 No 8 12 JIC O Ring Flow Meter GAO0013 eps 2 No 6 8 JIC Reducer Pressure Gauge Kit 671212 No 6 and No 8 JIC Swivel Tee Pressure Gauge No 6 6 Hose 4 fo GC
12. e attachment mounted on the truck 1 Remove the arm assembly from the attachment as described in Section 5 2 1 2 Perform one or all of the following procedures as needed Arm Bar Service Remove the capscrews fastening the arm bar to the carrier For reassembly tighten the capscrews to a torque of 48 52 ft lbs 65 70 Nm Contact Pad Service Remove the nuts and capscrews fastening the contact pad to the arm If only the front portion of the contact pad is worn rotate it 180 and reinstall For reassembly tighten the nuts under the rubber washers to a torque of 48 52 ft Ibs 65 70 Nm Tighten the castellated nuts to allow flexibility and install the cotter pins Contact Pad Quick Disconnect Arm Top Shim Plate Rubber Washer Contact Pad Bottled Water Arm 19 S ERVICE 5 3 5 3 1 20 Load Stabilizer Cylinder Cylinder Removal The following procedures can be performed with the attachment mounted on the truck a 1 Bottled Water Units Remove the capscrews fastening the bumper to the frame For reassembly tighten the capscrews to a torque of 48 52 ft lbs 65 70 Nm ME SRS WARNING Make sure the overhead hoist Ay N Es has a rated lifting capacity of at least 1000 GE los 450 kg 2 Attach an overhead hoist to the arm carrier arm base Take up slack in the chain 3 Remove the capscrews fastening the cylinder clevis to the arm carrier For reassembly
13. e retaining ring in its groove Pull the rod out to the fully extended position This will position the retainer so the spiral snap ring can be installed KN e sus 9 AST Shell 8 7 Hetainer ELA LL hd BE LE LL LE 44 44 DL EGE LE LA BELLE LEA Piston D AN wa NIE EEI ODO gt 000 rom y OA NS LL LL LL bd Le SS0063 eps SS0256 eps SS0084 eps 25 ERVICE S 55 Valves 55 4 Valve Removal A 1 Remove the hoses from the valve Tag the hoses for reassembly WARNING Before removing any hoses relieve pressure in the hydraulic system Turn the truck off then actuate the truck control valve s several times in both directions 2 Remove the capscrews fastening the valve to the frame For reassembly tighten the capscrews to a torque of 12 14 ft lbs 17 19 Nm 55 2 Solenoid Valve Removal 1 Remove the wires connected to the solenoid coil terminals Tag the wires for reassembly WARNING Before removing any hoses relieve pressure in the hydraulic system Turn the truck off then actuate the truck control valve s several times in both directions A 2 Remove the hoses from the valve Tag the hoses for reassembly 2 Remove the capscrews fastening the valve to the carriage For reassembly tighten the capscrews to a torque of 12 14 ft Ibs 17 19 Nm dal
14. e procedures except for the following e Operate the sideshifter through several full cycles to force air in the system to the truck hydraulic tank Check for leaks at all fittings 204312 ID LS0175 tif 23 S ERVICE 5 4 2 Cylinder Disassembly 5 4 3 24 1 2 Sideshifter Cylinder Inspection Clamp the cylinder in a soft jawed vise Clamp lightly on the base end only Position the cylinder rod in the fully extended position Hemove the spiral snap rings from the retainer See the illustration below Tap the retainer into the shell approximately 2 in SS0059 eps 50 mm Remove the retaining ring by placing a screwdriver on one side of the ring near the split and tapping with ahammer The retaining ring will compress and turn sideways CAUTION Do not scratch the cylinder bore Remove the rod assembly from the cylinder See the illustration below Clamp the rod assembly in a soft jawed vise or between two blocks of wood Never clamp directly on the rod sealing surface Remove the nut fastening the piston to the rod Remove the piston and retainer Place the piston or retainer in the soft jawed vise to remove the seals Pry the seals up with a blunt screwdriver Cut the seals to remove it CAUTION Do not scratch the seal grooves 550255 Inspect all components for nicks or burrs Minor nicks or burrs can be removed with 400 grit emery cloth NOTE Minor nicks are those that will
15. everse the above procedures except as follows e The cartridge valve back up rings and O rings must be installed as shown below for proper operation e Lubricate the cartridge and seals with hydraulic oil prior to reassembly Solenoid Valves Back up Ring O Ring and Back up Ring Installation Solenoid Cartridge Valve 501801 204312 ERvicE se oideshifter Bearings 5 6 1 Sideshifter Bearing Lubrication The sideshifter will require lubrication with chassis grease every 500 hours of operation Apply grease at the zerk fitting lube points shown Sideshift to expose the upper fittings 5 6 2 Sideshifter Bearing Service 4 ar O N 204312 Remove the load stabilizer from the sideshifter as described in Section 5 1 Remove the sideshifter from the truck as described in Section 5 1 2 Disconnect the cylinder anchor pin from the anchor bracket Remove the anchor bracket 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 back side Measure the exposed thickness of the lower bearings If the thickness is less than 1 16 in 1 5 mm replace both bearings For reassembly reverse the above procedures except for the following e Clean the frame upper hook and lower bearing pockets of any built up grease e Clean all parts prior to reassembly e After the sideshifter is reassembled and mounted on the truck
16. h the truck off open the truck auxiliary control valve s several times in both directions Check the pressure supplied by the truck Refer to the truck Service Manual The recommended truck pressure is 2000 psi 140 bar TRUCK PRESSURE MUST NOT EXCEED 3000 PSI 207 BAR measured at the carriage hose terminal 2 Check the flow volume at the carriage hose terminal The recommended flow volume is 2 5 GPM 9 L min 3 Sideshift completely to the right and hold the control handle in this position for 5 seconds Check for external leaks at the cylinder fittings and hoses 4 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 5 Disconnect the cylinder base end hose from the hose terminal or internal reeving fitting Place the hose end in a bucket Start the truck Actuate the sideshift left control handle for 5 seconds e f there is oil flow out of the base end of the cylinder the cylinder seals are defective and require service Hefer to Section 5 4 2 e f there is no oil flow out of the rod end of the cylinder the problem is not hydraulic Fully 6 in 150 mm raised maximum stabilizer arm LS0166 tif Place the cylinder base end hose in a bucket 204312 T ROUBLESHOOTING 46 Electrical Circuit Solenoid equipped attachments oee the wire diagrams and schematic shown 1 2
17. hift Left B Sideshift Right C Stabilizer Up D Stabilizer Down LOAD STABILIZER NON SIDESHIFTING A Stabilizer Up B Stabilizer Down LOAD STABILIZER SOLENOID ACTIVATED SIDESHIFTING A Sideshift Left A Stabilizer Up press knob button B Sideshift Right B Stabilizer Down press knob button L30190 tif 204312 NSTALLATION 24 Load Stabilizer Installation Test functions A Raise Stabilizer B Hold truck valve open 10 seconds to remove air C Repeat for sideshitt if equipped Clamp force adjustment To reduce clamp force Turn internal setscrew counterclockwise Oo Remove plug a Adjust 10 Non Adjustable Relief Arm operation and adjustment Fold down Arm Quick disconnect Arm A Pull out pins Position the arm resting B Fold down arm on a stack C Install pins Pull out pins D Reverse for fold up Actuate control valve to lower the arm carrier Install pins Back away Reverse for installation Adjust to take up arm movement L50191 tif 8 204312 P ERIODIC MAINTENANCE 3 1 1 00 Hou Mal ntenance IMPORTANT After completing any service procedure test each function through 5 complete cycles First Every time the lift truck is serviced or every 100 hours test the attachment empty then test each function with of truck operation whichever comes first complete the a load to make sure the attachment operates correctly follo
18. izer Circuit There are seven potential problems that could affect the stabilizer operation e Incorrect hydraulic pressure volume from truck e Kinked supply hoses e External leaks e Physically jammed arm e Faulty electrical connection solenoid equipped attachments e Defective solenoid valves solenoid equipped attachments e Valve assembly malfunction 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 1 Check the pressure supplied by the truck Refer to the truck Service Manual The recommended truck pressure is 2000 psi 140 bar TRUCK PRESSURE MUST NOT EXCEED 2300 PSI 160 BAR measured at the carriage hose terminal 2 Check the flow volume at the carriage hose terminal The recommended flow volume is 5 GPM 19 L min Minimum 8 GPM 30 L min Recommended 10 GPM 37 L min Maximum 3 Solenoid Valve equipped attachments Press the control knob clamp button e f the solenoid valve clicks it is working correctly Continue troubleshooting e f the solenoid does not click test the electrical circuit as described in Section 4 5 4 Install a pressure gauge to the cylinder rod end test tee fitting 5 Start the truck Retract the cylinder and build up pressure as in clamping on a load Note the gauge reading e f the gauge reading is 1800 25 psi 124
19. lect the correct hose reels for the mast and truck RECOMMENDED HYDRAULIC SUPPLY OPTIONS Load Stabilizer Non Sideshifting A RH THINLINE 2 Port Hose Reel Supply Group OR B Mast Internal Reeving Sideshifting Non Solenoid Activated Load Stabilizer A and B RH THINLINE 2 Port Hose Reel Group and Mast Internal Reeving OR A RH THINLINE 4 Port Hose Reel Supply Group Sideshifting Solenoid Activated Load Stabilizer A RH 6 N 1 Cable Hose Reel Supply Group OR A and B RH Cable Reel Supply Group and Mast Internal Reeving L30185 tif 2 204312 NSTALLATION 23 Sideshifter Installation 1 Remove from box 1000 ib 450 Kg 2 Remove lower hooks T ltl 3 Mount on truck Truck carriage center notch 60 66 in 15 17 Nm x 32 36 in 7 9 Nm KO 06 in 4 1 5 mo 13 in 3 0 mm Tighten to 115 125 ft Ibs 155 170 Nm LSO186 tif 204312 3 NSTALLATION 24 Load Stabilizer Installation Attach overhead hoist 1000 Ibs 450 kg 2 Remove lower hooks 3 Mount on truck ES 3 163 e n Dr Br g 2 4 Install lower hooks 140 150 ft llbs 190 200 Nm 2 sp 18 20 ft Ibs S 20 30 Nm gt lt Center Carriage Truck carriage center notch Hook With the hook front capscrews SM finger tight tighten the side capscrew first LS0187 tif 4 204312 NSTALLATION Install solenoid valve
20. loader Stop Fins must cover all of the threads but not contact the thread relief chamfer The length of the stop fins can be trimmed with a sharp knife if more engagement is needed The piston will not enter the shell if the loader contacts the thread relief chamfer Cylinder Shell T Apply a thick film of petroleum jelly to the inside of the cylinder shell piston loader and piston seals Piston 8 Insert the rod piston assembly through the loader into the Loader cylinder shell If resistance is encountered tap the rod end with a rubber mallet 9 Remove the loader from the shell CAUTION Do not scratch the cylinder bore the retainer to a torque of 60 70 ft lbs 81 95 Nm Piston Hod Shell Retainer VA LL LL LL LL LL F i gt gt TURNS TRIER RAZZ Z JS E Z EE a a SU yy y A LS0174 fif 204312 ERvicE s4 sideshifter Cylinder 5 4 1 Sideshifter Cylinder Removal 1 Remove the load stabilizer from the sideshifter as described in Section 5 1 2 Position the forks to access the cylinder WARNING Before removing any hoses A relieve pressure in the hydraulic system Turn the truck off then actuate the truck control valve s several times in both directions 3 Disconnect the hydraulic lines from the cylinder ports Plug the lines and cap the cylinder ports 4 Remove the cotter pin and clevis pin from the cylinder ends 5 For reassembly reverse the abov
21. nd service guides for E Load Stabilizers Note that all specifications are shown in US and Metric units where applicable IMPORTANT All hardware on E Series attachments is metric All hosing and fittings are JIC 11 Special Definitions A statement preceded by WARNING is information that should be acted upon to prevent bodily injury A WARNING is always inside a ruled box CAUTION A statement preceded by CAUTION is information that should be acted upon to prevent machine damage IMPORTANT A statement preceded by IMPORTANT is information that possesses special significance NOTE A statement preceded by NOTE is information that is handy to know and may make your job easier 204312 NSTALLATION Truck Requirements Truck Relief Setting 2000 psi 140 bar Recommended 2300 psi 160 bar Maximum 2 1 Truck Flow Volume 5 GPM 19 L min Minimum 8 GPM 30 L min Recommended 10 GPM 37 L min Maximum Dimension A ITA ISO Mounting Minimum Maximum Class 14 96 in 380 0 mm 15 00 in 381 0 mm Class lll 18 68 in 474 5 mm 18 74 in 476 0 mm Clean carriage bars Inspect for damaged notches L30184 tif 22 Recommended Hydraulic Supply The attachment will require one of the following hydraulic supply arrangements All hoses and fittings should be at least No 6 with 9 32 in 7 mm minimum I D Refer to Cascade Hose amp Cable Reel Selection Guide Form 4099 to se
22. nd the notches are undamaged Dimension A ITA ISO Mounting Minimum Maximum Class Il 14 96 in 380 0 mm 15 00 in 381 0 mm GAOO028 eps 6 1 4 Torque Values WF 12D Wt mee _ Ft lbs Nm e 1620 2530 Ooie LS0183 tif 204312 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 Italia S R L European Headquarters Via Dell Artigianato 1 3 050 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 Hocklea QLD 4107 Australia Tel 1 800 227 223 Fax 461 7 3373 7333 cascade C73 Cm TM Cascade Corporation 2007 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 oparton 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
23. or the lower mounting hooks e Install the lower mounting hooks tight against the carriage bar then back off one rib position The clearance between the hooks and carriage bar must be 06 in 1 5 mm minimum to 125 in 3 0 mm maximum Tighten the capscrews to a torque of 115 125 ft lbs 155 169 Nm Truck Carriage Bar 1 16 in 1 5 mm 1 8 in 3 mm LS0169 tif 204312 17 S ERVICE s Arm Assembly 5 2 1 Arm Assembly Removal 18 The following procedures can be performed with the attachment mounted on the truck WARNING Make sure the overhead hoist has a rated lifting capacity of at least 1000 lbs 450 kg 1 Attach an overhead hoist to the arm carrier arm base Take up slack in the chain 2 Remove the capscrews fastening the cylinder clevis to the arm carrier 3 Remove the arm assembly though the top of the frame 4 For reassembly reverse the above procedures except as follows e ighten the cylinder clevis capscrews to a torque of 48 52 ft lbs 65 70 Nm e Inspect the arm bar bearings for wear If the bearing contact surfaces are worn to less than 125 in 3 mm they should be replaced e Lubricate the full length of the bearings and arm bars with chassis grease during reassembly Arm Carrier Arm Bar Bearings Cylinder Clevis LS0170 tif 204312 S 5 2 2 204312 ERVICE Arm Service The following procedures can be performed with th
24. rom the valve and sideshift cylinder if equipped Tag the hoses for reassembly Remove the lower hook capscrews fastening the load stabilizer to the sideshifter or truck carriage Lift away the load stabilizer Stabilizer Down ar c N For installation reverse the above procedures except as follows e Install the lower mounting hook capscrews finger tight and the side capscrew Tighten the side capscrew into the nut to a torque of 18 20 ft Ibs 25 30 Nm Tighten the lower hook capscrews to a torque of 140 150 ft lbs 190 200 Nm l EE 7j d 140 150 ft Ibs 190 200 Nm LS0168 tif 18 20 ft Ibs 25 30 Nm 1 Co 4 With the hook front capscrews finger tight tighten the side capscrew first Hook 16 204312 ERVICE 5 1 2 Sideshifter Removal 1 Remove the forks from the sideshifter WARNING Before removing any hoses relieve pressure in the hydraulic system Turn the truck off then actuate the truck control valve s several times in both directions a y 87 7 2 Disconnect the hoses from the cylinder If wrench clearance is limited remove the cylinder for better access lag the hoses for reassembly 3 Remove the lower mounting capscrews 4 Attach a 1000 Ibs 450 kg capacity overhead hoist Remove the sideshifter from the truck 5 For installation reverse the above procedures except for the following special instructions f
25. th 400 grit emery cloth NOTE Minor nicks are those that will not bypass oil under pressure If they cannot be removed with emery cloth replace the part e Inspect the outside of the shell for deformities that could weaken the shell s performance when under pressure Heplace if necessary SP LLLA LET N ESSE TI LE LL LD 4 NN dM A LD UIN LE SE A 4 204312 Claw type wrench Remove seal from piston Do not MIDS SSS LS0173 tif scratch the groove 21 S ERVICE 5 3 4 Load Stabilizer Cylinder 3 22 10 Install the retainer over the rod then into the shell Tighten Reassembly p 1 Lubricate all new seals and rings with petroleum jelly or equivalent 2 Note the direction of the U cup seals If installed backwards the seals will not work properly For proper seal placement see illustration below 3 Polish the piston and retainer chamfer angle with emery cloth This allows the seal to slide over the chamfer easier Do not allow lower 4 Install the new seals on the piston and retainer Hook one 6 edge of loader to side of the seal in the groove and push it over the piston contact thread relief on retainer as shown chamfer 5 Install the piston on the rod and tighten the piston retaining nut to a torque of 43 47 ft lbs 58 64 Nm 6 Place the piston loader in the cylinder shell The
26. tighten the capscrews to a torque of 48 52 ft Ibs 65 70 Nm 4 Remove the capscrew and nut from the cylinder base end Cylinder Clevis WARNING Before removing any hoses relieve pressure in the hydraulic system Turn the truck off then actuate the truck control valve s several times in both directions 5 Pull the cylinder out of the frame Disconnect plug and tag the hoses to the cylinder fittings 6 Remove the clevis from the cylinder rod For reassembly tighten the nut to a torque of 22 29 it lbs 30 40 Nm 7 For installation reverse the above procedures LS0172 tif 204312 5 3 2 5 3 3 Load Stabilizer Cylinder Disassembly 1 Clamp the cylinder in a soft jawed vise Clamp lightly at the extreme base end only 2 Remove the retainer by using a claw type spanner wrench part no 678598 3 Remove the rod assembly from the cylinder See the illustration below 4 Clamp the rod assembly at the rod end Never clamp directly on the rod sealing surface 5 Remove the nut fastening the piston to the rod Use a strap wrench to keep the rod from rotating while removing the nut 6 Place the piston or retainer in a soft jawed vise to remove the seals Pry the seals up with a blunt screwdriver Cut the seal to remove it CAUTION Do not scratch the seal grooves Load Stabilizer Cylinder Inspection e nspect all components for nicks or burrs Minor nicks and burrs can be removed wi
27. wing maintenance procedures before returning it to the job e Inspect the load stabilizer lower hooks Tighten the side capscrew to a torque of 18 20 ft lbs 25 27 Nm Tighten the hook capscrews to a torque of 140 150 ft lbs 190 200 Nm See Section 5 1 step 5 e Inspect the clearance between the truck lower carriage bar and the sideshifter if equipped Retighten the lower hook capscrews See Section 2 3 step 4 32 500 Hour Maintenance After 500 hours of lift truck operation in addition to the 100 hour maintenance perform the following procedures e Apply chassis grease to the sideshifter if equipped upper bearing zerk fitting and lower bearings See section 5 6 1 Apply chassis grease to the load stabilizer arm bars See Section 5 2 1 step 4 33 1000 Hour Maintenance After 1000 hours of lift truck operation in addition to the 100 and 500 hour maintenance procedures perform the following procedures e nspect the thickness of the sideshifter upper bearings If either of the bearings are worn to less than 1 16 in 1 5 mm thick on the back surface see Section 5 6 2 for replacement e nspect the exposed thickness of the sideshifter lower bearings If the exposed thickness is worn to less than 1 16 in 1 5 mm on the back surface see Section 5 6 2 for replacement e nspect the exposed thickness of the arm bar bearings If the exposed thickness is worn to less than 1 8 in 3 mm see Section 5 2 1 for repl
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