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674219R1_30C/45C Push/Pull Service

1. 52 674219 Rev 1 3 Slide Rod Out of Cylinder sucio Service 5 5 Platens 5 51 Removal and Installation with unit mounted on truck 5 5 2 E 5 5 3 CAUTION if you are removing your 48 inch 122 cm platens to install shorter platens you must also install the spacers and shims supplied with the platens in the push pull cylinders S e Section 5 4 8 for spacer installation procedures O Extend the faceplate fully O With the platens flat on the floor remove the capscrews securing the hooks to the platens Back the truck and attachment away from the platens Q To install reverse the above procedures Tighten the capscrews to a torque of 200 210 ft lbs 270 285 Nm Platen Shims NOTE Platen tips should align within 1 4 6mm With faceplate extended 36 inches 91 cm from frame the platens should make contact with the gripper jaw Add shims to lower the platen tips or remove shims to raise platen tips Extend the faceplate approximately 36 inches 91cm Oo With the platens off the floor a few inches slowly loosen the platen capscrews WARNING Do not remove capscrews O Back the capscrews out until the platens no longer touch the gripper jaw Tighten capscrews slowly until the platens contact the gripper jaw and platen tips are aligned Either add or remove shims an appropriate amount to maintain platens in this position NOTE To add or remove shims the platen
2. 674219 Rev 1 sector D Service 5 4 7 5 4 8 Gripper Cylinder Service Read the General Service Procedures paragraph 5 4 6 before proceeding O Remove the snap ring Tap screwdriver Retainer ring 2 Remove the retainer ring by first tapping the retainer into shell bore Then place a screwdriver on one side ofthe ring and tap the screwdriver gently with a hammer Take care not to gouge shell bore with screwdriver The retainer ring should compress at the split and turn sideways as shown at right Grasp the ring and pull it out O Pull the rod assembly out of the shell O Remove the nut securing the piston to the rod O Slide the piston and retainer off the rod O Remove and replace all seals Perform the inspection and reassembly procedures listed in paragraph 5 4 6 retainer Replace all seals Be sure to replace these seals Remove the nut For reassembly Torque to 40 45 ft lbs 54 61 Nm Push Pull Cylinder Service HE pl and retainer Pull rod assembly out Read the General Service Procedures paragraph 5 4 6 before proceeding O Use a pin type spanner wrench to remove the retainer 2 Pull the rod assembly out of the shell O Remove the nut securing the piston to the rod Remove retamer CAUTION The 45C piston nut should with pin type be removed and replaced with piston Be sure to replace spanner wrench nut 674002 this Oring Remove and repla
3. should be turned so corresponding adjusting capscrew will contact lever on stop valve A more precise faceplate stop position may be attained by adjusting the capscrews on the selector Loosen the lock nut and turn the capscrew counter clockwise to decrease the dimension of faceplate to platen tips clockwise to increase the dimension of faceplate to platen tips 5 62 Stop Valve Service O Extend the faceplate to gain access to the stop valve WARNING Before removing any hoses relieve pressure in the hydraulic system Turn the truck off then open the truck auxiliary control valve s several times in both directions Hydraulic Faceplate Stop Group Stop valve Selector Adjustment screw HYDRAULIC STOP Disconnect the hydraulic tubes from the stop valve Remove the capscrews fastening the stop valve to frame 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 inner valve surfaces Remove the plug spring and plunger O Wash the valve body with cleaning solvent and blow dry i O Lubricate all internal components with STP or petroleum jelly prior to reassembly Reassemble the valve positioning the O rings and back up rings as shown Reinstall the valve on the frame and connect the hydraulic tubes Remove components 54 Back up Ring Back up Ring O Ring Remove components 674219
4. 16 ft lb 19 22 N m O Lubricate the faceplate rollers and guides with Dubois FGG 2 food industry grease Cascade Part No 669306 O Inspect the bolts securing the gripper pad Tighten if necessary WARNING Tighten the platen hook capscrews to a torque of 200 210 ft Ibs 270 285 N m O Tighten the lower mounting hook capscrews to a torque of 105 115 ft lbs 140 155 Nm 1000 Hour Maintenance After each 1000 hours of lift truck operation in addition to the 100 hour and 500 hour maintenance procedures perform the following O Check the sideshift bearing strips and segments for excessive wear Replace if necessary Keep the bearing strips and segments well lubricated with Dubois FGG 2 food industry grease Cascade Part No 669306 O On sheet retainer models check the carrier assembly bearing segments for excessive wear Replace if neces sary Keep the bearing strips and segments well lubri cated with Dubois FGG 2 food industry grease Cascade Part No 669306 2000 Hour Maintenance After each 2000 hours of lift truck operation in addition to the 100 hour 500 hour and 1000 hour maintenance procedures perform the following procedure O Replace all arm bushings and thrust washers IMPORTANT After completing any service procedure always test each function through 5 complete cycles First test the clamp empty to bleed excess air trapped in the system Then test each function with a load t
5. 45C 30C san D Service 5 3 5 3 1 5 3 2 42 Valves Load Push and Load Push Pull Valve a Removal and Installation O Extend the faceplate WARNING Before removing any hoses se ang K i relieve pressure in the hydraulic system and tubing E Turn the truck off then open the truck auxiliary contro valve s several times Pa A in both directions E Load Push Pull O Remove tag and plug ali hoses and tubing from the oo Valve shown valve lt AAA R sd IS as ee emove the two capscrews and lockwashers retaining iS 2 the valve to the attachment frame For reassembly po Ai tighten the capsrews to a torque of 7 8 ft lbs fi a A 10 11 Nm eO capscrews b s O For reassembly reverse the above procedures 7 z uk Load Push Valve Disassembly and Service IMPORTANT Service the Valve in a clean work area 0 Remove the valve from the attachment as described in Section 53 1 2 Remove fittings and plugs O Remove the check valve cartridges O Clean all parts with kerosene or solvent See Section 5 3 11 O For reassembly reverse the above procedures except Detail A as follows e The check valve cartridge back up rings and O rings must be installed as shown in Section 5 3 11 e Lubricate the check valve cartridges with STP or petroleum jelly prior to reassembly e Tighten all fittings and cartridges except plugs to a ot ro Sa torque of 10 15 ft lbs 13 19 Nm See Section 5 3
6. 15 00 in 381 0 mm 2659x 674219 Rev 1 57 58 sin O Specifications 6 13 Torque Values Note that all specifications are shown in US and Metric units where applicable Not Shown All cylinder piston nuts See Sections 5 5 7 8 9 10 All cylinder retainers See Sections 5 4 7 8 9 10 Valve fittings and cartridges 10 15 ft lbs 13 19 Nm Additional equipment for SHEET SAV See Section 5 8 1 E Fastener Thread Size Nm Ft Lbs 19 22 47 53 10 12 60 70 270 285 140 155 _ 80 95 674219 Rev 1 Do you have questions you need answered right now Call your nearest Cascade Service Department AMERICAS Cascade Corporation U S Headquarters 2201 NE 201st Fairview OR 97024 9718 Tel 800 CASCADE 227 2233 Fax 888 329 8207 EUROPE AFRICA Cascade Italia S R L European Headquarters Via Dell Artigianato 1 37030 Vago di Lavagno VR Italy Tel 39 045 89891 11 Fax 39 045 8989160 ASIA PACIFIC Cascade Japan Ltd 2 23 2 Chome Kukuchi Nishimachi Amagasaki Hyogo Japan 661 0978 Tel 81 6 6420 9771 Fax 81 6 6420 9777 Cascade Australia Pty Ltd 1445 Ipswich Road Rocklea QLD 4107 Australia Tel 1 800 227 223 Fax 61 7 3373 7333 SA TM OCascade 1986 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
7. 37L min No 6 No 6 9 32in 7mm 9 32in 7mm Supply Hose and Fitting Size Minimum Orifice Size O Flowless than minimum will result in slow faceplate speed O Flow greater than maximum can result in excessive faceplate speed reduced system performance and short hydraulic system life Hydraulic Oil Cascade attachments are compatible with SAE 10W petroleum base oil per Mil Spec MIL 0 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 2659w 151 5 scum Installation Instructions 22 Installation Non Sideshifting NOTE Sideshifting Load Push and Load Push Pull Installation begins with section 2 3 WARNING Rated capacity of the truck attachment combination is a responsibility of the original truck manufacturer and may be less than shown on the attachment nameplate Consult the truck nameplate 221 Prior to Installation install the Quick Change lower mounting hooks For Bolt On type hooks proceed to Section 2 2 2 Quick Change Type A Install the components as shown Tighten the capscrews to a torque of 105 115 ft lbs 140 155 N m Type A Right side shown Quick Change Type B a Install the guides to the baseplate mounting holes with the guide hole offset in the upward position 5 8 in 16mm from top of guide to hole center Tighten the ca
8. Disconnect the hose at the left hand push pull cylinder rod end Plug or cap the open ports and hoses Install a drain line as shown in the illustration and apply pressure to extend the cylinder A steady stream of oil after fulkextension indicates a bypass at the seals Refer to Section 5 4 for cylinder inspection and servicing procedures Install drain VIEWED FROM FRONT OF ATTACHMENT 674219 Rev 1 35 36 sim Troubleshooting 4 6 4 6 1 Troubleshooting the Sheet Retainer Circuit There are five potential problem areas that could affect the sheet retainer operations e Insufficient truck hydraulic pressure e Defective solenoid coil or cartridge Worn or defective cylinder seals e Defective Diode Faulty electrical connection Sheet Retainer Function Troubleshooting WARNING Before removing any hoses relieve pressure in the hydraulic system Turn the truck off then 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 2000 PS 140 ban measured at the junction block 2 Check the flow volume at the junction block See Section 6 1 1 for the recommended flow volumes If the truck pressure and flow volume are correct proceed with the pressure test 3 Troubleshoot the sheet retainer elect
9. N O NC N C SV3 SV2 sv2 Complete installation of the cable and control knob Owner supplied Wiring THREE FUNCTION W Sheet Sav Two button contro knob Solenoid Valve Red Retainer N O i Green sv3 Diode Control Knob Cable y Solenoid so Valve Diode White Green White Push Pull NC White sv2 Black Red Sideshift Push Pull NO NC SV3 SV2 Complete installation Owner supplied of the cable and Wiring contro knob 674219 Rev 1 9 10 so 2 Installation Instructions 2 32 Installation Cont TWO FUNCTION WiElectric Stop Group Kimit switch asas Two button control knob Solenoid stop faceplate movement Diode Valve 7 5 Amp Control Knob 7 5 Amp Fuse Sideshift Push Pull Limit Switch N O NC SV3 Sv2 White Green ground Owner supplied Wiring Complete installation of the cable and control knob THREE FUNCTION W Electric Stop Group Solenoid Three button control knob Diode vave White Red f Limit switch opens to Control stop faceplate movement Knob 7 5 Amp Fuse 4 Limit E SS EN ae aa a Switch Red Black Sideshift Push Pull Platen Green NO NC N C SV3 sv2 sv2 Complete installation Owner supplied of the cable and Wiring control knob 674219 Rev 1 Remove air from the system by extending the faceplate fully and keeping it there for 10 20 seconds with the control valve actuated Sideshift the
10. Pull alve reverse the colors shown Gripper Cylinder Hose Terminal Hose Ree Platen Sideshift Cylinder Push Pull Auxiliary Valve Hose Terminal inex BET gt Sideshift Auxiliary Valve 28 674219 Rev 1 ad Troubleshooting 4 2 18 Circuit Schematic Load Push Pull Sideshifting Platens 674219 Rev 1 Push Pull Cylinders Truck Hydraulic Pump 29 sean Troubleshooting 4 3 4 3 1 30 Push Pull Circuit There are seven potential problems that could affect push pull operation e Insufficient hydraulic pressure External leaks Faulty electrical connection Defective solenoid coil or cartridge on solenoid equipped attachments e Worn or defective cylinder seals e Valve assembly malfunction e Kinked supply hoses Before proceeding with a test determine whether the push function pull function or the gripper function is at fault Then follow the check list under the problem function Section 4 3 1 43 2 4 3 3 or 4 3 4 to isolate the problem area Electrical Troubleshooting Solenoid Equipped Attachments See the wire diagrams and schematics shown in Section 2 3 2 step 11 Use the proper schematic while following the steps below 1 Check the control knob circuit fuse Replace if necessary 2 Check for loose electrical connections at the truck ignition switch control knob button s solenoid coil terminals and diodes 3 Remove the diode
11. Rev 1 sem Service s7 Electrical Faceplate Stop Group 5 7 1 Adjustment O Extend faceplate to expose stop switch Adjustment is made by loosening the capscrew and rotating the actuator wire Rotate actuator counter clockwise to decrease faceplate to platen tip dimension Rotate clockwise to increase the faceplate to platen tip dimension NOTE When the arm contacts the actuator wire the normally closed switch opens to stop faceplate travel Wiring is connected to terminals 1 and 2 for normally closed operation 674219 Rev 1 Adjusting capscrew Limit Switch Actuator Wire ELECTRICAL STOP 55 san D Service se Sheet Retainer Mechanism 5 81 Removal and Installation Q Extend the faceplate and actuate sheet release mode This will raise the sheet retainer bar off platens WARNING To remove platens prop sheet retainer bar in raised position and turn truck OFF to avoid possible injury 2 Set attachment and platens on floor Remove platen capscrews raise attachment to clear platens back attachment away and set on floor or pallet O Actuate sheet retain mode to lower sheet retainer bar to floor or pallet 4 Remove attachment from truck See Section 5 1 WARNING Before removing any hoses relieve pressure that might by present in the hydraulic system With the truck off open the truck auxiliary control valve s several times in both directions O Remove sheet retai
12. arrow points in this direction 13 14 seio4 Troubleshooting 4 1 3 Get All The Facts Before You Begin Working On The Attachment It is important that you gather all the facts regarding the problem before you begin service procedures The best way is to talk with the operator Ask for a complete description of the maltunction The following guidelines will help you decide where to begin your troubleshooting procedures A Push Pull Circuit e Attachment will not pull load Faceplate will not extend or retract Faceplate operates slowly Gripper bar will not lower or raise Gripper bar is not sequenced with the push pull function Gripper bar will not hold the slip sheet when pulling load onto platens If you encounter one of these problems refer to section 4 3 B Sideshift Circuit e Attachment will not sideshift e Attachment sideshifts slowly If you encounter one of these problems refer to section 4 4 C Adjustable Platen Circuit e Piatens will not move e Platens move very slowly If you encounter one of these problems refer to section 4 5 D Sheet Retainer Circuit e Sheet retainer bar will not move e Sheet retainer will not hold slip sheet when pushing load off platens e Sheet retainer bar moves slowly if you encounter one of these problems refer to section 4 6 E Sideshifting Platen Circuit e Platen will not sideshift e Platen sideshifts slowly If you encounter one of these problem
13. attachment was removed from the truck 18 Remove the capscrews and pins from the rod end of the push pull cylinders 00 00 6 O Remove the frame capscrews and pins that hold the pantograph arms to the frame Attach a hoist chain if attachment was 7 removed from truck Remove capscrews and pins 8 er _ Attach hoist chain J to faceplate Remove cotter pin i N Remove capscrews A and castellated nut fy N and pins For Reassembly Torque Capscrews to 14 16 ft lbs 19 22 Nm Y Primary Arm Y Q Remove capscrews 5 and pins Secondary Arm Twist each arm A toward center Remove cotter pin 1 and pin from link 674219 Rev 1 39 40 san D Service 5 2 2 5 2 3 Service and Reassembly O Inspect all shims and washers and replace any that are scored or worn unevenly A inspect the Telflon bushings for wear Replace the bush ings if the coating is scored or worn through Reassembly is the reverse of the disassembly proce dures except as follows e Apply chassis lube to the arm pivot pins prior to reas sembly eInstall and adjust the gripper hoses as described in Section 5 2 4 CAUTION Shim the primary arms at the bottom to position each clevis as shown Shim the top of the pri mary arms to provide 030 inch 75mm maximum clearance as shown Shim the secondary arm at the bottom to provide 030 inch 75mm maximum
14. attachment several times to force air from the sideshift cylinder to the truck reservoir NOTE This should correct an irregularly extending faceplate If it does not retract the faceplate and repeat the process Operate the unit through several complete cycles and make sure all functions operate smoothly and correctly PUSH PULL UNITS e The gripper jaw should open prior to the faceplate extension when the control handle is pushed forward e The gripper jaw should close completely prior to faceplate retraction when the control handle is pulled back PUSH PULL UNITS WITH FLOW CONTROL MANIFOLD OR SOLENOID VALVE e SPEED ADJUSTMENT The flow contro manifold and solenoid valve have a separate speed adjustment range of 30 for the load push and load pull functions See Section 5 3 10 for adjustment proce dures e HIGH VOLUME BYPASS ADJUSTMENT The flow control manifold and solenoid valve have a bypass orifice for use with high volume truck applications The bypass should be adjusted open for high volume trucks to reduce engine stall during actuation of the attachment See Section 5 3 8 for adjustment procedures PUSH PULL UNITS WITH MANUAL OR ELECTRIC STOP GROUPS The optional faceplate stop groups control the amount of faceplate retraction to prevent the platens from extending beyond the end of the unit load being carried and possibly damaging adjacent loads already stacked To adjust a manual or electric stop group Se
15. clockwise to increase the speed or counterclockwise to decrease the speed The adjustment range is 30 Adjust as necessary while operating the attachment Do not bottom out the adjustment Operating pressure will be lost Tighten the lock nuts after final adjustment 5 311 Check Valve Cartridge Seal Details O rings DETAIL A DETAIL B Load pull speed adjust QU S Load push diga speed adjust FLOW CONTROL MANIFOLD DETAIL C FLOW CONTROL SOLENOID VALVE e Load pull ne speed adjust Load push speed adjust O rings DETAIL D 674219 Rev 1 sucio D Service ss Cylinders Gripper Cylinder Removal and Installation O See Section 5 2 3 to remove the cylinder 5 4 1 2 Reverse the procedures to install the cylinder Push Pull Cylinder Removal and installation CAUTION ifthe attachmentis equipped with adjustable retainer cylinders as shown below the retainers must be adjusted prior to hose installation and attachment operation Service procedures are similiar to standard cylinders See step 5 for adjustment procedures 5 4 2 O Remove tag and plug the hoses at the push pull cylinder 2 Remove the capscrews and pins retaining the rod ends NOTE The cylinder may be swung out and serviced at this time To completely remove the cylinder proceed Remove the capscrews eyebolt and pin holding the cylinder to the frame Note position of eccentric pin for reasse
16. downward 5 8 in 16mm from bottom of guide to hole center to minimize the gap 6 Remove the push pull cylinder rod end pins Manually pull the faceplate away from the frame 674219 Rev 1 E EO Truck lower carriage bar Inspect Pp clearance Quick change lower hook Type B Left side shown Remove cylinder rod end pins Lower Carriage bar Bolt On Type Lower Carriage a Bar sf seio 2 Installation Instructions 232 Installation Cont Install the sideshift cylinder rod to the anchor bracket Push the faceplate back against the frame and reinstall the push pull cylinder rod end pins Reversing the Sideshift and Push Pull ports Flow Contro Manifold equipped units only Units equipped with a flow control manifold have the option of turning the manifold over to reverse the location of the Push Pull and Sideshift ports This will accommodate trucks already plumbed with Push Pull supply hoses on the left side and Sideshift supply hoses on the right side of the truck See Section 5 3 9 Position the attachment 4 in 10cm 4 in 10cm sideshift cylinder stroke to one side of center NOTE Open both fittings on the sideshift cylinder to X j AG allow the rod to move easily FLOW CONTROL Measure the hydraulic hose length required to connect MANIFOLD the hoses to the hose terminal Remove the hoses and cut to length as required CAUTION Flush the hoses
17. removing any hoses relieve pressure in the hydraulic system Turn the truck off then open the truck auxiliary contro 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 2000 PSI 140 bar measured at the junction block 2 Check the flow volume at the junction block See Section 6 1 1 for the recommended flow volumes If the truck pressure and flow volume are correct proceed with the troubleshooting 3 On solenoid equipped attachments press the push pull button e if both the push pull and sideshift solenoids click the valve is working correctly Continue the trouble shooting check list e If only the push pull solenoid clicks the sideshift solenoid cartridge spool is jammed in the closed position Replace the solenoid cartridge as described in Section 5 3 5 4 inspect the sideshift bearing strips and segments between the truck carriage and attachment frame for excessive wear Replace if necessary Keep the bearing strips and segments well lubricated with Dubois FGG 2 food industry grease Cascade part no 669306 5 The sideshift cylinder seals may be worn Install a drain line in the base end of the cylinder and apply pressure to retract the cylinder A steady stream of oil after full retraction indicates a bypass atthe seals Ref
18. speed Q Flow greater than maximum can result in excessive faceplate speed reduced system performance and short hydraulic system life Hydraulic Oil Cascade attachments are compatible with SAE 10W petroleum base oil per Mil Spec MIL 0 5606 or MIL 0 2104B Use of synthetic or aqueous base hydraulic oil is not recom mended Contact Cascade if fire resistant hydraulic oil must be used In orderto conform to industry standard practice the hoses should be connected to the truck auxiliary valve as indicated by the chart Function in Motion ofthe operator s hand sequence of Attachment when actuating the truck auxi location to Movement liary control handle while the operator facing the load Sideshift Right R doru ideshift Ri earward or Sideshift 9 E Sideshift Left Forward or Down Pull rearward Rearward or U Push Pull p Push forward Forward or Down Platens In Rearward or U Adjust Platens R Platens Out Forward or Down Retain Rearward or U Sheet Retain P Release Forward or Down Sideshift Right Rearward or Up Sideshift Platens Forward or Down Sideshift Left 2659x 61 2 Truck Carriage Truck carriage must conform to ISO dimensional standard 2328 equivalent to Industrial Truck Association ITA dimen sions shown Make sure the truck carriage is clean and the notches are undamaged Dimension A ITA ISO A Class Il 14 94 in 380 0mm
19. stall repeat steps 1 through 3 e if the truck does not stall adjustment is complete Flow Control Manifold Port Reversal The flow contro manifold can be turned over to reverse the location of the Sideshift and Push Pull ports WARNING Before removing any hoses relieve pressure in the hydraulic system Turn the truck off then open the truck auxiliary control valve s several times in both directions Remove the capscrews fastening the manifold to the frame Remove the two plug fittings from the top of the manifold Disconnect the elbow fittings from the connector fittings Remove the connector fittings O Disconnect the sideshift hoses from the elbow fittings if equipped O Turn the manifold over then reassemble 674219 Rev 1 FLOW CONTROL SOLENOID VALVE Plug fitting CONTROL MANIFOLD Remove capscrews and plug fittings Flow Control Manifold Disconnect sideshift hoses if equipped UA A ada LA PE Disconnect the elbow fittings and remove connector fittings Turn the manifold over then reassemble e Sideshift hoses if equipped 47 48 san D Service 5 340 Push Pull Speed Adjustment The optional flow control manifold and solenoid valve have a separate speed adjustment range of 30 tor the Load Push and Load Pull functions O Loosen the lock nut on each adjustable valve cartridge 2 Turn the adjustment screw with a hex wrench
20. 11 Detail C 674219 Rev 1 sein Service 5 33 Load Push Pull Valve Disassembly and Service IMPORTANT Service the Valve in a clean work area O Remove the valve from the attachment as described in Section 5 3 1 See Section 5 3 11 Remove fittings and plugs Derails O Remove the check valve cartridges O Clean all parts with kerosene or solvent For reassembly reverse the above procedures except as follows See Section 5 3 11 Detail B See Section 5 3 11 Detail A e The check valve cartridge back up rings and O rings must be installed as shown in Section 53 11 e Lubricate the check valve cartridges with STP or petroleum jelly prior to reassembly e Tighten all fittings and cartridges except plugs to a torque of 10 15 ft lbs 13 19 Nm See Section 5 3 11 Detail C LOAD PUSH PULL VALVE See Section 5 3 11 See Section 5 3 11 Detail B Detail A See Section 5 3 11 Detail A See Section 5 3 11 See Section 5 3 11 Detail B Detail C LOAD PUSH PULL VALVE WITH SIDESHIFTING PLATENS 674219 Rev 1 43 san D Service 5 3 4 Solenoid Valve TEPEE Removal and Installation Determine which version you have as shown and use that illustration for valve removal and installation as follows Remove the cover plate as shown Remove cover plate WARNING Before removing any hoses relieve pressure in the hydraulic system Turn the truck off then open the truck
21. 1600 60A Steel Road Sparton Kempton Park South Africa Tel 27 11 975 9240 Fax 27 11 394 1147 Cascade Korea 121B 9L Namdong Ind Complex 691 8 Gojan Dong Namdong Ku Inchon Korea Tel 82 32 821 2051 Fax 82 32 821 2055 Cascade New Zealand 15 Ra Ora Drive East Tamaki Auckland New Zealand Tel 64 9 273 9136 Fax 64 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 65 6795 7555 Fax 65 6863 1368 11 36 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 674219 R 1
22. 4219 Rev 1 19 20 suo 4 Troubleshooting 4 29 Hosing Diagram Load Push Pull Sideshift without Solenoid Push Pull Gripper Cylinder N FACEPLATE RETRACT and E ti SAL Go RA Load GRIPPER BAR DOWN PRESSURE EHEHE E SS Push Pull N u RETURN eae ES gt gt SLAVE HE ER gt NOTE For faceplate EXTEND and gripper bar UP reverse the colors shown Hose Terminal Push Pull Auxiliary Valve Hose Lo Reel o Sideshift SS Auxiliary r Vaiye Gripper Push Pull O Cylinder A LS IES ih DO SIDESHIFT RIGHT A Load 4 OS PRESSURE Sz Push Pull S Valve RETURN NOTE For sideshift LEFT reverse the colors shown Terminal E S CEI f MANIFOLD or XD In SSR BRACKET Push Pull Auxiliary Valve VEZ Sideshitt Auxiliary Valve 674219 Rev 1 san Troubleshooting 4 2 10 Circuit Schematic Load Push Pull Sideshift without Solenoid Both Cylinders Push Pull 5 Cylinders C2 an mm re o Gripper 1 Load Cylinders I Push Puli A V Q VE l t Siete ET Cylinder I Manifold if equipped In In SSL EXT Hose Perini f F a 1 Terminal L Hose i Hose E si Reel j Push Pull Sideshift Ns 4 a Auxiliary s SATE Auxiliary Valve Em E Valve Ea Truck Relief Valve Truck Hydraulic Pump 674219 Rev 1 21 wun4 Troubleshooting 1 241 Hosing Dia
23. A statement preceded by IMPORTANT is information that posseses special significance NOTE A statement preceded by NOTE is information that is handy to know and may make your job easier 2 Installation Instructions 21 WARNING Rated capacity ofthe truck attachment combination is a responsi bility of the original truck manufacturer and may be less than that shown on the attach ment nameplate Consult the truck nameplate Truck Requirements e Truck Relief Valve Setting 2000 psi recommended 2300 psi maximum e Hydraulic flow should fall within the volume range shown in the table e The truck hydraulic system must supply oil to the attach ment that meets the specifications shown in the table e Recommended hose and fitting size No 6 with minimum fitting orifices of 9 32 in 7mm e Truck carriage must conform to ISO dimensional standard 2328 equivalent to Industrial Truck Association ITA dimensions shown in Section 61 2 e Make sure the truck carriage is clean and the notches are undamaged e In order to conform to industry standard practice the hoses should be connected to the truck auxiliary valve as indicated by the chart in Section 64 1 674219 Rev 1 Hydraulic Specifications Pressure Recommended 2000 140 bar Maximum 2300 2300 160 bar 160 bar e 3 GPM Flow Minimum T1L min 9 GPM 6 GPM Recommended 34L min 22L min Aa 15 GPM 10 GPM 56L min
24. General Cylinder Service Procedures 50 Cylinder Services sp o a a lea Cap eS 51 52 RATAS A A a talar 53 Platen Removal and Installation 53 Platen SRIMS 3 est are ee a a la e a a 53 INSPECUON ut ra a ee eck ia a dow Beeches 53 Hydraulic Faceplate Stop Group o o 54 Adjustment ico wile o ine eB De A tl a ee 54 Stop Valve Service ooo o 54 Electrical Faceplate Stop Group 2 o 55 AGIUSIMONE 0 ad e e ti 55 Sheet Retainer Mechanism 2 0 o o 56 Removal and Installation 2 0 0 0 000 0000 ee uae 56 Specifications Section6 000 57 AAA aie dada co Sete ae ee na ated Gee ke AA 57 TICK GAMAQGO e apra tira Eel eo a a el Go Ge ie a 57 Torque Values o oo o 1 58 mar 674219 Rev 1 sewn 1 Introduction 11 This manual provides the installation instructions periodic maintenance requirements troubleshooting procedures and service guides for 30C and 45C Load Push and Load Push Pulls Note that all specifications are shown in US and Metric units where applicable Special Instruction Definitions A WARNING A statement preceded by 44 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
25. N if Cascade replacement hoses are not used the hoses must meet the following specifications No 4 Hoses with No 4 fittings Meets SAE 100 R7 specifications Seamless nylon inner tube wrapped with a single synthetic fiber braid Polyurethane cover O Hose Ois marked at 25 5 65 cm and 265 67 cm from one end Attach that hose end to the gripper cylinder base end tee fitting O Hose Dis marked at 30 5 78 cm and 31 5 80 0 cm from one end Attach that hose end to the gripper cylinder rod end tee fitting O Route the pair of hoses through the secondary and primary arm to the valve as shown Q Position hose markings at clamping locations A and D Take slack out of hoses where attached to the arms O Fully extend the faceplate Position hoses between clamps B and C to be tight but not stretched O Tighten the six clamp capscrews to a torque of 7 8 ft lbs 10 11 N m 7 Extend and retract the faceplate noting any areas where the hose is being stretched or pinched Adjust as required a Ed Ed 7 EN E 3 Hose 1 ne b 1 P A ei K Position hoses to be not stretched AS tight but fi EO j 674219 Rev 1 Hose P N Se 25 5 65cm 45C 30C 65 5 166cm 56 0 142cm 94 5 240cm 60 5 153cm 45C 30 101 5 258cm Position the hose markings 1 Hose P N 672994 Route the hoses to the valve 45C 30C
26. ade P N 671477 e ANo 6 swivel nut run tee 37 JIC suitable for mounting the gauge e A metal plug and cap No 6 37 JIC for plugging hoses and capping fittings e Aneedle shutoff valve rated for 2500 psi 175 bar Cascade P N 673681 e Voltmeter or test light for solenoid equipped attachments Ohmmeter for solenoid equipped attachments Assemble the hydraulic test instruments as shown No 6 Swivel 674219 Rev 1 No 6 37 Flared Female Fitting Hydraulic Specifications oc ae 2000 2000 140 bar 140 bar 2300 2300 160 bar 160 bar Pressure Recommended Maximum E 3GPM 3 GPM Flow Minimumo Lmin tmin 9 GPM 6 GPM Recommended S4L min 22Umin 15 GPM 56L min No 6 9 32in 7mm 10 GPM 37L min No 6 9 32in 7mm Maximum Supply Hose and Fitting Size Minimum Orifice Size O Flowless than minimum will result in slow faceplate speed Flow greater than maximum can result in excessive faceplate speed reduced system performance and short hydraulic system life Hydraulic Oil Cascade attachments are compatible with SAE 10W petroleum base oil per Mil Spec MIL 0 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 2659w 151 5 Pressure NOTE Make sure Hose the
27. as follows to prevent damage to the attachment hydraulic components Connect the hoses to the truck hose terminal Connect the hoses together using a union fitting Start the truck and actuate the truck control valve in both directions for about 30 seconds to carry any debris in the hoses to the truck hydraulic tank and filter Remove the union fittings and connect the hoses to the attachment fittings as shown Position the hose guards to prevent the hoses from being scuffed by the frame SOLENOID Pull MANIFOLD T BRACKET VALVES Push SSR SSL SSR Pull SSR SSL Push SSL Pull Push A Push the attachment 4 inches to one side ion 8 674219 Rev 1 san2 Installation Instructions 232 Installation Cont Solenoid Equipped Attachments The electric cable leading from the attachment should be tied to the hoses to prevent scuffing of the cable during attachment sideshifting See the electrical schematic to complete a g Control installation Knob Sofenoid Valve Diode TWO FUNCTION E Amp One button control knob use Black White em Sideshift Push Pull Owner supplied Complete installation N O NC Wiring of the cable and sv3 sv2 control knob THREE FUNCTION s lene wo button control knob iT Diode Valve Control Knob 7 5 Amp Fuse Green Sideshift Push Pull Platen
28. assembly and Service IMPORTANT Service the Manifold in a clean work area Remove fittings plugs and Remove the manifold from the attachment as described flow control cartridges in Section 5 3 6 2 Remove the fittings plugs and flow control cartridges Remove the high volume bypass components Q Clean all parts with kerosene or solvent O For reassembly reverse the above procedures except as follows e The flow control cartridge back up rings and O rings must be installed as shown in Section 5 3 11 e Lubricate the flow control cartridges with STP or petroleum jelly prior to reassembly e Tighten all fittings and cartridges except plugs to a torque of 10 15 ft lbs 13 19 N m e Adjust the high volume bypass setscrew as described in Section 5 3 8 See Section 5 3 11 Detail C Remove the high volume bypass components 46 674219 Rev 1 ss D Service 5 3 8 High Volume Bypass Adjustment 5 3 9 The flow control manifold and solenoid valve have a bypass orifice for use with high volume truck applications over 16 GPM 60L min The bypass can be adjusted to reduce truck engine stall during actuation of the attachment NOTE The bypass orifice setscrew is adjusted closed at the factory Remove the plug fitting Turn the setscrew counterclockwise one turn with a screwdriver Tighten the jam nut Replace the plug fitting O Start the truck and actuate the attachment e l the truck continues to
29. auxiliary contro valve s several times in both directions 4 Disconnect 2 Remove tag and plug all hoses or tubes at the valve 6 amp and tag all Disconnect all electrical leads at the solenoid coils a eee ti NOTE Mark each lead for ease in reinstallation O Remove the capscrews retaining the valve to the frame O Installation is a reverse of removal except as follows e See Section 2 3 2 step 11 for wiring diagrams Remove tag and plug all hoses and tubing Disconnect and tag 3 Remove capscrews all electrical leads O 4 gt gt Remove C d D r cover X q D Remove Cover Plate E gt plate Y Remove capscrews Disconnect and tag all electrical leads Remove tag and plug all hoses and tubing LG Remove tag and plug A ali hoses and tubing 44 674219 Rev 1 sein Service o 5 3 5 Solenoid Valve Disassembly and Service NOTE The Solenoid Valve you are servicing may differ from the assemblies shown Seal placement and coil assembly is typical for all valves IMPORTANT Service the Solenoid Valve in a clean work area 11 Remove the valve from the attachment as described in Section 5 3 4 Remove fittings and plugs Remove the solenoid coils CAUTION Always replace the coils with a coil of the same voltage Q Remove the check valve and solenoid cartridges O Remove the high volume bypass components if equipped O Clean all parts with k
30. cascade my Service Manual 30C 45C Load Push and Load Push Pull Serial Numbers 673290 through 679295 PN Manual Number su R 1 Cascade Cascade is a Registered Trademark of Cascade Corporation Contents Page Introduction Section 1 ccccc aaa aaa 1 Pad Installation Instructions Section 2 1 Truck Requirements o 1 Installation Non Sideshifting o o 2 Prior to Installation 0 0 ee 2 Installation ss mes rn a eee a a 3 Prior to Operation 26 santas na A ee me ee 4 Installation Sideshifting 0 o o es 5 Prior to Installation o ooo 5 Installation 0 o o o o o A AI 6 Prior to Operation o e e 11 Periodic Maintenance Section 3 12 Troubleshooting Section 4 13 General Procedures oa aaa 13 Truck System Requirements 0 0 a 13 TOOISSREGUITED s or i ok te Ge E i a 13 Get All The Facts a i aei ar a Be we a ta 14 PIUMADING 8 15 Sendra tte ts noe a SP te ce Bhd Dan aan RAR Dewees 15 Hosing Diagrams ss aka wee hae ke ee ee Se 15 28 Circuit Schematics 0 cares 15 29 Troubleshooting the Push Pull CirGuit 30 Electrical Troubleshooting Solenoid Equipped Attachments 30 Push Hydraulic Function 2 ee 31 Pull Hydraulic Function 2 0 0 0 0 a 32 G
31. ce For reassembly Slide the piston and retainer from the rod O al seals includino tighten to a compensator valve seal pg Si CAUTION On units equipped VN NJ na RE CAN 610 675 N a ith platens shorter than 48 e SS a WI piatens shorter tnan f pe ANNE A 45C 550 600 t Ibs inches 122 cm split spacers i and shims must be installed in the push pull cylinders If your 740 810 N m ER AY aan q unit was factory ordered with A platens shorter than 48 inches 122 cm the spacers and YA shims are factory installed If you are installing the shorter platens the spacers and shims are supplied with the platens for field installation Remove the nut To install the spacers and 4 Remove piston shims you need only remove For reassembly tighten to a and retainer torque of the retainer and slip the shims 30C 350 400 ft 1bs and split spacers into place 470 540 N m Torque the capscrews to 9 ft lbs 45C 450 500 ft lbs 12 Nm Reinstall the retainer 610 675 N m 0 Remove and replace all seais including the compensator valve seals O Perform the inspection and reassembly procedures in paragraph 5 4 6 674219 Rev 1 51 san D Service 5 49 Sideshift Cylinder Service Read the General Service Procedures paragraph 5 4 6 before proceeding Remove the capscrews securing the washer to the retainer Partially extend rod approx 4 and slide Tap screwdriv
32. chment upper hook centering tab with the closest truck upper carriage bar notch and raise the truck carriage into position behind the attachment Lift the attachment 2 in 5cm off the pallet NOTE The attachment may not be perfectly centered on the carriage bar when the centering tab is engaged in the upper carriage bar notch WARNING The upper mounting hook must be properly engaged with the upper carriage bar The centering tab must be engaged in the mating notch on the upper carriage bar NOTE The lower hooks cannot be properly installed if the locating tab is not engaged in the carriage notch Engage the lower hooks with the truck lower carriage bar Bolt On Type Installthe hooks and capscrews Tighten the capscrews finger tight Tap the end of the hooks with a hammer in the direction of the adjust arrow for maximum engagement with the carriage bar Tighten the capscrews to a torque of 105 115 ft lbs 140 155 Nm Quick Change Type A Turn both hooks up and reinstall the pin The maximum allowable clearance between the hooks and carriage bar is 1 8 in 4mm as shown Quick Change Type B Remove the locking pins Slide the hooks up to engage with the carriage bar Install the locking pins through the upper holes CAUTION If the clearance between the carriage bar and the hooks exceeds 3 16 in 6mm the guides refer to Section 2 2 1 step 1 should be inverted and installed with the hole offset
33. clear ance as shown O After reassembly and installation on the truck extend and retract the faceplate 5 times to bleed excess air that may be trapped in the system If the faceplate extends at an angle after bleeding excess air and the cylinders are not defective see Section 4 3 2 and 4 3 3 use the following procedure to correct the misalignment NOTE If any major component frame faceplate panto graph arm etc has been replaced use this procedure to correct the misalignment a Fully extend the faceplate with the eccentric pin at a neutral position the letter N should be next to the capscrew b Measure the distance between the faceplate and the frame on both sides The measurements should be equal within 42 inch 13mm if measurements differ by more than inch 13mm the pin opposite the longest measurement should be moved to the R Retract position as follows c Remove the capscrew and eyebolt Insert a metal rod and slowly turn the pin around until the R is near the capscrew d Insert the eyebolt and tighten the capscrew toa torque of 35 39 ft lbs 47 53 N m e If still misaligned beyond Ye inch 18mm turn pin opposite shortest measurement to E extend position near the capscrew Gripper Mechanism Service O Remove the cotter pins and pins retaining the gripper cylinder rods to the gripper bar 2 Remove all the capscrews holding the gripper jaw to the faceplate The channel is now fr
34. e Section 5 6 or 5 7 PUSH PULL UNITS WITH ADJUSTABLE PLATENS The platens can be adjusted to a wider or narrower profile without tools to accommodate different size loads or for pallet handling See Section 5 5 1 for adjustment proce dures 674219 Rev 1 sion Installation Instructions 233 Prior to Operation FLOW CONTROL SOLENOID VALVE FLOW CONTROL MANIFOLD 11 si Periodic Maintenance 31 3 2 3 3 3 4 12 100 Hour Maintenance Every time the lift truck is serviced or every 100 hours of truck operation whichever comes first complete the following maintenance procedures O Inspect the platen shims at the bottom of the frame Tighten the bolts and readjust the shims as shown in Section 5 5 ifnecessary O Inspect the faceplate rollers and related parts for suffi cient lubrication If necessary lubricate with Dubois FGG 2 food industry grease Cascade Part No 669306 O Inspect the hoses mounted in the pantograph arms They should be mounted securely and without hose droop Check for hose wear and kinking at the primary and secondary arm connections Replace kinked or worn hoses 500 Hour Maintenance After each 500 hours of lift truck operation in addition to the 100 hour maintenance procedure perform the following O Inspect all bearings and shims at the pivot points for excessive wear Replace if necessary J Tighten the capscrews that secure the arm pivot pins to a torque of 14
35. e the hooks up and install the pins in the top holes WARNING Before removing any hoses relieve pressure in the hyd raulic system Turn the truck off then open the truck auxiliary control valve s several times in both direc tions 4 Disconnect tag and cap the attachment hoses at the carriage hose terminals O Disconnect the sideshift cylinder if equipped from the truck carriage anchor bracket Disconnect the electrical connection at the truck on solenoid mounted attachments Lower the truck carriage and back away from the attach ment 18 For reinstallation reverse the above procedures making sure the locating tab in the upper hook properly engages the notch in the upper truck carriage bar Lower Carriage and Back Away Retaining Pin Locking Pin E 674219 Rev 1 som D Service 5 2 5 2 1 Faceplate and Pantograph Arms Disassembly Remove the cotter pin and pin from the link on the backside of the faceplate Remove the cotter pin and castellated nut that join the secondary arms together Remove the pin Disconnect cap and tag the two gripper cylinder hoses at the gripper cylinder Attach a hoist chain to the faceplate Remove the capscrews and pins which hold the secondary arms to the primary arms Twist each secondary arm towards the faceplate center to remove them from the channels on the backside of the faceplate Q Attach a hoist to the frame assembly if the
36. ee WARNING Before removing any hoses relieve pressure in the hydraulic system Turn the truck off then open the truck auxiliary control valve s several times in both directions Remove tag and plug hoses at the gripper cylinders a Remove the nut retaining the cylinder to the faceplate and pull out the cylinder O Reassembly is the reverse of disassembly except as follows eTighten the cylinder anchor nuts until rigid then back off one turn Shim primary arms PRIMARY ARM to provide max clearance shown Frame 030 ZO 75 mm Y s Primary Arm N Faceplate 4 Inspect all f bushings 1 50 38mm SECONDARY ARM l N PE AR mer DT E Shim primary arms J 030 here to provide 14 75mm measurement shown Shim secondary arms at bottom to provide ax clearance shown a yi CV ir Y Y NAS KJ FRONT OF ATTACHMENT NEUTRAL CAM POSITION Remove tag and plug the hoses Remove nut and cylinder Remove oo capscrews A as pl N ed 1 A Remove cotter pin Loe 3 and clevis pin i q Remove all seven capscrews 674219 Rev 1 san D Service 5 2 4 Gripper Hose Installation The gripper hoses must be installed as described below for the hoses to properly track with the arms during faceplate extension and retraction Replacement hoses should be marked as shown at right CAUTIO
37. eplate EXTENDED a gripper bar UP and platens positioned Q Valve NARROW reverse the colors shown Platen Positioner Cylinder E Hose Que Terminal Sideshift Cylinder Gripper Cylinders Push Pull Cylinder SIDESHIFT RIGHT PRESSURE MAENE RETURN Push Pull Cylinder NOTE For sideshift LEFT reverse the colors shown E Push Pull TR Valve Platen Positioner Cylinder z A Hose meg Terminal Sideshift Truck Cylinder Auxiliary Valve 24 674219 Rev 1 4 Troubleshooting _ e 4 244 Circuit Schematic Load Push Pull Hydraulically Adjustable Platens Both Cylinders Push Pull Cylinders ES x TA 4 Grip Cylinders AN Y Load oa Push Pull Platen A ese Q ai Valve Positioner a iT E E Cylinder ps ni ii i ca y Es O Sv2 EA Sideshift Qs Cylinder Ly at i t vo y pi al Terminal a ay H Hose NS A fin Reel e one Solenoid Valve Valves with Flow Control only Truck Hydraulic Pump 674219 Rev 1 e sesion 4 Troubleshooting 4 215 Hosing Diagram Load Push Pull Sheet Retainer Sheet Sav Push Pull FACEPLATE RETRACT Cylinder GRIPPER BAR DOWN and SHEET RETAINER UP PRESSURE FREE Load RETURN all Push Pull gt SLAVE o 3 Note For faceplate EXTEND e u 2 1 4 Push Pult Cylinder reverse the colors shown In wW EXT Sheet Retain
38. er Cylinder Sideshift Cylinder E Gripper Cylinder Truck Auxiliary Valve Push Pull Solenoid Cylinder ExT SIDESHIFT RIGHT Load Push Pull Valve PRESSURE SEENEN RETURN NOTE For sideshift LEFT ae reverse the colors shown Sheet Retainer Cylinder Sideshift Cylinder MZ A pl Gripper i Cylinder Truck Auxiliary Valve 26 674219 Rev 1 sein Troubleshooting 4 2 16 Circuit Schematic Load Push Pull Sheet Retainer Sheet Sav Push Pull Cylinders Both Cylinders y A ra SV3 Ssv2 ge En Mel fi Valve y InEXT UL ___ lt _ _ Sheet Retainer Cylinder LJ C4 C3 C2 1 F Sideshift Cylinder Valve with Flow ntrol only Control 674219 Rev 1 Truck Hydraulic Pump 27 se Troubleshooting Cylind FACEPLATE RETRACT and vinda PP Es I J RETURN i y eS 4 2 17 Hosing Diagram Load Push Pull Sideshifting Platens 3 GRIPPER BAR DOWN Mx Puch Pull SS Push Pull F A A Gripper N PAi Cylinder PRESSURE SEENEN ES SLAVE DM Valv NOTE For faceplate EXTEND and In aera CRN e h gt Sy WS ci RS SSR In EXT TO gripper bar UP reverse the colors shown La c6 C4 Push Pull Hose GS In ee Cylinder Terminal RET HEA sh P MANIFOLD or BRACKET Push Pull Auxiliary Valve Sideshift Auxiliary Valve Push Pull SIDESHIFT RIGHT Cylinder PRESSURE MR Y RETURN Load NOTE For sideshift LEFT Push
39. er washer away from retainer Retainer ring Remove the retainer ring by first tapping the retainer in Then place a screwdriver on one side of the ring near the split and tap the screwdriver gently with a hammer The retainer ring should compress at the split and turn sideways Grasp the ring and pull it out Pull the rod assembly out of the shell Remove the nut securing the piston to the rod Slide the piston and retainer off the rod Remove and replace all seals Perform the inspection and reassembly procedures 90000 f K y R listed in paragraph 5 4 6 2 E PE E For reassembly Torque to ny 20 25 in lbs S a e R l 2 3 N m ez ES uz o E AT Es TEx 4 5 Remove the piston Pull rod Remove the nut and retainer es a ee For reassembly Torque to Remove and 40 45 ft lbs 54 61 Nem replace all seals 5 4 10 Adjustable Platen Cylinder Service Read the General Service Procedures paragraph 5 4 6 before proceeding O Remove the cotter pin pin and link at both ends of the cylinder 2 Use wrench to unthread the retainers Pull the rod assemblies out of the shell O Remove and replace all seals O Perform the inspection and reassembly procedures listed in paragraph 5 4 6 Remove and replace all seals O rings and backup rings AAA Ne ON EE CE Fe aS Ng pd y XN NS Remove retainers For reassembly Torque to 65 70 ft lbs 88 95 N m
40. er to Section 5 4 for cylinder inspection and servicing procedures Install drain line here VIEWED FROM FRONT OF ATTACHMENT 674219 Rev 1 4s Troubleshooting the 4 a 1 Gi ow E Hydraulically a Adjustable Platen a Circuit There are five potential problem areas that could affect the adjustable platen operation e Insufficient truck hydraulic pressure e Defective solenoid coil or cartridge e Worn or defective cylinder seals e Defective Diode e Faulty electrical connection 4 5 1 Adjustable Platen Function Troubleshooting PRESS BUTTON TO POSITION i PLATENS 4 BUTTON TO SIDE SHIFT O PUSH PULL WARNING Before removing any hoses relieve pressure in the hydraulic system Turn the truck off then open the truck auxiliary control valve s several times in both directions 1 Check the pressure delivered by the truck Refer to the THREE FUNCTION truck service manual The pressure must be within 100 Two button control knob psi 7 bar of specified truck pressure TRUCK PRESSURE MUST NOT EXCEED 2000 PSI 140 ban measured at the junction block 2 Check the flow volume at the junction block See Section 6 1 1 for the recommended flow volumes If the truck pressure and flow volume are correct proceed with the pressure test 3 Troubleshoot the adjustable platen electrical circuit as described in Section 4 3 1 4 The adiustable platen cylinder seals may be worn Extend the faceplate
41. erosene or solvent For reassembly reverse the above procedures except as follows e The check valve and solenoid cartridge back up rings and O rings must be installed as shown in Section 5 3 11 e Lubricate the check valve and solenoid cartridges Eos with STP or petroleum jelly prior to reassembly e Tight all fittings and cartridges except plugs to a torque of 10 15 ft lbs 13 19 Nm e Adjust the high volume bypass setscrew as described in Section 5 3 8 Remove check valves and solenoid See Section 5 3 11 Detail D See Section Remove 5 3 11 solenoid Detail C O coils Remove the high volume by pass o components THREE FUNCTION SOLENOID VALVE WITH FLOW CONTROL 674219 Rev 1 Remove YB solenoid Remove check valves and solenoid cartridges See Section 5 3 11 Detail D See Section 5 3 11 Detail C TWO FUNCTION SOLENOID VALVE SHEET SAVO 45 sind Service 5 36 Flow Control Manifold Removal and Installation WARNING Before removing any hoses Remove relieve pressure in the hydraulic system capscrews Turn the truck off then open the truck auxiliary control valve s several times in both directions Remove tag and plug all hoses and tubes to the manifold 2 Remove the capscrews fastening the manifold to the frame installation is a reverse of above procedures p Remove tag and plug all hoses or tubing 5 3 7 Flow Control Manifold Dis
42. g e Inspect the inside of the cylinder shell and remove any minor nicks and burrs see Note above with a butterfly hone Replace the cylinder shell if it is deeply gouged Cylinder Assembly e Lubricate all new seals with STP before installing e Toinstall a new seal on a piston or retainer hook one side of the seal in the groove and push it over the piston or retainer NOTE Polishing the chamfer angle will allow the seal to slide into the groove much easier e Carefully note the direction of U cup seals If they are installed backwards the seals will not seal properly Refer to the illustration of the cylinder you are servicing on pages 51 and 52 e Always reassemble the rod assembly by sliding the retainer on first then the piston assembly Install and torque the piston retaining nut before sliding the rod assembly back into the shell e When reassembling a cylinder always observe all torque values as shown in the appropriate illustration Remove Cotter Pins and Pins 1 Remove and plug tubes Remove capscrews For reassembly Torque capscrews to 7 9 ft lbs 10 12 Nem Pin type Spanner Wrench Load Push Pull Cylinder Clamp rod assembly in soft jawed vise Clamp cylinder in soft jawed vise Sideshift and Gripper Cylinder Ciamp cylinder in soft jawed vise Remove seal from piston CAUTION Do not scratch the groove Polish this chamfer Install new seals as shown
43. gram Load Push Pull Sideshift with Solenoid Gripper Cylinders Push Pull Cylinder FACEPLATE RETRACT and GRIPPER BAR DOWN In PRESSURE EH RETURN SLAVE az Solenoid Valve NOTE For faceplate EXTEND and Sideshift gripper bar UP reverse the colors shown Cylinder Gripper Cylinders Push Pull Cylinder SIDESHIFT RIGHT PRESSURE HRS RETURN MOL Push Pull NOTE For sideshift LEFT Cylinder reverse the colors shown Solenoid Valve Sideshift f Cylinder A Hose 9 Terminal 22 674219 Rev 1 Section TFT EE Wes 4 212 Circuit Schematic Load Push Pull Sideshift with en Push Pull Cylinders E Both Cylinders e RE Ee Tr O W sa E l Z Q Gripper 1 Cylinders 1 Di 1 i p ae Che Cylinder caf wea in In c3 C4 C2 C1 Es Sv3 Sv2 In a pa MAT HE Ep gl HZ l E Hose i Solenoid A Termina Valve i ot Mx EXT Valves with Flow Q Control only Truck Auxiliary Valve Truck Relief Valve Truck Hydraulic Pump 674219 Rev 1 23 sin 4 Troubleshooting 4 213 Hosing Diagram Load Push Pull Hydraulically Adjustable Platens FACEPLATE RETRACT GRIPPER BAR DOWN and Gripper Push Pull Cylinders Cylinder PLATENS POSITIONED WIDE In EXT y Solenoid PRESSURE MRE Valve RETURN Push Pull SLAVE ECE Cylinder NOTE For fac
44. graphite base grease to the bearing segments 674219 Rev 1 25 4mm Y Place template on center notch Mark both lines 43 Sheet Sav TEMPLATE 673253 lf template is missing use these dimensions a ket DO NOT weld here to locate bracket 3 25 in 82 5mm Use AWS E7018 rod Preheat to 300 350 F 150 175 C 0 40 inch 10mm fillet welds bottom and sides Locate a bearing segment Bon each side of the carriage side plates as near as the notches permit 32 in 812mm carriage 36 in 914mm carriage A 14 in 355mm MIN 16 in 406mm MAX A 14 in 355mm MIN 17 in 431mm MAX seio 2 Installation Instructions 2 3 1 Prior To Installation Cont Install the two lower bearing strips on the attachment and coat them with a graphite base grease Install the Quick Change lower mounting hooks For attachments with bolt on type hooks proceed to step 8 Quick Change Type A Install the components as shown Tighten the capscrews to a torque of 105 115 ft los 140 155 N m Quick Change Type B a Install the guides to the baseplate mounting holes with the guide hole offset in the upward position 5 8 in 16mm from top of guide to hole center Tighten the capscrews to a torque of 105 115 ft lbs b Slide the hooks over the top of the guides Install each locking pin through the hook lower hole Type A Right s
45. he hooks with a hammer in the direction of the adjust arrow for maximum engagement with the carriage bar Tighten the capscrews to a torque of 105 115 ft lbs 140 155 N m Quick Change Type A Turn both hooks up and reinstall the pin The maximum allowable clearance Truck Lower between the hooks and carriage bar is 1 8 in 4mm Carriage bar as shown Type B Quick Change Type B Remove the locking pins ia Left side shown Slide the hooks up to engage with the carriage bar p Clearance Install the locking pins through the upper holes F CAUTION If the clearance between the carriage ras bar and the hooks exceeds 3 16 in 6mm the er hock guides refer to Section 2 2 1 step 1 should be Layer inverted and installed with the hole offset downward Carriage Bar 5 8 in 16mm from bottom of guide to hole center to minimize the gap 674219 Rev 1 3 socion 2 Installation Instructions 222 Installation Continuea Pull Push 6 Measure the hydraulic hose length required to connect the hoses to the hose terminal Remove the hoses and cut to length as required CAUTION Flush the hoses as follows to prevent damage o to the attachment hydraulic components Connect the hoses to the truck hose terminal Connect o the hoses together using a union fitting Start the truck Es cas and actuate the truck control valve in both directions for about 30 seconds to carry any debris in the hoses to the truck hydrau
46. ide shown TO INSTALL THE CONTROL KNOB Solenoid Units Only O Remove the existing knob from the auxiliary valve control handle and install the new knob as shown Ifthe control handle is not threaded weld on the adapter supplied with the new knob NOTE It may be necessary to saw off a portion of the control handle to achieve a comfortable length CAUTION Secure the cable assembly to the control handle so the cable will not be pinched at the truck cowl when the handle is actuated If the control knob has 1 button then the two function side of the control knob placard should be showing When the control knob has 2 buttons then the three function side of the placard should be showing Fit the dimple on the placard into the recess on the knob and install the snap ring Type B Left side shown E in 1 mm Locking Pin Install new control knob Cable assembly not shown for clarity 3 8 16 UNC threads w Jam Nut L tighten to secure knob Adapter discard if not required Push Button facing toward driver 3 8 24 UNF threads Install control Auxiliary Truck knob placard Valve Control Handle Use Loctite 242 here only Snap Ring Dimple Down Recess Control Knob 674219 Rev 1 sin Installation Instructions 232 Installation Center the lift truck behind the attachment Tilt the mast forward Engage the atta
47. iewed from the driver s seat Plug the cylinder supply hose with a No 6 metal plug 4 Connect a pressure gauge with a needle shutoff valve and drain line to the valve fitting refer to Section 41 2 for an illustration of the gauge arrangement Put the drain line in an empty container 5 Open the needle valve no more than to 1 full turn Start the truck and let it idle 6 Operate the truck pull lever for 4 to 5 seconds then close the needle valve tightly Allow the gauge to reach and hold full truck relief pressure for 2 or 3 seconds then release the pull lever Observe the pressure gauge and note the following e f the gauge does not reach the specific truck pressure a 100 psi 7 bar loss is OK one of the following is responsibie internal Or External Leaks Refer to the accompanying diagram and check all areas that could have external leaks Repair as required and operate the attachment to determine if the problem has been solved Defective Push Pull Solenoid on attachments so equipped Refer to Section 4 3 1 for solenoid tests Shuttle In The Valve Assembly Is Not Shifting Refer to Section 5 3 for valve inspection and servic ing procedures The Piloted Check Vaive Or Relief Valve In The Valve Assembly Is Defective Refer to Section 5 3 for valve inspection and servic ing procedures e f the gauge does reach truck pressure a 100 psi 7 bar loss is OK the following is responsible for a malfunc ti
48. ifting Prior to Installation Skip Steps 1 through 4 if the unit is equipped with Quick Disconnect mounting hooks TO ATTACH THE SIDESHIFT CYLINDER ANCHOR BRACKET O Position the cardboard template in the center notch of the truck carriage 2 Mark the two lines shown and remove the template O If the template is not available use the dimensions shown to locate the bracket Template part no s are listed below Q Position the cylinder anchor bracket on the marks and weld the bracket in place using AWS E7018 rod Preheat to 300 350 F 150 175 C and weld the bottom and sides of the bracket with a 0 40 inch 10mm fillet weld All Class Il models except Sheet Sav TEMPLATE 667382 If template is missing use these dimensions to locate bracket BO NOT weld here 30C 3 65 in 92 7 mm 45C 4 40 in 111 7 mm 7 G IF 30C 1 75 in 80 7 mm Center Use AWS E7018 rod Preheat to 3009 350 F 150 175 C 0 40 inch 10mm fillet welds bottom and sides All Class Ill models TEMPLATE 671174 If template is missing use these dimensions to locate bracket DO NOT weld here 4 40 in 111 7mm 1 00 in Use AWS 7018 rod Preheat to 300 3500F 150 175 C 0 40 inch 10mm fillet welds bottom and sides ALL UNITS PERFORM THE FOLLOWING O Place the sideshifting bearing segments in the notches of the truck carriage as shown Apply a liberal coating of
49. ion 2 3 2 step 11 Use a voltmeter or test light to take a current reading at the electrical leads from the control knob button when the button is depressed e f there is no current to the limit switch electrical leads troubleshoot the electrical circuit for shorts e f there is current to the limit switch electrical leads test the limit switch 4 To test the limit switch place the ohmmeter leads across the limit switch leads With the switch in the neutral position the onmmeter should register a reading The ohmmeter should not show a reading when the limit switch is activated e l the limit switch fails either of these tests replace and adjust the switch as described in Section 5 7 1 Rev 1 ubleshooting PRESS BUTTON FORSTOP THREE FUNCTION Three button control knob THREE FUNCTION Three button control knob setor D Service 51 38 Attachment Removal and Installation Fully extend the faceplate Lower the attachment onto a pallet bar 6 Disconnect the Lower Hooks Bolt On Type Remove the lower mounting hooks For reassembly tighten the capscrews to a torque of 105 115 ft los 140 155 N m Quick Change Type A Pull out the retaining pin and rotate the hooks to the position shown For reassembly turn both hooks up and reinstall the pin Quick Change Type B Pull out the locking pins slide the hooks down and reinstall the pins in the lower holes For reassembly slid
50. lenoid coil is defective and should be replaced DIODES P N 666950 P N 672535 SCNA SCPA COIL COIL PART APPROXIMATE VOLTAGE NUMBER RESISTANCE 12V 667327 6 1 Ohms 24V 667328 28 1 Ohms 36V 667329 70 1 Ohms 48V 667330 10811 Ohms NOTE Ohm readings are for Cascade Coils not Racine or Waterman type 674219 Rev 1 sim Troubleshooting 4 3 2 Push Hydraulic Function WARNING Before removing any A hoses relieve pressure in the hydraulic system Turn the truck off then 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 hose terminal 2 Check the flow volume at the hose terminal See Section 614 1 for the recommended flow volumes If the truck pressure and flow volume are correct proceed with the troubleshooting 3 At the attachment valve assembly disconnect the supply hose that leads to the base end of the right hand push pull cylinder as viewed from the driver s seat Plug the cylin der supply hose with a No 6 metal plug 4 Connect a pressure gauge with a needle shutoff valve and drain line to the valve fitting refer to Section 41 2 for an illustration of the gauge arrangement Put the drain line in an empty container 5 Open
51. lic tank and filter 6 Remove the union fitting and connect the hoses to the attachment fittings as shown Manifold or bracket 223 Prior to Operation Remove air from the system by extending the faceplate fully and keeping it there for 10 20 seconds with the control valve actuated NOTE This should correct an irregularly extending face plate if it does not retract the faceplate and repeat the process a second time Operate the unit through several complete cycles and make sure all functions operate smoothly and correctly PUSH PULL UNITS e The gripper jaw should open prior to the faceplate exten sion when the control handle is pushed forward e The gripper jaw should close completely prior to faceplate retraction when the control handie is pulled back PUSH PULL UNITS with FLOW CONTROL MANIFOLD e SPEED ADJUSTMENT The flow control manifold has a separate speed adjust ment range of 30 for the load push and load pull functions See Section 5 3 10 for adjustment procedures e HIGH VOLUME BY PASS ADJUSTMENT The flow control manifold has an adjustable by pass orifice for use with high volume truck applications The FLOW CONTROL MANIFOLD by pass should be adjusted open for high volume trucks to reduce engine stall during actuation of the attachment See Section 5 3 8 for adjustment procedures 674219 Rev 1 sei 2 Installation Instructions 2 3 2 3 1 Installation Sidesh
52. mbly Installation is a reverse of the above procedures ADJUSTABLE RETAINER CYLINDERS e Loosen the setscrew in the jam nut ring Back off the jam nut ring to the end of the inner retainer e Adjust inner retainer out to the end of its travel The ihreads will be exposed about 1 inch 25cm e Manually extend the faceplate to set square with the platen tips at the desired extension e Adjust the inner retainer inward to contact the cylinder piston The faceplate must remain square with the platen tips e Tighten the jam nut ring to a torque of 75 100 ft lbs 98 130 Nm Tighten the setscrew to a torque of 16 18 ft lbs 20 24 Nm oo O 543 Sideshift Cylinder Removal and Installation O Remove tag and plug the hoses at the sideshift cylinder 2 Remove the cotter pins and pins at the rod and base ends and lift out the cylinder O Installation is a reverse of the above procedures 544 Sheet Retainer Cylinder Removal and Installation Use same steps as 5 4 3 For service see 5 4 9 674219 Rev 1 Remove capscrew and pin WARNING Before removing any tubes relieve pressure in the hydraulic system Turn the truck off then open the truck auxiliary control valve s several times in both directions WARNING Remove push pull cylinder rod end pins to avoid possible injury due to inadvertant faceplate retraction Remove capscrew eyebolt and pin For reassembly Torque capscrews to 14 16 f
53. ner cylinder Remove the cotter pins and both clevis pins Remove the tubes to cylinder and cap fittings WARNING Carrier assembly is heavy and should be removed and or replaced with a care Guide PP Sheet Retainer Bar Bar IS O Remove carrier assembly See top view illustration at o right Remove 6 capscrews from guide bars Make sure sideshift cylinder has been disconnected form carrier 7 Replace damaged or worn bearing segments or Bearing Segment bearing strips Lube bearings prior to assembly O For reassembly reverse the above procedures except Guide Bar Bearing Strip as follows e Tighten the guide bar capscrews to a torque of Grease Carrier early 56 60 ft lbs 77 81 Nm Fitting JN Tighten the Sheet Retainer Bar capscrews to a INRA AN torque of 23 25 ft lbs 31 34 Nm IVA N gt AS TOP VIEW Assembled Frame Carrier Assy 674219 Rev 1 seo O Specifications s11 Hydraulics Hydraulic Specifications 30C 2000 Pressure Recommended 140 bar 2300 160 bar 3GPM 11L min a 9GPM 34L min 2300 160 bar 3GPM 11L min 6 GPM 22L min Maximum Pim Flow Minimum Recommended i 15 GPM 10 GPM Maximum S6L min 37L min E Hose and Fitting Size No 6 No 6 Minimum Orifice Size 9 32in 7mm 9 32in 7mm 2659w 156 5 O Flow less than minimum will result in slow faceplate
54. o make sure the attachment operates correctly before returning it to the job 674219 Rev 1 cam Troubleshooting 41 41 1 41 2 General Procedures WARNING Before servicing any hyd raulic component relieve pressure in A the system Extend the faceplate 18 to 24 in 46 61 cm turn the truck off and open the truck auxiliary valves several times in both directions After completing any service procedure always test the function through several cycles First test the attachment empty to bleed air trapped in the system to the truck tank Then test the attachment with a load to be sure it operates cor rectly before returning it to the job Stay clear of the load while testing Do not raise the load more than 3 in 75mm off floor while testing Truck System Requirements e The lift truck must supply sufficient hydraulic pressure to handle the heaviest load PRESSURE MUST NOT EXCEED 2300 PSI 160 BAR Hydraulic flow should fall within the volume range shown in the table e The truck hydraulic system must supply hydraulic oil to the attachment that meets the specification shown in the table Tools Required In addition to a normal selection of hand tools you will need e Two No 6 hoses with No 6 female fittings e A pressure gauge capable of measuring pressure to 2500 psi 175 bar Cascade P N 671212 e Aninline flow meter capable of measuring hydraulic flow to 20 GPM 80 L min Casc
55. oning pull circuit Push Pull Cylinder Is Defective When the faceplate extends unevenly with the right side out further than the left suspect the left hand cylinder vice versa for the right hand cylinder To further check the cylinders individually install a drain line to the base end port and apply pressure to retract the cylinder A steady oil stream after full retraction indicates a bypass of oil at the piston inner or outer seals or compensator valve Refer to Section 5 4 for cylinder inspection and servicing procedures Plug this Hose kj Right Hand Cylinder Left Hand Cylinder Install Pressure Gauge PULL FUNCTION TEST Push Pull Cylinders Sideshift Cylinder Solenoid Valve Junction Block es DEFECTIVE PUSH PULL CYLINDER Right Side extends farther 674219 Rev 1 sim Troubleshooting 4 3 4 Gripper Function Troubleshooting WARNING Before removing any hoses relieve pressure in the hydraulic system Turn the truck off then open the truck auxiliary control valve s several times in both directions 1 Inspect the gripper bar for mechanical jamming caused by bent or broken components 2 Inspect the hoses from the Load Push Pull valve to gripper cylinder Replace the hoses if either is kinked 3 Extend the faceplate Disconnect the hose at the left hand push pull cylinder rod end Plug or cap the open ports and hoses with metal fittings Disconnect
56. port and apply pressure to retract the cylinder A steady oil stream after full retraction indicates a bypass of oil at the piston inner or outer seals or compensator valve Refer to Section 5 4 for cylinder inspection and servicing procedures 674219 Rev 1 Plug This Hose o Right Hand a AD os E Cylinder sa EA Left y Hand o lt Cylinder LA Ss 27 UN Test Port DS gt es gt AED SAG install Pressure ff Q Gauge Needle Valve E PUSH FUNCTION TEST Push Pull Cylinders N l Solenoid Valve gt Hose Terminal Sideshift Cylinder Right Side extends farther DEFECTIVE PUSH PULL CYLINDER 31 socio 4 Troubleshooting 4 3 3 32 Pull Hydraulic Function WARNING Before removing any A hoses relieve pressure in the hydraulic system Turn the truck off then 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 hose terminal 2 Check the flow volume at the hose terminal See Section 61 1 for the recommended flow volumes If the truck pressure and flow volume are correct proceed with the troubleshooting 3 At the valve assembly disconnect the supply hose that leads to the rod end of the left hand push puil cylinder as v
57. pscrews to a torque of 105 115 ft bs b Slide the hooks over the top of the guides Install each locking pin through the hook lower hole Type B Ro in 16mm left side shown Locking Pin 2 674219 Rev 1 ass A E ua snide LESI la UOT MST UGUO 3 222 Installation REVERSING THE PUSH PULL PORTS Units equipped with a flow control manifold have the option of turning the manifold over to reverse the location of the Push Pull ports This will accommodate trucks already plumbed with Push Pull supply hoses on the left side of the truck See Section 5 3 9 n Hf Center the lift truck behind the attachment Tiit the mast forward Engage the upper hook locating tab with the closest upper carriage bar notch and raise the truck T carriage into position behind the attachment Lift the attachment 2 in 5cm off the pallet A NOTE The attachment may not be perfectly centered A AEE So on the carriage bar when the locating tab is engaged in the upper carriage bar notch WARNING The upper mounting hook must be properly engaged with the upper carriage bar The locating tab must be engaged in the mating notch on the upper carriage bar NOTE The lower hooks cannot be properly installed if the locating tab is not engaged in the carriage notch amp Engage the lower hooks with the truck lower carriage bar Bolt On Type Install the hooks and capscrews Tighten the capscrews finger tight Tap the end of t
58. rical circuit as described in Section 4 3 1 4 The sheet retainer cylinder seals may be worn Extend the faceplate Disconnect the hose at the left hand push pull cylinder rod end Plug or cap the open ports and hoses Install a drain line as shown in the illustration and apply pressure to extend the cylinder A steady stream of oil after full extension indicates a bypass at the seals Refer to Section 5 4 for cylinder inspection and servicing procedures PRESS BUTTON TO R N THREE FUNCTION Two button control knob A Install drain line here VIEWED FROM FRONT OF ATTACHMENT 674219 Rev 1 section ILO 4 7 1 674219 Troubleshooting the Electrical Faceplate Stop Groups There are three potential areas that could effect the electrical faceplate stop operations e Defective limit switch improper limit switch actuator adjustment e Faulty electrical connection Electrical Faceplate Stop Function Troubleshooting 1 Adjust the limit switch actuator as described in Section 5 7 1 2 Operate the attachment in the push pull function without the stop button depressed f the push pull function is working properly continue the troubleshooting check list e If the push pull function is not working properly troubleshoot the push pull electrical circuit as described in Section 4 3 1 3 Disconnect the electrical leads at the limit switch See the wire diagrams and schematics shown in Sect
59. ripper Function Troubleshooting lt 33 Troubleshooting the Sideshift Circuit 34 Troubleshooting the Hydraulically Adjustable Platen Circuit 35 Troubleshooting the Sheet Retainer Circuit 36 Troubleshooting the Electrical Faceplate Stop Groups 37 Service Section 5 Juca pap er A 38 Attachment Removal and installation 38 Faceplate and Pantograph Arms o o o o o o 39 Disassembly ici Dr o A ea 39 Service and Reassembly e fa Ca erase a 40 Gripper Mechanism Service o 40 Gripper Hose Installation o o 4 Vaese a aah es dE LO he Gee ia i ani ed 42 Load Push and Load Push Pull Valve Removal and installation 42 Load Push Valve Disassembly and Service 42 Load Push Pull Valve Disassembly and Service 43 Solenoid Valve Removal and Installation 44 Solenoid Valve Disassembly and Service 45 Flow Control Manifold Removal and installation 46 Flow control Manifold Disassembly and Service 46 High Volume Bypass Adjustment 47 Flow Control Manifold Port Reversal 47 Push Pull Speed Adjustment 0 48 Check Valve Cartridge Seal Details 48 CINES as o a E a a 49 Removal and installation o o 49 50
60. s from the solenoid coil terminal s 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 4 Three Function Attachments Remove the three electrical leads from the frame mounted diode Test for high resistance in one direction and no resistance in the other direction between the center terminal and each of the outer terminals If there is no resistance in both directions between the center terminal and either of the outer terminals replace the diode 5 Disconnect the electrical leads from the solenoid coil terminals Use a voltmeter or test light to take a current reading at the electrical leads from the control knob button when the button is depressed e if there is no current to the solenoid troubleshoot the electrical circuit for shorts e f there is current to the solenoid test for coil continuity 6 To test for coil continuity place an ohmmeter test lead on each solenoid coil terminal e if there is an ohmmeter reading the coil is good Check the resistance against the resistance values in the chart to determine if the coil voltage is properly matched to the truck voltage e f the coil is good and the coil voltage is correct but the solenoid does not click when the control button is depressed the solenoid cartridge is jammed and should be replaced e If there is no ohmmeter reading shown the so
61. s must be removed from the attachment Q Set platens flat on floor 5 Disengage platen lock pin spring clips 16 Remove platen retaining capscrews Q Tilt truck mast back Raise attachment about 4 and back away from platens only enough to allow space to insert remove shims 18 Install capscrews into platens add orremove appropriate amount of shims If needed apply a piece of strong tape to hold shims in place O Return truck attachment to original position engage platens and return the mast to upright position 110 Reinstall platen capscrews Tighten to a torque of 200 210 ft lbs 270 285 Nm Engage platen lock pins Inspection Q Check the platen tips for nicks Flatten out nicks with a hammer and smooth the edges with a file or grinder 2 An application of wax or paraffin on the top of the platens will reduce friction between the platens and slip sheets Use a piece of steel woo to remove excess wax 674219 Rev 1 Remove capscrews AWARNING Torque to 200 210 ft los 270 285 N m Platen tips must be even or within 1 4 6mm of each other Add shims to raise platen tips Remove shims to lower tips SIL ES SER 53 sein Service 5 6 5 61 Adjustment O Extend faceplate to expose stop mechanism Depress selector and turn to corresponding number stamped in selector of inches 0 3 6 or 9 faceplate is to be positioned to for full back travel Number selected
62. s refer to section 4 4 F Electrical Faceplate Stop Circuit Faceplate will not stop e Faceplate will not stop in correct position If you encounter one of these problems refer to section 4 7 674219 Rev 1 sesion Troubleshooting 42 Plumbing 4 21 Hosing Diagram Load Push Non Sideshifting Push Pull Cylinder FACEPLATE RETRACT Load PRESSURE amp Push Push P RETURN BRACKET MANIFOLD Valve Bu Cylinder SLAVE E H ose NOTE For faceplate EXTEND Terminal reverse the colors shown Truck Es Auxiliary o Valve E 4 2 2 Circuit Schematic Push Pull Cylinders c2 Both Cylinders Load Push Valve In RET In EXT Manifold i 1 lf equipped tin EXT se Terminal Hose Reel Truck Auxiliary Truck Relief Valve Truck Hydraulic Pump 674219 Rev 1 16 sein Troubleshooting 4 2 3 Hosing Diagram Load Push Sideshift without Solenoid Push Pull Cylinder SIDESHIFT RIGHT and Ss FACEPLATE RETRACT PRESSURE RETURN SLAVE NOTE For sideshift LEFT and faceplate EXTEND reverse Hose the colors shown Terminal Load Push Pull Valve Hose Reel Sideshift Cylinder Push Pull Hose Auxiliary Terminal Valve Sideshift sh CRIS a a a 4 24 Circuit Schematic E a S Both Cylinders A Push Pull ied Cylinders Q Ql Push Pull 1 Valve Sideshift Cylinder In EXT TR Manifold if equipped In SSL In EXT Ho
63. se m FT Hose Terminal p e Hose HE Hose Reel J Er a Reel Sideshift Push Pull pst Alt SLX MALE DA Auxiliar Truck Hydraulic Pump 674219 Rev 1 sucio 4 Troubleshooting 4 25 Hosing Diagram Load Push Sideshift with Solenoid FACEPLATE RETRACT PRESSURE THESE RETURN mavae SLAVE om a Push Pull Cylinder NOTE For faceplate EXTEND o reverse the colors shown Push Pull Valve TO r Hose Termina Truck Auxiliary Valve Push Pull A Cylinder SIDESHIFT RIGHT PRESSURE GN RETURN EEE In EXT NOTE For sideshift LEFT Sol dai reverse the colors shown olenoid Valve Push Pull Cylinder Truck Auxiliary Valve 674219 Rev 1 17 sio 4 Troubleshooting 4 2 Circuit Schematic Load Push Sideshift with Solenoid Push Pull Cylinders Both Cylinders 18 674219 Rev 1 4 27 Hosing Diagram Load Push Pull Non Sideshifting s4 Troubleshooting Push Pull E Gripper Cylinder a Cylinders FACEPLATE RETRACT and GRIPPER BAR DOWN PRESSURE MIA RETURN SLAVE TI NOTE For faceplate EXTEND and gripper bar UP reverse the colors shown Push Pull Cylinder BRACKET or MANIFOLD mm Hose Push Pull Auxiliary Valve 2 j j i Both Cylinders 4 2 8 Circuit Schematic a Push Pull Cylinders Gripper Cylinders Load Push Pull Valve Manifold if equipped Truck Hydraulic Pump 67
64. t lbs 1 Remove tag and plug hoses ADJUSTABLE RETAINER CYLINDER Jam Nut Ring Inner Retainer Remove tag and plug hoses Remove cotter 2 Remove cotter pin pin ana pin and pin 49 san D Service 5 4 5 5 4 6 50 Adjustable Platen Cylinder Removal and Installation Remove the attachment from the truck according to the procedures in section 5 1 Extend the faceplate before removal O Remove and plug the tubes at the cylinder 2 Remove the cotter pins and pins at both ends of the cylinder Remove the capscrews retaining the cylinder to the frame and lift out the cylinder Q Installation is a reverse of removal General Cylinder Service Procedures Cylinder Disassembly e Use a pin type spanner wrench to remove push pull cylinder retainer e When servicing a cylinder clamp it in a soft jawed vise as shown Never clamp the cylinder shell or the cylinder rod sealing area in a vise e Toremove the seal from a piston or a retainer put the piston or retainer in a soft jawed vise Pry the seal up with a blunt tool such as a screwdriver then cut the seal to remove it Be careful not to scratch the seal groove Cylinder Inspection e Inspect the rod piston and retainer for nicks or burrs If deeply gouged replace the part Minor nicks and burrs can be removed with an emery cloth NOTE A minor nick is one that will not cause a bypass of oil when the cylinder is operatin
65. the hose connected between the rod end ports of the gripper cylinders Install adrain hose to each of the cylinder rod end fittings Operate the attachment in the pull function to extend the gripper cylinders e f oil is present as a steady stream after full extension the cylinders require inspection and service as described in Section 5 4 e if oil is not present after full extension continue troubleshooting 4 Remove the hose from the Load Push Pull valve C4 port fitting Install the pressure gauge shut off valve and drain hose to the fitting Operate the attachment in the pull function e if the gauge does not register a pressure reading remove and service the Load Push Pull vaive See e Section 5 3 for service procedures e ifthe gauge registers a low pressure reading check for E kinked hoses we Le Connect the pressure gauge shutoff valve and drain hose to the valve C4 port fitting Remove hose from valve C4 port fitting c 674219 Rev 1 33 34 socio Troubleshooting 44 Troubleshooting the Sideshift Circuit There are six potential problem areas that could affect the sideshift operation e Insufficient truck hydraulic pressure e External Leaks e Damaged sideshift bearing strips and segments e Defective solenoid cartridge on solenoid equipped attachments Faulty electrical connection e Worn or defective cylinder seals 441 Sideshift Function Troubleshooting WARNING Before
66. the needle valve no more than Veto 1 full turn Start the truck and let it idle 6 Operate the truck push lever for 4 to 5 seconds then close the needle valve tightly Allow the gauge to reach and hold full truck relief pressure for 2 or 3 seconds then release the push lever Observe the pressure gauge and note the following e lfthe gauge does not reach the specific truck pressure a 100 psi 7 bar loss is OK one of the following is responsible Internal Or External Leaks Refer to the accompanying diagram and check all areas that could have external leaks Repair as required and operate the attachment to determine if the problem has been solved Defective Push Pull Solenoid on attachments so equipped Refer to Section 4 3 1 for solenoid tests Shuttle In The Valve Assembly Is Not Shifting Refer to Section 5 3 for valve inspection and servic ing procedures The Piloted Check Valve Or Relief Valve in The Valve Assembly Is Defective Refer to Section 5 3 for valve inspection and servic ing procedures e f the gauge does reach truck pressure a 100 psi 7 bar loss is OK the following is responsible for a malfunc tioning push circuit Push Pull Cylinder Is Defective When the faceplate extends unevenly with the right side out further than the left suspect the left hand cylinder vice versa for the right hand cylinder To further check the cylinders individually install a drain line to the base end

674219R1_30C/45C Push/Pull Service

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