667450_L & P Push/Pull Service Manual
Contents
1. Load Push Load Push Pull Equalizer Valve Service GEES Se NEN LI Nylon U Cup Nylon Ring Seal Ring Plug O Ring Spring Stop Spring Ball Spacer Washer IMPORTANT The plug must be torqued to 6 ft lbs min 8 ft lbs max Figure 13 Equalizer Valve 4 Reassemble thecylinder Reinstall the cylinder in the frame but do not connect the cylinder rod to the pantograph mechanism NOTE All soft parts O rings seals etc must be replaced when reassembling the cylinder 5 Connect all hoses and complete the equalizer valve test on page 6 6 After both cylinders have been tested and adjusted connect the rods to the pantograph mechanism Bleed the cylinder according to instructions on page 6 EQUALIZER VALVE TEST PROCEDURE See Figure 14 1 Hydraulically extend the cylinders 2 Tee a pressure gauge into the pressure line feeding the base end of the right hand cylinder 3 Disconnect the right hand cylinder rod end hose at fitting A 4 Place the hose in a container 5 Feather the truck valve to extend the cylinders When oil begins flowing from the open hose into the container note the pressure reading on the gauge This is the equalizer valve s relief pressure and it should read between 1400 and 1700 PSI 6 If the equalizer valve is not relieving within this range disassemble the cylinder and change the number of spacers behind the spring according to th2. Inspect the brass washers for wear Replace the washers if they are scored or if they are worn unevenly ASSEMBLY Assembly of the pantograph mechanism is the direct reversal of disassembly with the following exceptions 1 Inspect all shims and washers and replace any that are scored or worn unevenly 2 Inspect the teflon bushings for wear and replace if the Figure 4 Pantograph Tolerances coating is scored or worn through NOTE Cascade 4 Shim the primary arms at the bottom to achieve dimension recommends lubricating the bushings A 3 The following tolerances must be met on reassembly by 5 When dimension A is met there must be 060 inch properly shimming the primary pivot points See Figure 4 clearance at the top of the primary arm Cylinder Service CYLINDER REMOVAL 2 Remove the retainment that fastens the gripper jaw to the Push Pull Cylinder cylinder rod The gripper jaw must be up to expose the retainment 1 Extend the faceplate 3 Remove the self locking nut securing the cylinder base to 2 Remove the hoses to each cylinder Tag and cap the hoses the faceplate Remove the cylinder and ports 3 Remove the rod and shell end anchor pin and lift the CYLINDER DISASSEMBLY Seylnder out at Ae ramo Push Pull Cylinder See Figure 5 and 6 4 The cylinders are not interchangeable They have identical l f outside dimensions but the right hand cylinder has a larger 1 Service the cylinder in a clean work area with a
3. 2 1 Remove the gripper cylinder rod retainment 2 Let the jaw drop and rest on the channel 3 Remove the capscrews holding the channel to the faceplate 4 Remove the gripper jaw and channel Load Push Load Push Pull Nut Gripper Cylinder Channel Faceplate Fastening Capscrew Figure 2 Gripper Assembly Algrip Pad Replacement See Fig 3 1 Grind off the skip welds and remove the Algrip surface Grind the gripper jaw smooth Skip weld the new Algrip surface in place Use welding rod E 7018 See Figure 3 Al grip Pad Bolt on Pad Replacement See Fig 3 1 Remove old pad Replace with new pad and torque the capscrews to 9 12 ft Ibs see Figure 3 Bolt on Pad M Algri Gripper Bar Pad Gripper Pad Gripper Bar Gripper Pad a E e Lockwasher Da Capscrew Torque to 9 12 ft Ibs Figure 3 Gripper Pad Replacement Primary Arms To complete the disassembly of the pantograph mechanism the primary arms must be removed The primary arms can also be disconnected to remove the complete pantograph mechanism and faceplate from the attachment frame 1 Remove the pins from the rod end of the two push pull cylinders 2 Each arm pivots on a pin running the height of the frame Remove the capscrews from the ears on top of the frame and pull the pin out of the frame Do not pry on the ear If the pin sticks use a soft punch to drive the pin out from the bottom
4. cascade eC e Service Manual Load Push Load Push Pull 8 Manual Number 667450 cascade corporation P O Box 20187 e Portland Oregon 97220 e 503 666 1511 Contents Page Introduction 8 Description ll 1 Frame Service 1 Pantograph Mechanism Service Disassembly amp Inspection Assembly Cylinder Service Cylinder Removal Cylinder Disassembly Seal Replacement Cylinder Assembly amp Installation Equalizer Valve Service Installation Test Procedure Bleed Instructions Sequence Valve Service Valve Removal RS Pe di Sequence Valve Disassembly amp Inspection Needle amp Relief Valve Disassembly Valve Assembly CO OO OO OO DOCA FANNN NH gt Hydraulic Schematics Load Push Load Push Pull Introduction and Description This manual includes service instructions for the load push and load push puil These two attachments have the following common components carrier assembly forks or platens pantograph mechanism and cylinders The load push uses a relief valve The load push pull valve includes a sequence plunger along with relief valve The load push pull also has a gripper assembly incorporated into the faceplate Both attachments are designed to handle palletless loads The cylinders power the pantograph mechanism and faceplate which pushes a load off the forks The load pull faceplate includes a gripper assembly which grips a s
5. dequate inside diameter Mark the cylinders before removing room to lay out the cylinder components R 2 Place the cylinder pivot end in a soft javved vise Do Not Gripper Cylinder Load Pull Only clamp the cylinder shell in the vise 1 Remove the hoses at the cylinder and cap the hoses and 3 Use a socket wrench to loosen the setscrew found only ports on older cylinder from the threaded washer See Figure 5 Snap Ring Nylon Ring U Cup Seal Compensator Nyton Ring Valve Piston Spacer O Ring Back up Ring Do Rod e 2 Load Push Load Push Pull Back up Ring Nylon Ring Figure 5 Push Pull Cylinder Two Piece Retainer Compensator Valve Bo GS KW Piston Nylon Ring Back Up Ring O Ring Back Up Nylon Ring Ring Figure 6 Push Pull Cylinder One Piece Retainer 4 Use a pin type spanner wrench to remove the threaded washer retainer from the shell NOTE Do not use a hammer and punch to loosen the retainer The proper spanner wrench is shown in Figure 7 ye yy 4 Z re Figure 7 Use a Pin Type Spanner Wrenc Figure 8 Gripper Cylinder Load Push Load Push Pull Plunger Snap Ring Nylon Ring 5 Pull the rod and piston assembly straight out of the shell Inspect the shell for scoring A scored shell must be replaced 6 Inspect th rod for nicks or scratches Nicked or scratched rods must be replaced 7 To remove the piston nut clamp the c
6. dle to the Extend position for about 20 seconds This action circulates oil throughout the attachment hydraulic system and forces any air in the system to the truck reservoir 3 Retract the faceplate fully then repeat Step 2 In most cases two cycles of faceplate extension followed by 20 seconds of continued control handle actuation will be sufficient to bleed all the air from the system NOTE As a check while the faceplate is extended manually grab the faceplate and shove it from side to side while watching both push cylinders The cylinder rods should not move If either cylinder rod is spongy the system still contains some air Repeat the above procedures as required Sequence Valve Service The valve is located below the push pull cylinders The older load push valve contains a needle and relief valve plus two checks for the push cylinders The older load push pull valve contains a needle and relief valve three ball checks and a sequence plunger to properly time the gripper and push pull functions A newer push pull sequence valve contains two additional ball checks for the gripper cylinders plus an adjustable sequence plunger to vary the timing of the push grip pull sequence VALVE REMOVAL 1 Remove the single capscrew holding the valve to the attach ment frame A roll pin prevents the valve from turning 2 Remove the hoses from the valve Cap and label the hoses Lay the valve in a clean working area f
7. e following guidelines FOR RH CYLINDER DISCONNECT THIS HOSE FROM A AND PLACE IN CONTAINER FOR tH CYLINDER CONNECT 8 TO A AND PLACE THIS MOSE IN THE CONTAINER RIGHT HAND Cri J g 4 i INDER Figure 14 Equalizer Valve Test Procedure e Each spacer adjusts the relief pressure approximately 100 PSI e Subtracting spacers will decrease the relief pressure e Adding spacers will increase the relief pressure NOTE For proper operation no more than four spacers should be used 7 To test the left hand cylinder equalizer valve remove the base end pressure line from the right hand cylinder at point B and connect it to the open end at point A 8 Disconnect the left hand cylinder rod end hose from the valve and place the hose in a container 9 Feather the truck valve to extend the push cylinders When oil flows from the rod end hose note the pressure reading on the gauge The valve should relieve at 1400 1700 PSI 10 If the valve s relief pressure is not within this range repeat step 6 on the left hand cylinder BLEED INSTRUCTIONS Before operating the attachment make sure the truck reservoir contains a sufficient supply of hydraulic oil as recommended by the truck manufacturer 1 Power the faceplate to the fully extended position Don t be alarmed if on the first cycle or two the faceplate extends irregularly or at an angle 2 After the faceplate is fully extended keep the control han
8. h Pul Sequence Valve with Needle Valve Assembly Valve Body Top A Spacer K BS Spring Allen Head Plug Plunger D Stop Sprin amp PLOS Hex Head Figure 16 Load Push Pull Sequence Valve Load Push Load Push Pull SD NEEDLE AND RELIEF VALVE DISASSEMBLY valve Inspect the ball and ball seat and reseat the ball as described above Inspect the plunger and plunger bore See Figures 17 and 18 The valve body must be replaced if the bore is scored 1 Remove the allen head plugs from the top of the valve body Replace the plunger if it is scored A 5 Remove and inspect the needie valve Check the O ring 2 Remove the ball spacer and spring from the right hand bore and back up ring and replace if visible wear or damage is Inspect the seat and replace the valve if the seat is nicked apparent or scored Inspect the ball and replace if it is nicked 3 If there is leakage reseat the ball by sharply tapping it into VALVE ASSEMBLY I its seat vvith a brass punch Assembly of the sequence valve adjustable sequence valve and the needle and relief valve is the direct reversal of 4 Remove the allen head O ring plugs from each end of the disassembly Plunger Needle Valve Assembly Figure 17 Load Push Needle and Relief Valve Spring Plunger a Na pacer Ball Figure 18 Load Push Relief Valve without Needle Hydraulic Schematics Contact Cascade s Service Department at 800 547 5266 fo
9. lip sheet under the load so the cylinders can pull a load onto the forks Frame Service The load push push pull frame includes a carrier assembly which mounts to the truck carriage and carries the forks or platens and a pantograph mechanism which pushes and or pulls theload Sideshifting and non sideshifting carriers are available for either attachment The sideshifting carrier is serviced like the L series sideshift Pantograph Mechanism Service Adjustments to the pantograph mechanism can be made with out removing the attachment from the truck Realignment of the faceplate by bleeding the push pull cylinders is covered on the installation forms 5130 or 5138 non sideshifting DISASSEMBLY and INSPECTION Faceplate and Secondary Arms See Fig 1 1 Extend the faceplate 2 Unpin the stabilizer bar and swing it away from the faceplate 3 Remove the center pivot pin where the two secondary arms cross Note the location of the shims and washers 4 Remove the pins joining the secondary and primary arms Pull the secondary arms and faceplate away from the primary arms Note the location of the shims 5 Swing the secondary arms parallel to the faceplate and lift the arms to free them from the roller channels in the faceplate i Primary Arm Pin ae Le deis Stabilizer Primary a Arms Arms Center Pivot Pin Faceplate Figure 1 Pantograph Mechanism Gripper Assembly Removal See Fig
10. n See Figure 11 or 12 ABS NN y NE NI For Reassembly Lube Torque To 300 325 ft lbs Figure 11 Push Pull Cylinder Seal Cutaway Two Piece Retainer Figure 9 Remove Seal With Dull Screwdriver CYLINDER ASSEMBLY AND INSTALLATION Assembly and installation is a direct reversal of the removal and disassembly procedure with the following exceptions 1 Coat all seals with STP 2 When reassembling the gripper assembly tighten the self locking nut securely than back off one half turn to allow the cylinder to align during gripper jaw operation Back Up Ring O Ring Z N au N N AXZ RIZZI U Cup Nylon Sea Ring Nylon Ring Load Push Load Push Pull Nylon O Ring Ring Back Up For Reassembly Lube Torque To 400 425 ft lbs Figure 12 Push Pull Cylinder Seal Cutaway One Piece Retainer INSTALLATION 1 Using the special tool provided with the Equalizer Valve Kit unthread the Blug and remove the old valve from the piston NOTE If necessary a tool may be fabricated from a 3 8 drive screwdriver socket Proto part no 5244 using the dimensions shown below 2 Thoroughly clean the valve port in the piston 3 Install the new equalizer valve as shown in Figure 13 using two spacers behind the spring NOTE Some kits include a washer to be placed on the plug behind the O ring If the kit does not contain a washer the plug has been machined to self seal with the O ring
11. nchon 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 5M 8 78 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 Part No 667450 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 Form 5190
12. or disassembly SEQUENCE VALVE DISASSEMBLY AND INSPECTION Figure 15 and 16 1 Remove the allen head plugs from the top of the valve body 2 Remove the spring spacer and ball from the bore Examine the ball and ball seat for nicks and wear Replace the sequence valve if the seat is nicked or scored Replace a nicked ball The free length of the springs should measure inch 3 If there is leakage reseat the ball by sharply tapping it into its seat with a brass punch 4 Remove the two hex head plugs from each end of the valve which retain the plunger The valve has a spring and a stop that contact each end of the plunger The plunger springs should measure 1 inch free length NOTE Change both springs at the same time 5 Remove the allen head plug from the side of the valve This is the relief valve which contains a spring ball and spacer that should be removed examined and reseated if required NOTE All components should be cleaned in solvent and inspected for wear If any valve bore or seat is nicked or scored replace the sequence valve A nicked or scored ball must be replaced 6 Remove and inspect the needle valve Check the O ring and back up ring and replace if visible wear or damage is apparent Load Push Load Push Pull Roli Needle Pin Valve Assembly e pa I im eee 20 Ra an E Nus Allen Head d ne ze Plunger El Stop Spring Hex Head Plug Figure 15 Load Pus
13. r procedures to convert from this system to the system shown below i Load Push Hydraulic Schematic without Needle Valve Load Push Load Push Pull Contact Cascade s Service Department at 800 547 5266 for procedures to convert from this system to the system shown below Load Push Pull Hydraulic Schematic with Needle Valve a Load Push Pull Hydraulic Schematic without Needle Valve 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 8989 160 ASIA PACIFIC Cascade Japan Lid 2 23 2 Chome Kukuchi Nishimachi Amagasaki Hyogo Japan 661 0978 Tel 81 6 6420 977 1 Fax 81 6 6420 9777 Cascade Australia Pty Ltd 1445 Ipswich Road Rocklea QLD 4107 Australia Tel 1 800 227 223 Fax 61 7 3373 7333 Cascade Corporation 1978 Cascade Canada Inc 5570 Timberlea Blvd Mississauga Ontario Canada L4W 4M6 Tel 905 629 7777 Fax 905 629 7785 Cascade Africa Pty Ltd PO Box 625 Isando 1600 60A Steel Road Sparton Kempton Park South Africa Tel 27 11 975 9240 Fax 27 11 394 1147 Cascade Korea 121B 9L Namdong Ind Complex 691 8 Gojan Dong Namdong Ku I
14. ylinder rod end flat in a vise Remove the piston nut Slide the piston off the rod 8 Remove the compensator valve from the piston Inspect the ball and seat for wear The free length of the spring should be 1 inch 9 Slide the retainer off the rod and remove the snap ring from the inside bore of the retainer Gripper Cylinder See Fig 8 1 Service the cylinder in a clean work area with adequate room to lay out the cylinder components 2 Place the retainer in a vise using brass jaws or wood blocks to prevent cylinder damage 3 Remove the four retaining capscrews and separate the head retainer tube and plunger Back Up Ring O Ring Tube O Ring Back Up Ring O Ring Back Up Ring Retainer Retaining Capscrew 4 SEAL REPLACEMENT See Figures 10 11 and 12 Both the push pull and gripper cylinders use O ring piston seals The push pull uses a U cup rod seal 1 Piston seals can be pryed out of their groove with a dull screwdriver See Figure 9 NOTE Do not scratch the machined groove or leakage will result 2 Push pull rod seals slide out of the groove with the snap ring removed Gripper cylinder rod seals can be carefully pried out of their groove with a dull screwdriver 3 Replace all soft parts O rings seals etc after lubricating seals with STP NOTE The open side of the retainer cup seal in the push pull cylinder must face the piston end of the cylinder Use STP for assembly lubricatio
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