Fork & Carriage Mount
Contents
1. LP0598 eps 3 6849001 Fork Retainer Type Clevis Pin Cotter Pin Washer Ne LPO599 eps OR Cotter Pin LPO601 eps 11 S ERVICE 42 Clamp Assembly 42 1 Removal 1 Lower the clamp assembly onto a pallet 3 The clamp assembly can be disengaged by removing the two mounting pin retainers and mounting pins connecting the carriage fork boom mounting bars to WARNING Before removing any hoses the clamp assembly For reassembly tighten the pin relieve pressure in the hydraulic system i 20 ft N With the truck off open the truck auxiliary i s n control valve s several times in both 4 For reassembly reverse the above procedures with the directions following exceptions e Inspect the boom mounting bars for damage or wear 2 Disconnect the hoses from the bulkhead fittings Tag e Inspect the mounting pins for wear and replace if hoses for reassembly Plug the hoses and cap the valve necessary fittings Adjustable Stops Layer Picker Ney Clamp Assembly of oN ree Mounting Pea aad 2 par Disconnect Hoses 42 6849001 _ S ERVICE 42 2 Arms Removal and Installation The following procedure can be performed without rem2. 6849001 I NTRODUCTION 11 Introduction This manual provides the Periodic Maintenance Troubleshooting Service and Specifications for the Cascade Carriage Mount and Nameplate Fork Mount Layer Pickers Carriage Mount Model In any communication about the attachment refer to the product catalog and serial numbers stamped on the nameplate as shown If the nameplate is missing the numbers can be found stamped on one of the following locations Fork Mount Model The right side of the mounting frame Carriage Mount Model The upper center back of the mounting frame IMPORTANT All hoses tubes and fittings on layer picker are JIC NOTE Specifications are shown in both US and Metric units All fasteners have a torque value range of 10 of stated value Fork Mount Model i Nameplate I e 2 2 30B LPF B100 e 4 Le Cascade Corporation Icons amp Patents www cascorp com support 6095754 a a C C SN 12 Special Definitions N of N LP0587 eps The statements shown appear throughout this manual where special emphasis is required Read all WARNINGS and CAUTIONS before proceeding with any work Statements labeled IMPORTANT and NOTE are provided as additional information of special significance or to make your job easier WARN
3. S ERVICE MANUAL Layer Picker Carriage Mount amp Fork Mount Models Manual Number 6849001 Cascade Corporation Cascade is a Registered Trademark of Cascade Corporation 5 INTRODUCTION Section 1 Introduction Special Definitions 1 PERIODIC MAINTENANCE Section 2 100 Hour Maintenance 500 Hour Maintenance 1000 Hour Maintenance 2000 Hour Maintenance TROUBLESHOOTING Section 3 General Procedures Truck System Requirements Tools Required Troubleshooting Chart Layer Picker Loads Plumbing Hosing Diagram Clamp Reach Circuits Hydraulic Schematic Without Flow Pressure Control Valve Clamp Function Supply Circuit Test Clamp Circuit Test SERVICE Section 4 Layer Picker Removal Carriage Mount Fork Mount Clamp Assembly Removal Arms Removal and Installation Contact Pad Rotation Replacement Contact Pad Camber Adjustment Arm Bearing Replacement Clamp Valve Removal Installation Valve Service Clamp Cylinders Cylinder Removal and Installation Cylinder Disassembly Cylinder Inspection Cylinder Reassembly SPECIFICATIONS Section 5 Specifications 21 Hydraulics 21 Auxiliary Valve Functions 21 Truck Carriage 21 Torque Values Carriage Mount 22 Torque Values Fork Mount 23 WIWINMIP s l Las O k L k i 4 1 IlOI
4. 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 TM Cascade Corporation 2014 Cascade Canada Inc 5570 Timberlea Blvd Mississauga Ontario Canada L4W 4M6 Tel 905 629 7777 Fax 905 629 7785 Cascade Africa Pty Ltd PO 625 1600 60A Steel Road Sparton Kempton Park South Africa Tel 27 11 975 9240 Fax 27 11 394 1147 Cascade Korea 121 91 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 11 2014 Cascade do Brasil Pra a Salvador Rosa 131 141 Jordand polis S o Bernardo do Campo SP CEP 09891 430 Tel 55 13 2105 8800 Fax 55 13 2105 8899 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 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 Indusiries Pte Ltd 18 Tuas South Street 5 Singapore 637796 Tel 65 6795 7555 Fax 65 6863 1368 Part Number 6849001
5. arm lug 6849001 17 S ERVICE 4 3 2 Cylinder Disassembly 1 Clamp the cylinder in a soft jawed vise at the extreme head end only Do not clamp in middle of shell 2 Unscrew and remove the retainer using a claw type spanner wrench as shown Cascade Part No 678598 3 Remove the rod piston assembly from the cylinder 4 To remove the piston clamp the rod assembly in a vise on the wrench flats as shown CAUTION Do not clamp on the cylinder rod sealing surface 5 Remove the piston nut and remove the piston from the cylinder rod 6 Place the piston or retainer in a soft jawed vise to remove the seals Pry the seals or O rings up with a brass seal removal tool Cascade Part No 674424 and cut the seals to remove them CAUTION Do not scratch seal grooves Rod End Hex Washer Spherical Nut Spherical Nut Locking Cap Piston W Locking NN NS 18 6849001 _ S ERVICE 4 3 3 Cylinder Inspection Inspect the rod piston and retainer for nicks or burrs Minor nicks or burrs may be removed with 400 grit emery cloth If they cannot be removed replace the parts e Inspect the cylinder bore and remove any minor nicks or burrs with a butterfly If they cannot be removed replace the part e Inspect the outside of the shell for any deformities or cuts that could impair performance or cause leaks under pressure If necessary replace the part e Inspect the spherical nuts and hex washer
6. for wear and replace as necessary 4 3 4 Cylinder Reassembly 1 Lubricate all new seals and O rings with petroleum jelly 2 Note the direction of the U cup seals Pressure seals must be installed with the lip toward the high pressure side of the cylinder 3 Polish the piston and retainer chamfer angles with 400 grit emery cloth to ease seal installation 4 Install a new seal and O ring on the piston Install the piston seal from the rod end side of the piston by hooking one side into the groove and carefully working the seal over the piston as shown 5 Install a new rod seal back up ring and wiper seal in the retainer ID and a new O ring and back up ring on the retainer OD as shown NOTE Use internal seal installation tool Cascade Part No 599512 to ease seal installation If installing by hand form the seal into kidney shape and position into the internal groove Use finger pressure to smooth the seal into the groove 6 Apply petroleum jelly to the piston internal O ring and install the piston on the rod Tighten the nut to 65 ft lbs 85 Nm 5 OR Piston U Cup Pressure Seal Note seal direction Back Up Ring if equipped O Ring K x SN pes nr Note seal direction 6849001 19 S ERVICE 43 4 Cylinder Reassembly 20 Continued 7 Place the piston loader into the cylinder shell IMPORTANT The loader must cover all of the shell threads but
7. supply hoses from the valve Plug the hose ends and tag for reassembly 3 Remove the capscrews fastening the valve to the top of the boom For reassembly tighten the capscrews to 65 ft lbs 90 Nm 4 Service the valve as described in Section 4 2 7 5 For reassembly reverse the above procedures IMPORTANT Verify that hoses are connected as shown Refer to hydraulic schematic Section 3 2 2 Valve Service IMPORTANT Service the valve in a clean work area 1 Remove the valve from the clamp assembly as described in Section 4 2 6 Remove the check valve cartridge from the valve and remove the O rings and back up rings Remove the fittings from the valve Clean all parts with solvent N For reassembly reverse the above procedures with the following exceptions e Replace O rings and back up rings on check valve cartridge as shown RC0311 eps CHECK VALVE CARTRIDGE Back Up Rings 3 CLAMP function hoses or tubes 2 LP0126 eps Cylinder Supply Hoses Front View If Equipped Early Models Check Valve Cartridge LP0580 eps 6849001 _ S ERVICE Clamp Cylinders 4 3 1 Cylinder Removal and Installation NOTE The following procedure can be performed with the attachment mounted on the truck and the clamp arms remaining on the attachment 1 Close the arms fully WARNING Before removing hydraulic lines relieve pressure in the attachme
8. ING A statement preceded by A WARNING is information that should be acted upon to prevent bodily injury A WARNING is always inside a ruled box CAUTION A statement preceded by CAUTION is information that should be acted upon to prevent machine damage IMPORTANT A statement preceded by IMPORTANT is information that possesses special significance NOTE A statement preceded by NOTE is information that is handy to know and may make your job easier 6849001 1 ERIODIC MAINTENANCE 2 1 2 2 NOTE If equipped with sideshifter assembly option for periodic maintenance schedule refer to Sideshifter Installation Manual Cascade Part No 672358 or Sideshifter Service Manual Cascade Part No 677487 100 Hour Maintenance Every time the lift truck is serviced or every 100 hours of truck operation whichever comes first complete the following maintenance on the layer picker e Check for loose or missing bolts damaged or worn hoses and hydraulic leaks e Inspect contact pads arms and forks for damage or wear Replace as necessary e Inspect clamp anchor nuts for proper connection and tightness If necessary tighten to 160 ft lbs 220 Nm e Check that the clamp assembly is level during normal operation Adjust as necessary Fork Mount Check that the retainer s lock is engaged 500 Hour Maintenance After each 500 hours of truck operation in addition to the 100 hour ma
9. There are five potential problems that could affect the CLAMP functions 5 j Incorrect load handling Refer to Operators Guide for suggested procedures Incorrect hydraulic pressure or flow from the lift truck External leaks Worn defective cartridge valves or cylinder seals Damaged or worn clamp arms or bearings upply Circuit Test Check the pressure supplied by the truck at the clamp assembly valve Pressure must be within the range shown in Specifications Section 5 1 PRESSURE TO THE ATTACHMENT MUST NOT EXCEED 2300 PSI 160 bar Check the flow volume at the clamp assembly valve Flow must be within the range shown in Specifications Section 5 1 Clamp on a load holding the lever in the CLAMP position for a few seconds Release the lever and check for external leaks at fittings hoses valve revolving connection and cylinder rods Clamp Circuit Test 1 2 3 Position the arms to midstroke Turn the truck off and relieve system pressure by moving the CLAMP lever back and forth several times Connect a 3000 psi 200 bar pressure gauge to the test port on top of the clamp assembly valve Start the truck and clamp on a load holding the lever in the CLAMP position for a few seconds Release the lever and watch the pressure gauge e Ifthe pressure drop is less than 150 psi 10 bar initially and additional drop does not exceed 25 psi 1 7 bar per minute the problem is not hydraulic Refer to Section 3 3 ab
10. er to Section 4 2 4 to determine pad camber 3 Remove the contact pad Rotate the pad 180 some pad layouts or install a new pad 4 For reassembly reverse the above procedures LP0086 eps 6849001 13 S ERVICE 4 2 4 Contact Pad Camber 14 Adjustment The following procedures can be performed with the attachment mounted on the truck 1 Extend the arms to midstroke Make sure that the clamp is not resting directly on the floor or pallet 2 Measure the distance between the pads at the top and bottom The difference between the two measurements is the pad camber i Position arms 3 Determine the camber adjustment required Refer to to midstroke recommended starting points in table below 4 Loosen the capscrews and nuts fastening the contact 1 pad to the arm base For reassembly tighten the capscrews to 65 ft lbs 90 Nm Positive Camber top of pads lean out 5 Install shims included in shim kit 6155363 as required Installing shims at the bottom of the pad provides positive camber top of pad leans out CAUTION Use an equal number of shims on each 3 contact pad Pad camber must be the same on all pads for proper load handling Measure from 2 pad centers Load Opposite Pads Lower Tier FOR MINIMUM POSITIVE CAMBER CANNED BOTTLED eas DENSE CASE GOODS Neutral to Posi
11. fer to Section 4 3 e Ifthe pressure drop is less than 150 psi 10 bar initially and additional drop does not exceed 25 psi 1 7 bar per minute one or more of the other cylinders is faulty and requires service Check the pressure of the other cylinders as described above to isolate the faulty cylinder Install new seals in all cylinders refer to Section 4 3 ISOLATING A SINGLE CYLINDER Clamp assembly CAUTION Plug all disconnected cylinder under test hoses and cap corresponding hoses connected cylinder fittings before starting truck Pressure gauge on valve test port 5 LP0108 eps Front View 6849001 S ERVICE 41 Layer Picker Removal 4 1 1 Carriage Mount WARNING Before removing any hoses A relieve pressure in the hydraulic system With the truck off open the truck auxiliary control valve s several times in both directions 1 Disconnect the truck supply hoses Plug the hoses and cap the fittings 2 Disconnect the lower mounting hooks Bolt On Type Remove the lower mounting hooks For reassembly tighten the capscrews to a toque of 165 ft lbs 225 Nm Quick Change Type Pull out the retaining pin slide the hook down and reinstall the pin in the lower hole For reassembly slide the hooks up to the locked ODG LP0597 eps position and install the locking pins in the top holes _ Lower the attachment onto pa
12. intenance perform the following procedures e Check the clearance between the lower mounting hooks and the truck carriage bar Quick Change Hooks 3 16 in 4 8 mm maximum Bolt On Hooks 3 32 in 2 4 mm minimum and 3 16 in 4 8 mm maximum If adjustment is necessary refer to Section 4 1 1 Tighten the lower hook capscrews to 125 ft lbs 170 Nm WARNING After completing any service procedure always test each function through five complete cycles First test with no load then test with a load to make sure the attachment operates correctly before returning it to the job Model Mounting Frame J Lower Hooks 0588 Contact Pads Fork Mount Model Mounting Frame Boom Mounting Bars Clamp Assembly Pin Retainer Arms Oe Contact LP0589 eps Pads 6849001 ERIODIC MAINTENANCE 2 3 2 4 1000 Hour Maintenance After each 1000 hours of truck operation in addition to the 100 and 500 hour maintenance perform the following procedures e Inspect clamp arms arm bearings boom mounting bars and center spacer bearings if equipped for wear Replace as necessary 2000 Hour Maintenance After each 2000 hours of truck operation in addition to the 100 500 and 1000 hour maintenance perform the following procedures e f equipped wi
13. lic flow should be within the range shown in Specifications Section 5 1 Hydraulic fluid supplied to the layer picker must meet the requirements shown in Specifications Section 5 1 Tools Required In addition to a normal selection of mechanic s hand tools the following are required Inline Flow Meter Kit 10 GPM 87 L min Cascade Part No 671476 20 GPM 75 L min Cascade Part No 671477 Pressure Gauge Kit 5000 psi 345 bar Cascade Part 671212 Assortment of fittings and hose Pallet hand truck to install clamp assembly on the mounting assembly Overhead hoisting capability that is at least the rated capacity of the attachment weight Refer to attachment nameplate Metric hex key allen set to adjust pressure reliefs Troubleshooting Chart Determine All The Facts It is important to gather all the facts about the problem before beginning any service procedures The first step is to talk to the equipment operator Ask for a complete description of the malfunction Guidelines below and on the following pages can then be used as a starting point to begin troubleshooting Clamp Circuit e Load slips after it has been picked up e Clamp assembly will not carry load up to its rated capacity e Clamp assembly arms move slowly or not at all To correct these problems refer to Sections 3 1 4 and 3 3 WARNING Before servicing any hydraulic components relieve pressure in the attachme
14. llet Tilt the mast forward and lower the carriage to remove the attachment from the truck 4 For attachment installation reverse the above procedures with the following exceptions e For complete installation procedure refer to Installation Instructions 222964 LP0596 eps 2 BOLT ON HOOKS QUICK CHANGE HOOKS Carriage Bar i Guide RC0368 eps N RC0367 eps Carriage Bar A 2 Tight against E lower carriage LH Lower Hook in bar Unlocked Position Locking Pin GA0451 eps_ Lower Hook 10 6849001 _ S ERVICE 41 2 Fork Mount WARNING Before removing any hoses A relieve pressure in the hydraulic system With the truck off open the truck auxiliary control valve s several times in both directions Disconnect the truck supply hoses Plug the hoses and cap the fittings Lower the attachment onto a pallet Fork Retainer Type Remove the cotter pin located underneath the fork mount from the clevis pin Keep track of washers Back Fork Pin Type Remove the cotter pin from each side of the clevis pin Keep track of the washers Back truck out of the fork mount slots For attachment installation reverse the above procedures with the following exceptions e For complete installation procedure refer to Installation Instructions 222964 1 OPEN CLAMP
15. low greater than maximum can result in excessive heating reduced system performance and short hydraulic system life GA0388 eps Hoses and Fittings Hoses and fittings for the CLAMP function should be No 6 with 250 in 7 mm minimum ID 5 1 2 Truck Valve Functions Check for compliance with ANSI ISO standards end Release Open GA0094 eps Hoist Up Clamp Close 5 1 3 Truck Carriage Carriage Mount Dimension A ITA ISO Minimum Maximum A Class 1 14 94 380 0 mm 15 00 in 381 0 mm Class 18 68 474 5 mm 18 74 in 476 0 mm GA0389 eps 6849001 21 S PECIFICATIONS 5 1 4 Torque Values Carriage Mount Fastener torque values for Carriage Mount Layer Pickers are shown in the table below in both US and Metric units All torque values are also called out in each specific service procedure section throughout the manual NOTE Allfasteners have a torque value range of 10 of stated value Ref Fastener Location Size Ft Ibs Nm 1 Contact Pad Capscrews 12 65 90 2 ArmLoad Guard Capscrews 12 65 90 3 Clamp Valve Capscrews M8 16 25 4 Cylinder Rod Anchor Nut 3 4 UNF 165 225 5 Adjustable Stop Jam Nuts 12 60 80 6 Pin Retainers 8 20 30 7 Upper Hook Capscrews M16 120 165 8 Lower Hook Capscrews M16 120 165 9 QD Guide Capscrew
16. not contact the thread relief chamfer If necessary trim the stop fins for a correct fit The piston will not enter the shell if the loader contacts the thread relief chamfer 8 Apply a thick film of petroleum jelly to the piston shell and loader Using a rubber mallet tap the piston rod assembly into the cylinder shell 9 Place the retainer loader over the rod end threads Apply petroleum jelly to the retainer ID and slide the retainer onto the rod Remove the loader and screw the retainer into the shell Tighten the retainer to 100 ft Ibs 135 Nm Stop Fins y g IMPORTANT Loader must not contact thread relief chamfer Piston Rod Assembly 7 RC0320 eps Cylinder a Shell Piston Seal Loader CL1074 eps 6849001 _ S PECIFICATIONS s1 Specifications 5 1 1 Hydraulics Truck Relief Settings 2000 psi 138 bar Recommended 2300 psi 160 bar Maximum Truck Flow Volume Min 2 Recommended 5 GPM 7 GPM 10 GPM 18 L min 37 L min 56 L min 30A amp 30B Cascade attachments are compatible with SAE 10W petroleum base hydraulic fluid meeting Mil Spec MIL O 5606 or MIL O 2104B Use of synthetic or aqueous base hydraulic fluid is not recommended If fire resistant hydraulic fluid is required special seals must be used Contact Cascade Flow less than recommended will result in slower than normal operating speed F
17. nt hydraulic system Turn the truck off and move the auxiliary control valves several times in both directions 2 Disconnect the hydraulic hoses from the cylinder to be removed Plug the hoses and cap the cylinder ports Tag hoses for reassembly 3 Disconnect the cylinder ends from the arm lug and frame by removing the cotter pin locking cap spherical nut and hex washer 4 Slowly slide the clamp arms outward 3 in 75 mm to remove the cylinder CAUTION Use care not to disengage the clamp arms from the clamp frame or the boom arms from the boom when removing the cylinders 5 Service the cylinder as described in Section 4 3 2 6 For reassembly reverse the above procedures with the following exceptions for the cylinder anchors e Lubricate threads with chassis grease and assemble cylinder anchors as shown nstall hex beveled washer on cylinder rod end NOTE Verify that the beveled side of washer faces mount see illustration e Tighten spherical nuts against rod hex washer and ylinder head end to 160 ft lbs 220 Nm NOTE Joints function with a loose operating clearance Lubricate with chassis grease nstall locking secure with new cotter CLAMP CYLINDER LP0603 eps Locking Cap Cotter Pin Cylinder Rod End L lt 7 6 NI N SA LP0164 eps Spherical Nut Hex Washer NOTE Beveled side faces
18. nt system Turn the truck off and move the truck auxiliary control valve levers several times in both directions A After completing any service procedure always test the attachment through several cycles First test empty to bleed any air trapped in the system to the truck tank Then test with a load to be sure the unit operates correctly before returning it to the job Stay clear of the load while testing Do not raise the load more than 4 in 10 cm off the floor while testing Flow Meter Kits 671476 10 GPM 37 L min 671477 20 75 L min Flow Meter 81 lt GA0013 eps 2 No 8 12 JIC O Ring 2 No 6 8 JIC Reducer Pressure Gauge Kit 671212 Pressure No 6 and No 8 Gauge No 6 6 Hose JIC Swivel Tee Sp fo o of 9 0014 No 4 6 Pipe JIC No 6 8 JIC No 4 No Reducer 6 and No 8 JIC O Ring Quick Disconnects Male Straight Thread O Ring Coupler No 4 Part No 212282 No 5 Part No 210378 O No 6 Part No 678592 Female JIC Thread a Coupler No 4 Part No 210385 No 6 Part No 678591 AC0127 eps NOTE Diagnostics Kit 394382 includes items marked 6849001 T ROUBLESHOOTING 3 1 4 Layer Picker Loads IF LOWER TIER OF LOAD BRIDGES DOWN Check for worn OR SLIDES OUT a
19. ove e lf the pressure drop is more than 150 psi 10 bar initially and additional drop exceeds 25 psi 1 7 bar per minute the clamp assembly check valve may be faulty Replace the cartridge If the pressure still drops as above one or more of the cylinders requires service WARNING Before removing hydraulic lines or components relieve pressure in the attachment hydraulic system Turn the truck off and move the auxiliary control lever several times in both directions 2 Flow Meter Pressure gauge on valve test port Clamp Assembly Valve LP0090 eps Front View 6849001 T ROUBLESHOOTING lines or components relieve pressure in 4 Totesta single cylinder isolate the other three by the attachment hydraulic system Turn disconnecting the hoses to the cylinder rod ends the truck off and move the auxiliary control Refer to the illustration shown below lever several times in both directions 3 3 2 Clamp Circuit Test Continued WARNING Before removing hydraulic CAUTION Plug the hose ends and cap the cylinder fittings before starting the truck 5 Start the truck and clamp on a load holding the lever in the CLAMP position for a few seconds 6 Release the lever and watch the pressure gauge e Ifthe pressure drop is more than 150 psi 10 bar initially and additional drop exceeds 25 psi 1 7 bar per minute the cylinder under test is faulty and requires service Re
20. oving the clamp assembly 1 Lower the clamp assembly onto a pallet until it just touches the surface 2 Disconnect the cylinder rod end from the arm to be removed For reassembly assemble the parts as shown Tighten the spherical nut against the hex washer to 160 ft lbs 220 Nm NOTE Rod end joint operates with a loose operating clearance Secure locking cap with a new cotter pin WARNING Keep hands and feet out from under contact pads and arms 3 Slide the arm out of the clamp frame Do not damage the bearings when removing the arm 4 For reassembly reverse the above procedures with the following exceptions LP0091 eps e Inspect the arm bearings for wear and replace if necessary Refer to Section 4 2 5 Locking Cap Cotter Pin e Apply chassis grease to the cylinder rod end joint 7 LP0116 eps Spherical Nut Hex Washer NOTE Beveled side faces arm lug 4 2 3 Contact Pad Rotation or Replacement 3 NOTE Contact pad surfaces that are worn or damaged over the entire pad area will require pad replacement If only the lower surface is worn some pads can be rotated 180 and reinstalled 1 Extend the arms fully Pad capscrews 2 Remove the capscrews and nuts fastening the contact washers nuts pad to the arm base For reassembly tighten the capscrews to 65 ft lbs 90 Nm NOTE Reinstall shims in original position to maintain same pad camber setting Ref
21. rm bearings Check for bent pads or arms straighten or replace Check hydraulics for low supply pressure Add or increase positive camber Refer to Section 4 2 4 Check for worn 2 contact pad surfaces replace IF LOWER TIER OF LOAD IS CREASED Check for bent pads or arms straighten or Check Center Spacer Bearings Re clamp layer so bottom edge is even with bottom of pads Check hydraulics for high supply pressure 6849001 replace LP0021 eps Re clamp load so bottom edge is even with bottom of pads Re clamp load squarely between pads T ROUBLESHOOTING 32 Plumbing 3 2 1 Hosing Diagrams Clamp Circuit Clamp Cylinders OPEN ARMS PRESSURE s RETURN ws NOTE For CLAMP ARMS reverse the colors shown Truck Auxiliary Valves Internal Reeving Hose Terminal LP0593 eps 6 6849001 T ROUBLESHOOTING 3 2 2 Hydraulic Schematic Clamp Valve Clamp Cylinders Check Cartridge CLAMP Internal 4 Position Hose Pressure Reeving Relief Valve Truck Auxiliary Valve CLAMP Truck Tank LP0594 eps 6849001 8 3 3 3 3 1 3 3 2 ROUBLESHOOTING Clamp Function
22. s M16 120 165 10 Frame Mounting Capscrews M20 235 320 11 Centering Tab Capscrews M16 120 165 LP0604 eps 22 6849001 _ S PECIFICATIONS 5 1 5 Torque Values Fork Mount Fastener torque values for the Fork Mount Layer Picker are shown in the table below in both US and Metric units All torque values are also called out in each specific service procedure section throughout the manual NOTE Allfasteners have a torque value range of 10 of stated value Ref Fastener Location Size Ft Ibs 1 Contact Pad Capscrews M12 65 90 2 Arm Load Guard Capscrews M12 65 90 3 Clamp Valve Capscrews M8 16 25 4 Cylinder Rod Anchor Nuts 3 4 UNF 165 225 5 Adjustable Stop Jam Nuts M12 60 80 6 Pin Retainers M8 20 30 3 5 LPO605 eps z 6849001 Do you have questions you need answered right now Call your nearest Cascade Service Department Visit us online at www cascorp com AMERICAS Cascade Corporation U S Headquarters 2201 NE 201st Fairview OR 97024 9718 Tel 800 CASCADE 227 2233 Fax 888 329 8207 EUROPE AFRICA Cascade ltalia 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
23. th load center support replace center load spacer bearings e Replace clamp arm bearings Refer to Sections 4 2 5 Fork Inspection After 2000 hours of truck operation forks in use shall be inspected at intervals of not more than 12 months for single shift operations or whenever any defect or permanent deformation is detected Severe applications will require more frequent inspection Fork inspection shall be carried out by trained personnel to detect any damage that might impair safe use Any fork that is defective shall be removed from service Reference ANSI B56 1 2005 Inspect for the following defects Surface cracks Straightness of blade and shank Fork angle Difference in height of fork tips Positioning lock Wear on fork blade and shank Wear on fork hooks Legibility of marking NOTE Fork Safety Kit 3014162 contains wear calipers inspection sheets and safety poster Also available is fork hook amp carriage wear gauge 209560 Class 1 and 209561 Class III 6849001 Load Center Support Center Spacer Bearings Arm Bearing Tubes Load Center Support Early Models Arm Bearings 8 3 1 3 1 1 3 1 2 3 1 3 ROUBLESHOOTING General Procedures Truck System Requirements Truck hydraulic pressure should be within the range shown in Specifications Section 5 1 PRESSURE TO THE ATTACHMENT MUST NOT EXCEED 2300 psi 160 bar Truck hydrau
24. tive 0 0 BOXED LIGHT Neutral CASE GOODS 9 LP0136 eps No shims FOR MAXIMUM POSITIVE CAMBER Pad Capscrews and Nuts 1 8 in 3 2 mm Contact Pad le Bottom Shim s it ieee LP0137 eps LP0519 eps IMPORTANT Shim all four pads equally 6849001 _ S ERVICE 4 2 5 Arm Bearing Replacement NOTE Replace all arm bearings if wear is found in one arm bearing 1 Remove the four clamp arms as described in Section 4 2 2 2 Remove the internal Teflon retaining rings from the clamp frame tubes NOTE Use Cascade brass tool 674424 or a thin blade screwdriver to remove the rings Avoid damaging the grooves in the frame Pull the bearings out of the frame 4 For reassembly reverse the above procedures with the following exception e Use new bearing retaining rings when installing the new bearings Clamp Frame Arm Bearings 3 Retaining Rings Front View Bearing Retainer Ring Cascade Tool Part No 674424 LP0134 eps 6849001 S ERVICE 426 Clamp Valve Removal 4 2 7 16 Installation WARNING Before removing hydraulic lines relieve pressure in the attachment hydraulic system Turn the truck off and move the auxiliary control valve several times in both directions A Disconnect the two CLAMP function hoses or tubes from the top of the valve Plug the hose or tube ends and tag for reassembly 2 Disconnect the eight cylinder
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