6880238_C-Series Layer Picker Service - Cascade Corporation

Cascade is a Registered Trademark of Cascade Corporation

cascadecorporation

ERVICE MANUALSC-Series

Manual Number 6880238

Layer PickersIncludes:Swing Models &Stationary Side Mount Models

ONTENTSC

i 6880238

PageINTRODUCTION, Section 1

Introduction 1Special Definitions 1

PERIODIC MAINTENANCE, Section 2Initial 50-Hour Maintenance 2100-Hour Maintenance 2500-Hour Maintenance 31000-Hour Maintenance 32000-Hour Maintenance 4

TROUBLESHOOTING, Section 3General Procedures 5

Truck System Requirements 5Tools Required 5Troubleshooting Chart 6Layer Picker Loads 7

Plumbing 8Hosing Diagram – Swing, Reach and Clamp Circuits 8Hosing Diagram – Hoist Circuit 9Hydraulic Schematic – Without Flow/Pressure Control Valve 10Hydraulic Schematic – With Flow/Pressure Control Valve 11Hydraulic Schematic – Electronic Swing Control 12

Clamp Function 13Supply Circuit Test 13Clamp Circuit Test 13

Reach Function 15Supply Circuit Test 15Reach Circuit Test 15

Swing Function 16Supply & Swing Circuit Test 16

Hoist Function 17Supply Circuit Test 17Lower Carriage Circuit Test 17

Electrical Circuit 18SERVICE, Section 4

Layer Picker Removal 19Clamp Assembly 21

Removal 21Arms – Removal and Installation 22Contact Pad Rotation, Replacement 22Contact Pad Camber Adjustment 23Arm Bearing Replacement 24Pivot Bushing 25Clamp Level Adjustment 25Clamp Valve Removal, Installation 26Valve Service 26

PageSERVICE, continued

Cylinders 27Clamp & Reach Cylinder Removal 27Fork Carriage Cylinder Removal 28Cylinder Disassembly 29Cylinder Inspection 29Cylinder Reassembly 31

Boom/Carriage Assembly 33Removal 33Boom Reeving Service 35Telescope Bars, Bearings 35Swing Valve Removal, Installation 36Valve Service 36Boom Replacement 37Swing Actuator Replacement 37Carriage Inspection & Service 38

Layer Picker Mast 39Inspection and Adjustments 39Chain Inspection 40Lift Chain Service 41Mast Hose Reeving Service 42Hoist Cylinder Removal, Installation 43Hoist Cylinder Bleeding 43Hoist Cylinder Service 44Mast Valve Service 45Mast Upright Disassembly 46Mast Upright Inspection 46Mast Upright Reassembly 47

Pressure/Flow Control Valve 48Removal, Installation 48Valve Service 48

Lower Carriage Solenoid Valve 49Coil Service 49Valve Service 49

Electronic Swing Control (if equipped) 50Solenoid Valve Service 50Stop Position Adjustment 51Troubleshooting 52

SPECIFICATIONS, Section 5Specifications 53

Hydraulics 53Auxiliary Valve Functions 53Torque Values 55

NTRODUCTIONI

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1.1 IntroductionThis manual provides the Periodic Maintenance, Troubleshooting, Service and Specifications for the Cascade Swing and Stationary Side Mount Layer Pickers.

In any communication about the Layer Picker, refer to the product catalog and serial numbers stamped on the nameplate as shown. If the nameplate is missing, the numbers can be found stamped on the mast.

IMPORTANT: All hoses, tubes and fittings on layer picker are JIC.

NOTE: Specifications are shown in both US and (Metric) units.

Nameplate

Nameplate

1.2 Special DefinitionsThe 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.

WARNING - A statement preceded by WARNING is information that should be acted upon to prevent bodily injury. A WARNING is always inside a ruled box.

CAUTION - A statement preceded by CAUTION is information that should be acted upon to prevent machine damage.

IMPORTANT - A statement preceded by IMPORTANT is information that possesses special significance.

NOTE - A statement preceded by NOTE is information that is handy to know and may make your job easier.

Swing Model

Stationary Side Mount Model

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2.2 100-Hour MaintenanceEvery time the lift truck is serviced or every 100 hours of truck operation, whichever comes first, complete the following maintenance on the layer picker:

• Check for loose or missing bolts, damaged or worn hoses and hydraulic leaks.

• Inspect contact pads, arms, and forks for damage or wear. Replace as necessary.

• Inspect clamp and boom cylinder anchor nuts for proper connection and tightness. If necessary tighten to 160 ft.-lbs. (220 Nm).

• Check that mast is vertical and clamp assembly is level during normal operation. Adjust as necessary.

• Lubricate mast upright rails. Cascade approved lubricant:

Power Punch MPG White Lithium Multi-Purpose Grease

IMPORTANT: Regular application of Cascade approved lube will prevent premature mast rail and thrust block wear.

Mast

Swing Boom

Clamp Assembly

Arms

Contact Pads

Carriage

Fork Carriage (if equipped)

Adjustable Solid Links

Lubricate areas indicated by heavy line full length of each mast upright every 100 hours.

Carriage

Inner Upright

Outer Upright

Load Rollers

WARNING: Failure to lubricate uprights properly may result in flaking material that can get into the operator's eyes and cause personal injury.

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2.1 Initial 50-Hour MaintenanceIMPORTANT: Layer Pickers with Cascade Mast – After the Layer Picker has operated the initial 50 hours, perform the 50 Hour Maintenance as described in Technical Bulletin TB 339, Layer Picker Initial 50 Hour Inspection and Adjustment. These maintenance steps will ensure the Layer Picker is properly adjusted and operating correctly. After the maintenance steps are complete, file a Warranty Claim to be reimbursed for time and travel.

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• Inspect and adjust (if necessary) the thrust bearing side-to-side clearance in mast upright and carriage. Check carriage alignment and verify that the total side-to-side clearance is 0.06 in. (1.5 mm) maximum at the tightest point throughout the travel of the carriage.

To adjust: Remove retainer and M12 capscrews from M24 capscrew. Turn capscrew until bearing touches the mast. Back off the capscrew 1/2 turn. Install retainer, tightening the capscrews to 48 ft.-lbs. (65 Nm). Verify side-to-side clearance.

2.3 500-Hour MaintenanceAfter each 500 hours of truck operation, in addition to the 100-hour maintenance, perform the following procedures.

• Inspect chains for proper tension and adjustment. Refer to Section 4.5-2.

• Lubricate full length of mast chains with chain lube (Cascade Part No. 200867).

• Check torque value on mast lower mounts and adjustable solid links.

• Check torque value on swing boom drive top capscrews, as shown. Use cross-pattern and tighten to 160 ft.-lbs. (215 Nm).

• Check torque value on swing actuator mounting capscrews. Tighten to 160 ft.-lbs. (215 Nm).

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Arm and Boom Bearing Tubes

Cylinder Rod-End Anchors

2.4 1000-Hour MaintenanceAfter each 1000 hours of truck operation, in addition to the 100 and 500-hour maintenance, perform the following procedures:

• Inspect clamp arm, boom arm and center spacer bearings for wear. Replace as necessary.

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M24 Capscrew – Turn to adjust side clearance

Thrust Bearing

M12 Capscrews

SwingActuator Capscrews

Swing ActuatorMounting Capscrews

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2.5 2000-Hour MaintenanceAfter each 2000 hours of truck operation, in addition to the 100, 500 and 1000-hour maintenance, perform the following procedures:

• Replace center spacer bearings.

• Replace clamp arm and boom arm bearings. Refer to Sections 4.2-5 and 4.4-3.

• Inspect load rollers and thrust bearings in mast and carriage. Refer to Section 4.5.

• 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/ITSDF B56.1 (ISO 3691).

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 & carriage wear gauge 209560 (Class II), 209561 (Class III) and 6105257 (Class IV).

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 Layer Picker operates correctly before returning it to the job.

Center Spacer Bearings

Load Center Support

Boom Bearings

Clamp Frame

Arm Bearings

Retaining Rings

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Pressure Gauge Kit671212

PressureGauge*

No. 6 and No. 8JIC Swivel Tee

No. 4-6 Pipe/JIC*

No. 6-6 Hose*

(2) No. 6-8 JIC Reducer

Flow Meter

No. 4, No. 6* and No. 8 JIC/O-Ring

No. 6-8 JIC Reducer

(2) No. 8-12 JIC/O-Ring

WARNING: Before servicing any hydraulic components, relieve pressure in the attachment system. Turn the truck off and move the truck auxiliary control valve levers several times in both directions.

After completing any service procedure, always test the layer picker 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.

Male Straight Thread O-Ring Coupler: No. 4 (Part No. 212282)* No. 5 (Part No. 210378) No. 6 (Part No. 678592)

Female JIC Thread Coupler: No. 4 (Part No. 210385)* No. 6 (Part No. 678591)

Quick-Disconnect Couplers

* NOTE: Diagnostics Kit 394382 includes items marked.

Flow Meter Kits671476 (10 GPM - 37 L/min)671477 (20 GPM - 75 L/min)

• Truck hydraulic pressure should be within the range shown in Specifications, Section 5.1. PRESSURE TO THE LAYER PICKER MUST NOT EXCEED 2300 psi (160 bar).

• Truck hydraulic 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.

3.1-2 Tools RequiredIn addition to a normal selection of mechanic’s hand tools, the following are required:

• Inline Flow Meter Kit: 10 GPM (37 L/min) - Cascade Part No. 671476. 20 GPM (75 L/min.) - Cascade Part No. 671477.

• Pressure Gauge Kit: 5000 psi (345 bar) - Cascade Part No. 671212.

• Assortment of fittings and hose.

• Magnetic Protractor/Level for vertical and horizontal adjustments.

• Pallet hand truck to install clamp assembly on mast.

• Overhead hoisting capability that is at least the rated capacity of the layer picker weight. Refer to layer picker nameplate.

• Metric hex key set to adjust pressure reliefs.

3.1 General Procedures3.1-1 Truck System Requirements

ROUBLESHOOTING

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3.1-3 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• Load slips after it has been picked up.

• Clamp assembly will not carry load up to its rated capacity.

• Clamp assembly arms move slowly or not at all.

To correct these problems, refer to Sections 3.1-4 and 3.3.

Reach Circuit• Clamp assembly will not extend or retract.

• Clamp assembly extends or retracts slowly or with jerky motion.

To correct these problems, refer to Section 3.4.

Swing Circuit• Boom will not swing in either direction.

• Boom swings in one direction only.

• Boom swings slowly or with jerky motion.


Hoist Circuit• Mast will not raise when loaded or unloaded.

• Mast has elastic or jerky action.

• Mast drifts down.

• Lower carriage will not raise or lower.


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3.1-4 Layer Picker Loads

Check for bent pads or arms, straighten or replace

Check for worn arm bearings

Add or increase positive camber, see Section 4.2-4

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5

Re-clamp layer so bottom edge is even with bottom of pads

Check hydraulics for low supply pressure

Check for worn contact pad surfaces, replace

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IF LOWER TIER OF LOAD BRIDGES DOWN OR SLIDES OUT:

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IF LOWER TIER OF LOAD IS CREASED:

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2

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1Reclamp load squarely between pads

Check hydraulics for high supply pressure

Reclamp load so bottom edge is even with bottom of pads

Check for bent pads or arms, straighten or replace

5 Check load spacer bearings

6 Add or increase negative chamber, see Section 4.2-4

ROUBLESHOOTING

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3.2 Plumbing3.2-1 Hosing Diagrams – Swing, Reach and Clamp Circuits

CLAMP Internal Reeving Hose Terminal

REACH Internal Reeving Hose Terminal

To CLAMP Internal Reeving Hose Terminal

To SWING Hose Reel

To SWING Truck Auxiliary Valve

To CLAMP Truck Auxiliary Valve

To CLAMP Truck Auxiliary Valve OR Flow/Pressure Control Valve

To REACH Truck Auxiliary Valve

Flow/Pressure Control Valve

To Truck TankTo Truck Tank

Clamp Cylinders

Truck Auxiliary Valves

To Hoist Circuit

Reach Cylinder

HOIST

RETRACT

CLAMP ARMS

OPENARMS

SWING RIGHT

Swing Valve

SWING LEFT

EXTEND

SWINGREACH

CLAMP

Clamp Valve

CLAMP ARMSPRESSURERETURN

NOTE: For OPEN ARMS, reverse the colors shown.EXTEND

PRESSURERETURN

NOTE: For RETRACT, reverse the colors shown.

SWING LEFTPRESSURERETURN

NOTE: For SWING RIGHT, reverse the colors shown.

CLAMP CIRCUITREACH CIRCUIT

SWING CIRCUIT

If equipped with Flow/Pressure Control Valve

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Hoist Cylinders

Solenoids

Fork Carriage Cylinders

To Hoist Cylinder

To Hoist Cylinder

To Hoist Cylinder

To Hoist Cylinder

Mast Lowering Control Valve

3.2-3 Hosing Diagram – Hoist Circuit

HOIST UPHOIST DOWN

RAISE CARRIAGE 1LOWER CARRIAGE 2

HOIST CIRCUIT(HOIST Solenoid De-Energized, if equipped)

FORK CARRIAGE (HOIST Solenoid Energized)

1 Fork Carriage Solenoid De-Energized

2 Fork Carriage Solenoid Energized

HOIST Truck Auxiliary Valve

HOIST Truck Auxiliary Valve

ROUBLESHOOTING

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3.2-4 Hydraulic Schematic –Without Flow/Pressure Control Valve

Clamp Valve

Clamp Cylinders

OPEN CLAMP

ReachCylinder

Hoist Cylinders

HydraulicFuse/Cushion(in cylinder)

RETRACT

EXTEND

HoistLoweringControlValve

LEFT RIGHTOptional Lower

Carriage Cylinders

OptionalSolenoidValves

TruckValves

Hose Reel

MastIHR

Connections

Truck Tank

Truck ReliefTruck Pump

HOISTSWING(if equipped) REACH CLAMP

3-PositionPressureRegulator

Swing Actuator

Swing Valve

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CW

CW

CCW

CCW

TANK

OP

OP

CL

CL

3.2-5 Hydraulic Schematic –With Flow/Pressure Control Valve

Clamp ValveClamp Cylinders

ReachCylinder

OPEN CLAMP RETRACT

EXTEND

Swing Actuator

Hoist Cylinders

LEFT RIGHT

HydraulicFuse/Cushion(in cylinder)

HoistLoweringControlValve

Hose ReelMast IHRConnection

Optional LowerCarriage Cylinders

Flow/PressureControl Valve

3-PositionPressureRegulator

OptionalSolenoidValves

Truck Valves

HOIST REACH CLAMP

Truck Pump Truck Relief

Truck Tank

SWING

Swing Valve

ROUBLESHOOTING

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3.2-6 Electronic Swing Control

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STOP Valve

Swing Valve

LEFT RIGHT

To HOIST Components

To REACH Components

Truck Tank

Truck ReliefTruck Pump

Hose Reel To CLAMP

Components

To 3-Position Pressure Regulator

DECEL Valve

Swing Actuator

Truck Valves

HOIST REACH CLAMPSWING

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3.3 Clamp FunctionThere are five potential problems that could affect the CLAMP functions:

• Incorrect load handling. Refer to Operator’s 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

3.3-1 Supply Circuit Test1 Check the pressure supplied by the truck at the clamp

assembly valve. Pressure must be within the range shown in Specifications, Section 5.1-1. PRESSURE TO THE CLAMP ASSEMBLY MUST NOT EXCEED 2300 PSI (160 bar).

2 Check the flow volume at the clamp assembly valve. Flow must be within the range shown in Specifications, Section 5.1-1.

3 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.

3.3-2 Clamp Circuit Test1 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.

2 Start the truck and clamp on a load, holding the lever in the CLAMP position for a few seconds.

3 Release the lever and watch the pressure gauge:

• If the 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 the five potential problems listed above (Section 3.3).

• If 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.

Front View

Flow Meter21

Pressure gauge on valve test port

Clamp Assembly Valve

CLAMP bulk fitting to valve

Top of Clamp Frame

2

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3.3-2 Clamp Circuit Test (Continued)

Clamp assembly cylinder under test (hoses connected)

Pressure gauge on valve test port

4 To test a single cylinder, isolate the other three by disconnecting the hoses to the cylinder rod ends, as shown below.

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:

• If the 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. Refer to Section 4.3.

• If the 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.

Install new seals in all cylinders (refer to Section 4.3), or check the pressure of the other cylinders, as described above, to isolate the faulty cylinder.

CAUTION: Plug all disconnected hoses and cap corresponding cylinder fittings before starting truck.

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.

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4

4

4

ISOLATING A SINGLE CYLINDER

Front View

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3.4 Reach FunctionThere are five potential problems that could affect the REACH function:

• Incorrect load handling. Refer to Operator’s Guide for suggested procedures.


• External leaks.

• Worn/defective cylinder seals.

• Damaged or worn boom arms or bearings.

3.4-1 Supply Circuit Test1 Check the pressure supplied by the truck at the REACH

cylinder. Pressure must be within the range shown in Specifications, Section 5.1-1. PRESSURE TO THE REACH CYLINDER MUST NOT EXCEED 2300 PSI (160 bar).

2 Check the flow volume at the reach cylinder. Flow must be within the range shown in Specifications, Section 5.1-1.

3 Actuate the REACH lever and extend or retract the boom fully, holding the lever in position for a few seconds. Release the lever and check for external leaks at fittings, hoses, revolving connection and cylinder rod. Correct any problems.

3.4-2 Reach Circuit Test1 Retract the boom fully. Turn the truck off and relieve

system pressure by moving the REACH control lever back and forth several times.

2 Disconnect the cylinder base end (EXTEND) hose and cap the end. Connect a drain hose to the cylinder base end fitting and route the hose to a drain bucket.

3 Start the truck and actuate the RETRACT control lever for 5 seconds:

• If there is substantial hydraulic flow out of the drain hose, the reach cylinder is faulty and requires service. Refer to Section 4.3.

• If there is no hydraulic flow out of the drain hose, the problem is not hydraulic. Refer to the five potential problems listed above (Section 3.4).

1

Flow Meter24

Pressure Gauge

Reach Cylinder

'Tee' Fitting on cylinder rod end port

WARNING: Before removing hydraulic lines or components, relieve pressure in the attachment hydraulic system. Turn the truck off and move the auxiliary control levers several times in both directions.

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ROUBLESHOOTING

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3.5 Swing FunctionThere are five potential problems that could affect the SWING function:

• Incorrect load handling. Refer to the Operator’s Guide for suggested procedures.


• External leaks.

• Worn or defective cartridge valves or actuator.

• Damaged boom.

3.5-1 Supply & Swing Circuit TestRemove either of the supply hoses to the swing valve. Connect a pressure gauge and flowmeter by using a 'tee' fitting connected to the supply terminal.

NOTE: The swing actuator functions hydraulically similar to a hydraulic cylinder. An internal piston is forced up and down on a curved-spline shaft, causing boom rotation left or right.

1 Check the pressure supplied by the truck at the swing valve. Pressure must be within the range shown in Specifications, Section 5.1-1. PRESSURE TO THE SWING DRIVE CIRCUIT MUST NOT EXCEED 2300 PSI (160 bar).

2 Check the flow volume into the swing valve. Flow must be within the range shown in Specifications, Section 5.1-1.

Swing left and right fully, holding the lever in position for a few seconds. Release the lever and check for external leaks at fittings, hoses, valve and swing actuator. Correct any problems.

3 Clamp and raise a maximum load and actuate the SWING LEFT control lever:

• If the boom swings slowly or not at all, the SWING LEFT relief valve cartridge may be faulty (perform a similar test for the SWING RIGHT relief valve cartridge). Replace the cartridges as required. If the boom still swings slowly or not at all, the actuator may be faulty.

4 Disconnect the SWING RIGHT tubing from the actuator and cap the tubing end. Connect a drain hose to the actuator fitting and route the hose to a drain bucket.

5 Start the truck and actuate the SWING LEFT control lever for 5 seconds:

• If there is substantial hydraulic flow out of the drain hose, the actuator is faulty and requires replacement. Refer to Section 4.4-7.

• If there is no hydraulic flow out of the drain hose, the problem is not hydraulic. Refer to the five potential problems listed above (Section 3.5).

NOTE: If equipped with Electronic Swing Control (ESC), refer to Section 4.8.

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WARNING: Before removing hydraulic lines or components, relieve pressure in the attachment hydraulic system. Turn the truck off and move the auxiliary control levers several times in both directions.

Pressure Gauge 1

Relief Valve Cartridge

3

4

Counterbalance Valve Cartridge

Flow Meter2

Swing Valve

Swing Actuator

Tubing to Actuator

Front View

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3.6 Hoist FunctionThere are five potential problems that could affect the HOIST function on the mast:

• Incorrect load handling. Refer to the Operator’s Guide for suggested procedures.


• External leaks.

• Worn or defective mast control valve or cylinder seals.

• Damaged or worn mast uprights, rollers, carriage.

3.6-1 Supply Circuit Test1 Check the pressure supplied by the truck at the mast

lowering control valve. Pressure must be within the range shown in Specifications, Section 5.1-1. PRESSURE TO THE MAST MUST NOT EXCEED 2600 PSI (180 bar).

2 Check the flow volume into the mast lowering control valve. Flow must be within the range shown in Specifications, Section 5.1-1.

3 Raise the mast fully and hold the hoist control lever in the RAISE position for a few seconds. Release the lever and check for external leaks at fittings, hoses, valve and cylinder rods or retainers. Correct any problems.

4 Lower the mast. If the mast exhibits problems during lowering, replace the lowering control valve cartridge. If the mast still exhibits problems, mast service is required. Refer to Section 4.5.

3.6-2 Lower Carriage Circuit Test1 Perform the mast supply circuit test as described in

Section 3.6-1. Correct any problems.

2 Check the lower carriage solenoids for proper operation. Refer to Section 3.7. For solenoid valve service, refer to Section 4.7. Correct any problems.

3 Raise a fully-loaded lower carriage (press button on HOIST control lever). If the carriage raises slowly or not at all, the cylinders are faulty and require service. Refer to Section 4.3.

NOTE: A pressure gauge can also be used to determining cylinder leak down. Use a 'tee' connection into the cylinder supply line.

Hoist supply from truck main valve.

Mast Lowering Control Valve

Cartridge

4

Dual Solenoid Valve

Lower Carriage Cylinders

Tee Fitting

ROUBLESHOOTING

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Switch Cable

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3.7 Electrical Circuit (Solenoid-equipped lower carriage)Lower carriage dual solenoid valves must work together. The dual valve arrangement provides a positive lockout of the carriage not selected. Use the electrical schematic and diagram shown below and follow the steps:

1 Check the control knob circuit fuses. Replace if necessary.

2 Check for loose electrical connections at the control knob push button, truck fuse block power source, and solenoid coil terminal connections.

3 Use a voltmeter to determine if voltage is present at the electrical leads when the push button is pressed.

• If there is no voltage to the solenoid coil, troubleshoot the electrical circuit for opens or shorts.

• If there is sufficient voltage to the solenoid coils, test for coil continuity. Continue to Step 4.

• If there is insufficient voltage to the solenoid coils, check the circuit for excessive voltage drop.

Dual Solenoid Valves

To Truck Power

Pushbutton Switch

Normally-Open Pushbutton

ELECTRICAL HOOKUP

Truck Fuse Block

12V Truck BatteryGround

Dual Solenoid Valves

HOIST Control Lever

Recommended Wire Sizes (user-supplied):Power –12 AWG Key, Pushbutton – 18 AWG

Switched

Key

4 Test for solenoid coil continuity by placing the ohmmeter test leads across the solenoid coil terminals (ohmmeter on Rx1 scale).

• If there is an ohmmeter reading, the coil is good.

• If the coil is good, but the solenoid valve does not 'click' when the control knob button is pressed, the solenoid cartridge may be jammed. Service or replace the solenoid valve. Refer to Section 4.7-1.

• If there is no ohmmeter reading, the coil is defective. Replace the coil. Refer to Section 4.7-2.

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WARNING: Before removing hydraulic lines, relieve pressure in the truck hydraulic system. Turn the truck off and move the auxiliary control valve levers several times in both directions.

Swing Right (CW) - lever back or down

2

Swing Left (CCW) - lever forward or up

Extend

Retract

Clamp

Open

3

Back (Driver's) View

3

4.1 Layer Picker Removal

4Hoist

Hoist

Solenoid adaption for lower carriage

4

(To Truck Main Valve)

IMPORTANT: It is recommended that the clamp assembly be removed before removing the mast/boom assembly.

1 Remove the clamp assembly as described in Section 4.2-1.

2 Swing Model – Disconnect the truck supply hoses to the hose reel. Tag hoses for reassembly. Plug the hoses and cap the hose reel fittings.

3 Disconnect the truck supply hoses to the mast internal reeving. Tag hoses for reassembly. Plug the hoses and cap the reeving hose terminals.

4 Disconnect the truck hoist supply hose. Plug the hose and cap the fitting.

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Modified Tilt Cylinders or Links

7Swing Boom

8

5 Ballast Plates (Ballast Carriage)

5

5

4.1 Layer Picker Removal (Continued)

Cylinder Mounts

Lower Carriage

Base End Anchor Nuts

9 For reassembly, reverse the above procedures with the following exceptions:

• Inspect the mast mount bearings or pin mounts for wear or damage. Replace or repair as necessary.

• Adjust the mast tilt cylinders or links so the mast is plumbed vertically during normal operation.

5 Remove the ballast plates (as shown), or remove the forks and lower carriage if equipped (shown opposite).

NOTE: To remove the lower carriage, the truck may need to be driven onto ramps or blocked up to provide clearance:

A) Disconnect the lower carriage cylinders supply hose at the 'tee' fitting. Plug the hose and cap the fitting.

B) Attach a hoist to the lift handles on the ballast carriage or lower carriage. Take up the slack.

C) Disconnect the cylinder base end anchor nuts (bottom of mast) from their mounts.

D) Remove the capscrews and remove the cylinder mounts from the mast. For reassembly, tighten the capscrews to 60 ft.-lbs. (80 Nm). Tighten the cylinder anchor nuts to 165 ft.-lbs. (225 Nm).

E) Lower the carriage assembly out through the bottom of the mast.

For reassembly, reverse the above procedures with the following exceptions:

• Service cylinders, if required. Refer to Section 4.3.

• Inspect, lubricate and shim the lower carriage rollers using the same procedures as for the upper carriage. Refer to Section 4.4-1, Step 10.

6 Attach an overhead hoist to the top of the mast as shown and take up the slack.

7 Disconnect the mast tilt cylinders or links. For reassembly, tighten the capscrews using the truck manufacturers torque specifications.

8 Disconnect the mast mounts and lift the mast/boom assembly away from the truck. Place the mast into a vertical mast stand, or lay the unit down on its back on a pallet. For reassembly, tighten the mast mount capscrews using the truck manufacturer's torque specifications.

WARNING: Check the layer picker weight (located on the nameplate) to make sure the overhead hoist and chains or straps are at least the rated capacity of the layer picker.

Mast

Stationary Side Mount Ballast

LP0420.eps

Mast Mounts, Capscrews

6880238

ERVICES

21

LP0830.eps

4.2 Clamp Assembly4.2-1 Removal

1 Lower the clamp assembly onto a pallet.

2 Disconnect the CLAMP function hoses from bulkhead fittings. Tag hoses for reassembly. Plug the hoses and cap the bulkhead fittings.

3 Disconnect the boom cylinder rod end from the clamp assembly bulkhead. For reassembly, tighten spherical retainer against hex washer, to a torque of 165 ft.-lbs. (225 Nm). NOTE: Joint operates with a loose clearance.

4 The clamp assembly can be disengaged from the mast by performing one of the following:

Bars remaining on the boom assembly – Remove the two cotter pins and pins connecting the boom telescoping bars to the clamp assembly. Remove the upper cotter hair pins and clevis pin from the upper turnbuckle. Back the truck away from the clamp assembly.

OR

Bars remaining on the clamp assembly – Back the truck away from the clamp assembly.


• Inspect the boom telescoping bars and bearings for damage or wear. Refer to Section 4.4-3.

• Inspect the clamp frame pivot pins for wear and replace if necessary.

• Apply chassis grease to the boom cylinder rod end spherical joints and to the clamp assembly mounting pins.

• Inspect clamp frame pivot bushings, replace if necessary.

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.

Boom Cylinder Rod End

5Layer Picker Clamp Assembly

Pivot Pins and Bushings

LP0847.eps

2

3

4

4

Cotter Pins

CLAMPOPEN

NOTE: Remove only when bars are remaining on the boom assembly.

6880238

ERIVCES

22

LP0831.eps

3

2Spherical Nut

Hex Washer

LP0116.eps

4.2-2 Arms – Removal and InstallationThe following procedure can be performed without removing the clamp assembly from the Layer Picker.

1 Lower the clamp assembly onto a pallet until the surfaces touch.

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 2Pad capscrews, washers, nuts

Arm

Spherical Nut

Cotter PinLocking Cap

Hex Washer. NOTE: Beveled side faces arm lug

Cylinder Rod End

3 Slide the arm out of the clamp frame. Do not damage the bearings when removing the arm.


• Inspect the arm bearings for wear and replace if necessary. Refer to Section 4.2-5.

• Apply chassis grease to the cylinder rod end joint.

4.2-3 Contact Pad – Rotation or ReplacementNOTE: 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.

2 Remove the capscrews and nuts fastening the contact pad to the arm base. For reassembly, tighten the capscrews to 65 ft.-lbs. (90 Nm).

NOTE: Reinstall any shims in original position to maintain same pad camber setting. Refer to Section 4.2-4 to determine pad camber.

3 Remove the contact pad. Install new contact pad or rotate the pad 180°.

4 For reassembly, reverse the above procedures.

LP0832.eps

6880238

ERVICES

23

LP0139.eps

LP0136.eps

LP0137.eps

4.2-4 Contact Pad Camber AdjustmentThe following procedures can be performed with the layer picker 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.

3 Determine the camber adjustment required. Refer to recommended starting points in table below.

4 Loosen the capscrews and nuts fastening the contact pad to the arm base. For reassembly, tighten the capscrews to 65 ft.-lbs. (90 Nm).

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 contact pad. Pad camber must be the same on all pads for proper load handling.

Positive Camber (top of pads lean out)

Position arms to midstroke

1

Measure from pad centers

3

2

FOR MAXIMUM POSITIVE CAMBER:

FOR MINIMUM POSITIVE CAMBER:

No shims

.12 in. (3.2 mm) Bottom Shim(s)

IMPORTANT: Shim all four pads equally.Front View

Shims(if used)

Pad Capscrews and Nuts

Contact Pad

Arm

4

CANNED / BOTTLED / DENSE CASE GOODS

BOXED LIGHT CASE GOODS

Neutral-to-Positive

Neutral

Opposite Pads - Lower TierLoad

5LP0760.eps

6880238

ERIVCES

24

LP0838.eps

LP0134.eps

4.2-5 Arm Bearing ReplacementNOTE: 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 retaining rings from the clamp frame.

NOTE: Use Cascade brass tool 674424 (or a thin blade screwdriver) to remove the rings. Avoid damaging the grooves in the frame.

3 Pull the bearings out of the frame.

4 For reassembly, reverse the above procedures with the following exception:

• Use new bearing retaining rings when installing the new bearings.

2

Arm Bearings

Front View

Retaining Rings

Clamp Frame

3

Bearing Retainer Ring

Cascade Tool Part No. 674424

2

6880238

ERVICES

25

4.2-6 Pivot Bushing1 Remove the clamp assembly from the boom with the

bars remaining on the boom assembly as described in Section 4.2-1, Steps 1-4.

2 Remove pivot bushings located in the arm bars.

3 Install new bushings into the arms. Replace with the same number of bushings removed.

4 For reassembly, reverse Steps 1-4 in Section 4.2-1.

LP0854.eps

23

LP0855.eps

Level contact pads with floor

Leveling Bars

Locknut

2,4

3

3

1

4.2-7 Clamp Level AdjustmentCAUTION: Boom cylinder and rod end anchor will be damaged if turnbuckles are not adjusted properly.

1 With the clamp facing straight ahead. Place a magnetic protractor/level on the clamp frame, as shown.

2 Loosen the locknuts on the leveling turnbuckles.

3 Adjust the turnbuckles to level the bottom of the contact pads with floor, unless otherwise noted by the supervisor.

4 Tighten locknuts.

6880238

ERIVCES

26

LP0835.eps

LP0837.eps

CLAMP

OPEN

RC0311.eps

4.2-8 Clamp Valve Removal, Installation


2

34.2-9 Valve ServiceIMPORTANT: Service the valve in a clean work area.

1 Remove the valve from the clamp assembly as described in Section 4.2-8.

2 Remove the valve cartridges from the valve and remove the O-rings and back-up rings.

3 Remove the fittings from the valve.

4 Clean all parts with solvent.


• Replace O-rings and back-up rings on valve cartridges as shown.

O-RingsO-Rings

CHECK VALVE CARTRIDGE RELIEF VALVE CARTRIDGE

Back-Up RingsBack-Up Rings

Body

Clamp Valve

1

2

3CLAMP function hoses or tubes

Cylinder Supply Hoses

Front View

1 Disconnect the two CLAMP function hoses or tubes from the valve. Plug the hose or tube ends and tag for reassembly.

2 Disconnect the eight cylinder 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 4.2-9.


IMPORTANT: Verify that hoses are connected as shown. Refer to hydraulic schematic, Section 3.2-4 or Section 3.2-5.

CL2687.eps

6880238

ERVICES

27

LP0843.eps

LP0839.eps

LP0840.eps

LP0164.eps

4.3 Cylinders4.3-1 Clamp & Reach Cylinder

RemovalNOTE: The following procedure can be performed with the layer picker 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 attachment hydraulic system. Turn the truck off and move the auxiliary control valves several times in both directions.

REACH Cylinder

CLAMP Cylinders

7Cotter PinLocking Cap

Spherical Nut Hex Washer (NOTE: Beveled side faces arm lug)

Cylinder Rod End

3 Boom Frame

4 Clamp Frame

Cylinder

Arm

Arm Lug

3

4

Clamp Frame

REACH CYLINDER

Cylinder

CLAMP CYLINDER

Roll Pins

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 head end from the boom or clamp frame by removing the cotter pin, locking cap and spherical nut.

IMPORTANT: Make sure that the inner and outer roll pin is in place when reinstalling to keep the cylinder shell from rotating while tightening.

4 Disconnect the cylinder rod end from the clamp frame or arm lug by removing the cotter pin, locking cap, spherical nut and hex washer.

5 Slowly slide the clamp arms or clamp frame 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.

6 Service the cylinder as described in Sections 4.3-3.

7 For reassembly, reverse the above procedures with the following exceptions for the cylinder anchors:

• Lubricate threads with chassis grease and assemble cylinder anchors as shown.

• Install hex beveled washer on cylinder rod end.

NOTE: Verify that the beveled side of washer faces arm lug, as shown below.

• Tighten spherical nut against hex washer to 160 ft.-lbs. (220 Nm).

NOTE: Joints function with a loose operating clearance. Lubricate with chassis grease.

• Install locking cap and secure with new cotter pin.

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ERIVCES

28

4.3-2 Fork Carriage Cylinder RemovalNOTE: The following procedures can be performed with the layer picker mounted on the truck.

1 Lower the fork carriage until the fork carriage cylinder rods are approximately 6 in. (150 mm) from being completely lowered. Block or chain the lower fork carriage.

2 For the cylinder to be removed, disconnect the cylinder rod end from the lug by removing the cotter pin, locking cap, spherical nut and hex washer.

3 Retract the cylinder rods until the cylinder rod disengages from the lug.

4 Disconnect the hydraulic hoses from the cylinder to be removed. Plug the hoses and cap the cylinder ports. Tag hoses for reassembly.

5 Disconnect the cylinder head end from the lug by removing the cotter pin, locking cap and spherical nut.

6 Lift the cylinder from base mount and angle inward. Remove the cylinder through the gap at the mast and fork carriage assembly, as shown.

NOTE: If required, remove the lower anchor to aid in removing the cylinder.

7 Service the cylinder as described in Sections 4.3-3, 4.3-4 and 4.3-5.

8 For reassembly, reverse the above procedures with the following exceptions for the cylinder anchors:

• Lubricate threads with chassis grease and assemble cylinder anchors as shown.

• Install hex beveled washer on cylinder rod end.

NOTE: Verify that the beveled side of washer faces lug, as shown.

• Tighten spherical nut against hex washer to 160 ft.-lbs. (220 Nm).

NOTE: Joints function with a loose operating clearance. Lubricate with chassis grease.

• Install locking cap and secure with new cotter pin.

WARNING: Before removing hydraulic lines, relieve pressure in the attachment hydraulic system. Turn the truck off and move the auxiliary control valves several times in both directions.

WARNING: To avoid possible injury, verify that the carriage is properly supported before disconnecting hoses. Use wood blocking or safety chains as necessary.

LP0164.eps

8Cotter PinLocking Cap

Spherical Nut Hex Washer (NOTE: Beveled side faces lug)

Cylinder Rod End

LP0867.eps

25

4Lower Anchor Capscrews

6880238

ERVICES

29

SS0062.eps

CL1072.eps

CL1073.eps

4.3-3 Cylinder Disassembly 1 Clamp the cylinder in a soft-jawed vise at the extreme

head end only. Do not clamp on the shell.

2 Unscrew and remove the retainer using a claw-type spanner wrench as shown. (Cascade Part No. 678598).

NOTE: For cylinders from the font of the fork carriage, remove the cylinder retainer by unscrewing it with a pin-type spanner wrench.

3 Remove the rod/piston assembly and spacer(s), if equipped, 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.

6

12

4

5

4.3-4 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.

• Inspect the cylinder bore and remove any minor nicks or burrs with a butterfly. If they cannot be removed, replace the part.

• 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.

• Inspect the spherical nuts and hex washer for wear and replace as necessary.

6880238

ERIVCES

30

Piston Retainer

Rod End Hex Washer

Shell

Piston Nut RodSpherical Nut, Locking Cap

Spherical Nut, Locking Cap

LP0581.eps

Reach, Clamp, Fork Carriage (back of carriage)

Fork Carriage (front of carriage)

LP0868.eps

Piston

Retainer

Rod End Hex Washer

Shell

Piston NutSpacer

Spacer

Rod



6880238

ERVICES

31

LP0275.eps

4Chamfer Angle3

4.3-5 Cylinder Reassembly1 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 exclusion 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 a '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 a torque of:

Clamp/Reach – 45 ft.-lbs. (60 Nm)Fork Carriage, Back – 70 ft.-lbs. (95 Nm)Fork Carriage, Front – 110 ft.-lbs. (150 Nm)

7 Place the piston loader into the cylinder shell.

IMPORTANT: The loader must cover all of the shell threads but 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 a torque of:

Clamp/Reach – 70 ft.-lbs. (95 Nm)Fork Carriage, Back – 125 ft.-lbs. (170 Nm)Fork Carriage, Front – 300 ft.-lbs. (407 Nm)

CL1074.eps

RC0320.eps

Cylinder Shell

IMPORTANT: Loader must not contact thread relief chamfer

7 Piston/Seal Loader

8Piston/Rod Assembly

9Retainer Seal Loader

Retainer

Stop Fins

6880238

ERIVCES

32

LP0582.eps

LP0869.eps

Note seal direction

Note seal direction

Piston U-Cup Pressure Seal Note seal direction

Piston U-Cup Pressure Seal Note seal direction

O-Ring

O-Ring

Rod Seal

Rod Seal

Wiper Seal

Wiper Seal

Dual Seal

5

5

4

4

6

6

O-Ring

O-Ring

Back-Up Ring

Back-Up Ring

OR

Reach, Clamp, Fork Carriage (back of carriage)

Fork Carriage (front of carriage)

6880238

ERVICES

33

LP0852.eps

LP0848.eps

4.4 Boom/Carriage Assembly

4.4-1 RemovalNOTE: The boom/carriage assembly may be removed through the bottom of the mast as a complete unit, to perform carriage inspection and service.


2 Remove the lower carriage (if equipped) as described in Section 4.1.

3 Raise the mast until the inner upright extends approximately 8 in. (20 cm) out the top of the mast.

4 Position blocks between the inner and outer upright, or chain the mast uprights together at the top of the mast. Lower the mast until the inner upright is securely blocked in position.

5 Disconnect the four internal reeving hoses at the carriage hose terminals. Tag hoses for reassembly. Plug hoses and cap terminal fittings.

6 Swing Model – Disconnect the two hose reel hoses at the up-connection hose terminals. Tag hoses for reassembly. Plug hoses and cap terminal fittings.

7 Attach an overhead hoist to the boom/carriage assembly as shown and take up the slack. Verify that the chains or straps are positioned properly.

8 Disconnect the mast lift chains from the carriage by removing the snap rings and sliding the chain anchors out from the rear of the carriage.

9 Lower the overhead hoist until the boom/carriage assembly clears the bottom of the mast inner upright

WARNING: Before removing hydraulic lines, relieve pressure in the attachment hydraulic system. Turn the truck off and move the auxiliary control valves levers several times in both directions.

IHR Hoses5

Hose Reel Hoses6

8Lift Chain Anchors


Hose Reel Terminal Up-Connection

IHR Hose Terminals

7

9Boom-Carriage Assembly

Load Roller

WARNING: Verify that the overhead hoist and chains or straps are rated for the weight of the attachment. Refer to nameplate for attachment weight.

6880238

ERVICES

34

LP0856.eps

M12 Capscrews

Load Roller

ThrustBearings

Retainer

Shim

M24 Capscrew – Turn to adjust side clearance

CARRIAGE & MAST LOAD ROLLERS

Lubricate areas indicated by heavy line full length of each mast upright. Outer

Upright

Load Rollers

Inner Upright

Carriage

4.4-1 Removal (Continued) 10 For reassembly, reverse the above procedures with the

following exceptions:

• Inspect carriage as described in Section 4.4-8.

• Lubricate upright rails. Cascade approved lubricant:


• Assemble load rollers with shims on carriage stub shafts. Shims should be installed to provide a total side-to-side clearance of 0.06 in. (1.5 mm) maximum at the tightest point throughout the travel of the carriage. Use an equal number of shims per side.

• Inspect and adjust (if necessary) the thrust bearing side-to-side clearance in mast upright and carriage. Check carriage alignment and verify that the total side-to-side clearance is 0.06 in. (1.5 mm) maximum at the tightest point throughout the travel of the carriage.

Remove M12 capscrews and retainer from the M24 capscrew. Turn M24 capscrew until bearing touches the mast. Back off the capscrew 1/2 turn. Install retainer, tightening the M12 capscrews to 48 ft.-lbs. (65 Nm). Verify side-to-side clearance.

• Check and adjust the lift chains as described in Section 4.5-1.

LP0043.eps

6880238

ERVICES

35

LP0861.eps

LP0135.eps

4.4-2 Boom Reeving ServiceWARNING: Before removing hydraulic lines, relieve pressure in the attachment hydraulic system. Turn the truck off and move the auxiliary control valves several times in both directions.

1

4.4-3 Telescope Bars, BearingsNOTE: The following procedures require that the clamp assembly be removed from the boom.


2 Slide the telescope bars out of the boom. Inspect the bars for straightness, and for nicks or protrusions that could damage the bearings. Replace if necessary.

3 Remove the bearing retaining rings from the clamp frame and pull the bearings out of the boom. Replace the bearings if worn or damaged.


• Lubricate bearings, if required.

Telescope Bar

Bearing

2 3

2 Boom Reeving Hoses

Hose Clamps

Hose Clamp

Bearing Retainer Ring

Cascade Tool 674424

3

1 Remove the hose clamps that secure the hoses to the carriage and boom. For reassembly, tighten the hose clamp capscrews to 8 ft.-lbs. (10 Nm).

2 Remove and replace the hoses one pair at a time. Tag ends for reassembly.


• Refer to Hydraulic Schematic, Section 3.2-4 or Section 3.2-5, to check for correct hose hookup.

LP0851.eps

6880238

ERVICES

36

LP0568.eps

LP0567.eps

4.4-4 Swing Valve – Removal, InstallationNOTE: The following procedures can be performed with the layer picker mounted on the truck.

WARNING: Before removing hydraulic lines, relieve pressure in the attachment hydraulic system. Turn the truck off and move the auxiliary control valve handles several times in both directions.


Up-Connection Tubing, Bracket

Hose Terminal Clamp

Swing supply hoses from hose reel

Swing Valve

Tubing to Swing Actuator

2

1Tubing to Valve2

1 Disconnect the tubing between the hose terminal up-connection and the swing valve.

2 Remove the two bolts fastening the valve and hose terminal clamp to the carriage. Remove the valve. For reassembly, tighten the bolts to 15 ft.-lbs. (20 Nm).

3 Service the swing valve as described in Section 4.4-5.



1 Remove the valve from the side of the mast carriage as described in Section 4.4-4.

2 Remove the cross-over relief cartridges.

3 Remove the counterbalance cartridges.


5 Clean all parts with solvent and air-blow dry.


• Replace the cartridges as shown.

RC0802.eps

4

Cross-over Relief Cartridges

Valve Body

Counterbalance Cartridges

3

2

O-Rings

COUNTERBALANCE CARTRIDGE

Back-Up Rings

O-Rings

Back-Up Rings

Adjustment Screw

CROSSOVER RELIEF CARTRIDGE

PP1518.eps

6880238

ERVICES

37

LP0259.eps

4.4-6 Boom ReplacementNOTE: The following procedure requires that the clamp assembly be removed from the swing boom.


2 Remove the hose clamps and hoses as described in Section 4.4-2.

3 Remove the telescope bars and bearings as described in Section 4.4-3.

4 Securely attach an overhead hoist to the boom assembly and take up the slack.

5 Remove the capscrews that fasten the lower boom to the swing actuator. For reassembly, use a cross-pattern and tighten the capscrews to 80 ft.-lbs. (110 Nm).

6 Remove the twelve capscrews that fasten the boom to the top of the swing actuator. For reassembly, use a cross-pattern and tighten the capscrews to 160 ft.-lbs. (215 Nm).

7 Lift the boom assembly away from the swing actuator.


Boom Top Mount Capscrews

5

64 Swing Actuator

Boom

Bottom Mount Capscrews

LP0260.eps

4.4-7 Swing Actuator ReplacementCAUTION: There are no field-serviceable components in the swing Actuator. Replace as a complete assembly.


2 Remove the boom as described in Section 4.4-6.

3 Disconnect and remove the tubing between the swing valve and the swing actuator.

4 Remove the four large capscrews that secure the actuator to the carriage. For reassembly, use a cross-pattern when tightening. Double-torque the capscrews by tightening to the final torque value of 450 ft.-lbs. (610 Nm), backing off 1/2 turn, and immediately retightening to 450 ft.-lbs. (610 Nm).

5 Remove the swing actuator.


Mast Carriage

Swing Actuator

Actuator Tubing

3

5 Swing Valve

Mounting Capscrews4

6880238

ERVICES

38

LP0849.eps

5

Retainer and Capscrews

Thrust Bearings

M24 Capscrew

Shoulder Capscrews

Load Rollers4

Weld Areas

Load Roller Shim

Load Roller Stubshafts


33

4.4-8 Carriage Inspection, ServiceNOTE: Thrust bearings may be replaced with the carriage in place. Load roller and shim replacement require that the carriage be removed from the mast.

1 Remove the clamp assembly (if necessary) as described in Section 4.2-1.

2 Remove the boom-carriage assembly (if necessary) as described in Section 4.4-1.

3 Inspect all thrust bearings for excessive wear or flat spots. Replace thrust bearings, if required.

Remove shoulder capscrews, retainer capscrews and retainer. For reassembly, install shoulder capscrews with bushings through the carriage into the thrust bearing. Capscrews will have space between carriage and capscrew head. Install M24 capscrew though carriage into thrust bearing. Install retainer and capscrews.

4 Inspect all load rollers for excessive wear, flat spots, cracks, or bearing roughness. Replace rollers if required. Keep track of shim locations.

5 Inspect all welds on the carriage including sideplates, horizontal bars or tubes, and chain anchor mounts. Repair any damaged welds, or replace the carriage. Refer to CAUTION statement.

6 Inspect all welded stubshafts for wear. If cracks are found on any of the other roller stubshaft bases repair any damaged welds, or replace the carriage. Refer to CAUTION statement.

CAUTION: Repairing cracks by welding must be approved by Cascade. Contact Cascade Service for approval and recommended welding procedures.


• Measure and adjust (if required) side-to-side clearance within the mast. Refer to Section 4.4-1, Step 10.

6880238

ERVICES

39

LP0119.eps

LP0118.eps

LP0117.eps

4.5 Layer Picker Mast

4.5-1 Inspection and AdjustmentsNOTE: The following procedures can be performed with the layer picker mounted on the truck.

Mast Upright, Roller InspectionExtend the mast to its full height and verify that the uprights and carriage extend freely and smoothly without binding. If problems are encountered, first check for proper lubrication. Refer to Periodic Maintenance, Section 2. Next check the side-to-side clearance of the inner upright and the carriage as follows:

• Pry between the upright or carriage and its corresponding thrust bearing so that the opposite thrust bearing is tight against the upright.

• Measure the clearance for the pair of rollers at 'XXX' as shown. If the clearance is not correct, the mast or carriage requires service. Refer to Section 4.5-9.

NOTE: Make sure that the mast thrust plugs do not interfere with the measurement when checking the side-to-side clearance.

Chain TensionChains must be under equal tension to ensure proper load distribution and mast operation. Inspect the lift chains for equal tension as follows: Raise the unloaded mast to put the chains under tension. Press the center of a strand of chain with the thumb, then press at the same place on the other chain of the pair. Each chain in a pair should have equal 'give'. If they do not, adjust the chains as described below.

Inspect the chains for wear or defects as described in Section 4.5-2.

Chain AdjustmentThe lift chains should be adjusted for the clamp clearance required above the floor for your specific application. Adjust chains as follows:

• Adjust one chain to achieve the specified contact pad clearance of 1.50 in. (38 mm) above the floor with the layer picker fully lowered.

• Adjust the other chain to achieve equal chain tension, shown above. Tighten the chain anchor jam nuts together to 60 ft.-lbs. (80 Nm).

• Raise and lower the mast several times to confirm the adjustments. Make sure the mast inner upright does not contact the upper stops on the mast outer upright (arrows). Chain Anchors,

Double Jam Nuts

RECOMMENDED CLAMP UNDERCLEARANCE

0.06 in. (1.5 mm) Max.

Pry here to check side-to-side clearance of mast uprights.

Mast Load Roller

NOTE: Use a similar procedure to check carriage.

WARNING: Never work on the mast with a load on the forks or attachment. Use supports or blocking when working with the mast raised. Do not allow anyone near the truck control handles per ANSI/ITSDF B56.1 (ISO 3691). Carriage

Load Roller

1.50 in.(38 mm)

6880238

ERVICES

40

A

AA

A

LP0120.eps

MA0065.eps

4.5-2 Chain InspectionNOTE: The following procedures can be performed with the layer picker mounted on the truck.

Wear or DamageInspect the chains for wear or defects as listed below and refer to illustration shown. If wear or defects are found in either chain, replace both strands of chain.

• Check for severe rust and corrosion.

• Check for cracked side plates.

• Check for tight joints.

NOTE: If suspected cause is rust or corrosion, joints may be loosened with penetrating oil followed by SAE 40 wt. oil. If tightness is caused by bent pins, bent side plates or peened plate edges, replace both chains.

• Check for protruding or turned pins.

• Check for excessive chain side wear.

NOTE: Excessive side wear may be caused by misaligned sheaves or other mast components. Correct any misalignment found.

• Check for worn, broken or misaligned chain anchors. Replace or adjust as required.

LubricationClean and lubricate the chains with SAE 40 wt. oil or heavy duty load grease (Cascade Part No. 200867). Refer to Periodic Maintenance, Section 2.

Chain StretchUse a chain wear scale (Cascade Part No. 661923) to check for excessive chain stretch. Raise the layer picker without a load about 1 ft. (30 cm) to put tension on the chains. Use the instructions printed on the scale and measure the chains as shown. If either chain is beyond the wear limit, replace both chains. Adjust as required.

New Chain Stretched Chain

Chain Wear Scale (Part No. 661923)

CRACKED SIDE PLATES

TIGHT PIN JOINTS

PEENED PLATE EDGES

PROTRUDING PINS

TURNED PINS

6880238

ERVICES

41

LP0121.eps

4.5-3 Lift Chain Service1 Lower the layer picker completely, then raise

approximately 6 in. (15 cm) off the floor. Place blocking under the boom-carriage assembly as shown, or use a safety chain to secure the carriage within the mast.

2 Lower the carriage until the mast lift chains are slack. Verify that the carriage is properly supported.

3 Remove the pins that fasten the chains to the lower chain anchors on the carriage.

4 Remove the pins that fasten the chains to the upper chain anchors on the mast outer upright. Roll the chains out of the sheaves to remove.

CAUTION: New chains are pressure-lubricated at the factory. Do not wash, sand blast, etch, steam clean, or paint the chains.


• Inspect chain anchors and mounts for wear or damage and replace if necessary.

• Inspect chain sheaves/bearings for wear or damage and replace if necessary.

• Use new pivot pins and cotter pins when installing new chains.

• Adjust chains as described in Section 4.5-1.

WARNING: To avoid possible injury, verify that the boom-carriage assembly is properly supported before disconnecting the mast lift chains. Use blocking or chains as necessary.

Chain Sheaves (on inner upright)

4

3

Mast

Upper Chain Anchor

Lower Chain Anchor

Carriage

Wood or Metal Blocking

NOTE: Boom assembly not shown for clarity

6880238

ERVICES

42

LP0131.eps

4.5-4 Mast Hose Reeving ServiceNOTE: The following procedures can be performed with the layer picker mounted on the truck.

1 Lower the layer picker fully.

WARNING: Before removing hydraulic lines, relieve pressure in the attachment hydraulic system. Turn the truck off and move the auxiliary control valve levers several times in both directions.

4 Internal Reeving Hose sheaves

2Mast IHR connection

Front View

3Carriage IHR connection

5Adjustable Hose Terminal Mounting

NOTE: RH reeving only shown for clarity. Use same procedures to service LH reeving.

2 Disconnect the internal reeving hoses from the hose terminals on the back of the mast.

3 Disconnect the hoses from the carriage and cap the fittings. Remove the hoses by pulling them through the sheaves.

4 Remove the capscrews and remove the hose sheaves from the chain sheave mounting pin shafts. Keep track of any spacer washers between the sheaves. For reassembly, tighten capscrews to 65 ft.-lbs. (88 Nm).


• Inspect the hoses and sheaves for wear or damage. Replace the parts as required.

• Adjust mast hose terminal brackets (if necessary) to remove any slack in hoses. Tighten capscrews to 38 ft.-lbs. (50 Nm). Tighten all hose fittings.

• Raise and lower layer picker several times to check for proper hose tracking. Use white tracer line on hoses to detect twisting and adjust hose ends if necessary.

6880238

ERVICES

43

LP0845.eps

4.5-5 Hoist Cylinder RemovalNOTE: The following procedures can be performed with the layer picker mounted on the truck.

WARNING: To avoid possible injury, verify that the mast inner upright is properly supported before disconnecting hoses. Use wood blocking or safety chains as necessary.

4.5-6 Hoist Cylinder Bleeding

WARNING: Air trapped in the cylinders can compress on the first extension which could rupture the cylinder shell and cause serious bodily injury or property damage.

Wood Blocking

1

Mast Inner Upright

Shim(s)

Snap Ring2

3Hoist Cylinder Hydraulic Connections

1 Raise the layer picker until the mast inner upright is about 2 ft. (50 cm) above the outer upright. Block or chain the inner upright securely to prevent it from moving.

2 Remove the snap rings that fasten the hoist cylinder rods to the inner upright. Lower the cylinder rods to disengage them from the inner upright.

IMPORTANT: Keep track of shims on the cylinder rod. Shims must be installed in their original location to prevent an extended mast from skewing.

3 Disconnect the cylinder supply hoses at the cylinder ports. Remove the special long fittings from the cylinder ports. Plug the hoses and cylinder ports.

4 Lift the cylinders from their base mounts and angle inward. Remove the cylinders through the gap at the top of the mast uprights as shown. Service the cylinders as described in Section 4.5-7.


• Bleed the cylinders before lifting a load. Refer to Section 4.5-6.

1 Extend the mast without a load to 90 percent of full stroke, then lower completely. Repeat three times.

2 Extend the mast without a load using 50 percent of full engine speed, then build full system pressure at the end of the stroke. For electric trucks, limit control valve movement to achieve 50 percent extension. Lower the mast completely. Repeat four times.

3 Cycle the mast with a half load (50 percent of mast rated capacity) through full cylinder extension. Repeat two times while checking for smoothness. Repeat the steps if cylinder extension is not smooth.

6880238

ERVICES

44

MA0814.eps

MA0813.eps

MA0815.eps

4.5-7 Hoist Cylinder Service1 Remove the cylinder as described in Section 4.5-5.

2 Unscrew and remove the retainer using a claw-typespanner wrench as shown. (Cascade Part No. 678598)

3 Remove the plunger/piston assembly from the shell.

4 Remove the hydraulic fuse / lowering cushion valvecomponents from the cylinder port.

5 Inspect all components as follows:

• Inspect the plunger, piston and retainer for nicks orburrs. Minor nicks or burrs may be removed with 400 grit emery cloth. If they cannot be removed, replace the parts.

• Inspect the cylinder bore and remove any minornicks or burrs with a butterfly. If they cannot be removed, replace the part.

• Inspect the outside of the shell for any deformities orcuts that could impair performance or cause leaks under pressure. If necessary, replace the part.

2

Snap Ring

Retainer

Plunger Wiper

Plunger Seal

Back-Up Ring

Retainer O-Ring

Shell

Plunger

Spacer

Snap Wire Retainer

Piston

Wear Ring

Hydraulic Fuse / Cushion Valve

Back-Up Ring

U-CupPressure Seal

Retainer

Shell

Strap Wrench

Claw-Type Spanner

Pin-Type Spanner

PistonPlunger

Snap Wire Retainer

Strap Wrench

64

7

3Plunger

9

9

6 Remove the piston (if necessary) by using a strap-typewrench on the plunger while turning the piston with a pin-type spanner wrench (Cascade Part No. 679917). See illustration.

CAUTION: Do not clamp on the plunger surface.

7 Turn the piston until the snap wire end is visible throughthe hole. Use a screwdriver to start the wire end out the hole. Turn the piston to feed the wire out.

8 Pull the piston from the plunger.

9 Replace the retainer and piston seals, back-up rings,O-rings, and bearing. Lubricate the new seals withpetroleum jelly prior to installation. Note the direction ofthe seals. Pressure seals must always be installed withthe lip toward the high pressure side of the cylinder.

10 Install the retainer on the plunger. Install the plunger/piston assembly into the cylinder shell. Tighten the retainer to 240 ft.-lbs. (320 Nm).

6880238

ERVICES

45

LP0123.eps

4.5-8 Mast Valve ServiceNOTE: The only serviceable part on the mast valve is the lowering control valve cartridge. Replace if symptoms are encountered as described in Troubleshooting, Section 3.1-3.

1 Completely lower the layer picker mast.

2 Disconnect the supply hose at the mast valve cartridge.

3 Remove the cartridge from the valve. Note stampedpart number on cartridge.

WARNING: Verify that the correct valve cartridge is used. Replacing the cartridge with a different part number cartridge may cause the mast to malfunction.

Cartridge 32

Mast Valve

Hoist Supply Hose4 For reassembly, reverse the above procedures.

6880238

ERVICES

46

LP0841.eps

WARNING: Check the mast weight (located on the nameplate) to make sure the overhead hoist and chains or straps are at least the rated capacity of the mast.

4.5-9 Mast Upright DisassemblyNOTE: The mast may be serviced on the truck, or removed and serviced horizontally on a pallet. To perform service on the truck, all Layer Picker components and hoist cylinders must be removed.

1 Remove the clamp assembly as described inSection 4.2-1.

2 Remove the boom-carriage assembly as describedin Section 4.4-1.

3 Remove the lift chains as described inSection 4.5-2.

4 Remove the Internal reeving hoses as described inSection 4.5-4.

5 Remove the hoist cylinders as described inSection 4.5-5.

6

Thrust Plugs

Upper Thrust Bearing Shim

Lower Thrust Bearing Shim

Mast Inner Upright

Check for Cracks on Stubshafts

Upper Thrust Bearings

Lower Thrust Bearings

Upper Load Rollers, Shims

4.5-10 Mast Upright InspectionInspect the following areas of the mast upright:

• Inspect the thrust plugs in the outer upright for wear.Replace the plugs if the wear surface is worn to lessthan 0.06 in. (1.5 mm) thickness.

• Inspect all load rollers for excessive wear, flat spots,cracks, or bearing roughness. Replace and adjustrollers if required. Keep track of shim locations.

• Inspect the chain and hose sheaves (if attached),bearings, mounting pins for wear. Replace theparts as required.

• Inspect all welds on the mast including crossbars,side-thrust roller mounts, chain anchor mounts.Replace or repair the uprights.

• Inspect the roller stubshafts. Replace the upright ifcracks are found on any of the stubshaft bases, or ifthe roller bearing bores are loose on the stubshafts.

CAUTION: Repairing cracks by welding mustbe approved by Cascade. Contact CascadeService for approval and recommended weldingprocedures.

• If equipped, inspect thrust bearings for excessivewear, cracks, or bearing roughness. Replace andshim as necessary. Refer to Section 4.5-11, Step 3.

6 Using an overhead hoist, lower the inner upright toexpose the upper and lower load rollers. Remove the load rollers and thrust bearings (if equipped). Keep track of shims.

7 Lift the inner upright out through the top of the mast.

Lower Load Rollers, Shims

6880238

ERVICES

47

LP0445.eps

LP0043.eps

LP0119.eps

4.5-11 Mast Upright Reassembly1 Lubricate the mast upright rails. Cascade approved

lubricant:


IMPORTANT: Regular application of Cascade approved lube will prevent premature mast rail, roller and thrust block wear.

2 Attach an overhead hoist to the inner upright and installthrough the top of the outer upright (refer to illustration on previous page).

.06 in. (1.5 mm) Max.

Pry here to check side-to-side clearance of mast upright.

Mast Load Roller

NOTE: Use similar procedure to check carriage.

4

Lubricate areas indicated by heavy line full length of each mast upright every 100 hours.

Outer Upright

1

Load RollersCarriage

Inner Upright

Carriage Load Roller

4 Assemble the load rollers on the stub shafts using theappropriate number of shims for proper clearance. The shims should be installed to provide a total side-to-side clearance of 0.06 in. (1.5 mm) maximum at the tightest point throughout the travel of the upright. Use an equal number of shims on each side.

NOTE: Make sure the mast thrust plugs do not interfere with the measurement when checking the side-to-side clearance.

3 If equipped, assemble the thrust bearings with theappropriate amount of shims so that the total side-to-side clearance between 0.03 in. (0.75 mm) to 0.06 in. (1.5 mm) at the tightest point throughout the travel of the upright. Use an equal amount of shims on each side.

• Adjust the upper thrust bearings with shims6142108.

• Adjust the lower thrust bearings with shims 6142091.

Tighten shim capscrews to 18 ft.-lbs. (25 Nm). Install the thrust bearings with shims and tighten capscrews to 49 ft.-lbs. (66 Nm).

Upper Thrust Bearing Lower Thrust BearingThrust Bearing Capscrew

Shim Capscrew

Shim Capscrews

6142108 Shim

6142091 Shim

Thrust Bearing Capscrew

5 Install the hoist cylinders as described in Section 4.5-5.

6 Install the internal hose reeving as described in Section4.5-4.

7 Install the lift chains as described in Section 4.5-3.

8 Install the boom/carriage assembly as described inSection 4.4-1.

9 Install the clamp assembly as described in Section4.2-1.

6880238

ERVICES

48

4.6 Pressure/Flow Control Valve4.6-1 Removal, Installation

LP0862.eps

1 Disconnect the hoses to the Pressure/Flow ControlValve. Plug and tag hoses for reassembly.

2 Remove the capscrews from the valve. For reassembly,tighten capscrews to 14 ft.-lbs. (19 Nm).

3 For reassembly, reverse the above procedures with thefollowing exceptions:

• Service the valve as described in Section 4.6-2.

• If required, adjust relief cartridges as described inSection 4.6-3.


1

2

LP0864.eps

LP0865.eps

LP0866.eps

O-Rings

O-Rings

O-Rings

Back-Up Ring

Back-Up Rings

LP0863.eps

Valve Body

Relief Cartridges

Priority Flow Control Cartridges

Check Valve Cartridges


1 Remove the valve from the clamp assembly asdescribed in Section 4.6-1.

2 Remove the valve cartridges from the valve and removethe O-rings and back-up rings.


4 Clean all parts with solvent.

5 For reassembly, reverse the above procedures with thefollowing exceptions:

• Replace O-rings and back-up rings on check valvecartridges as shown.

CHECK VALVE CARTRIDGE

Back-Up Ring

RELIEF CARTRIDGE

FLOW CONTROL CARTRIDGE

swittkop

Sticky Note

Corrected relief and flow control labels

6880238

ERVICES

49

LP0188.eps

Coils

Solenoid Valves

4.7 Lower Carriage Solenoid Valve

4.7-1 Coil Service1 Disconnect the wires from the coil terminals and remove

the coils from the valves.

2 Install new coils. Verify that the terminals are connected correctly. Refer to the electrical schematic in Section 3.7 for correct hookup.


Crossover Tubing

Adapter Bracket

WARNING: Never work on the mast with a load on the forks or attachment. Use supports or blocking when working with the mast raised. Do not allow anyone near the truck control handles per ANSI/ITSDF B56.1 (ISO 3691).

4.7-2 Valve Service1 Disconnect the hoses to the solenoid valves. Plug the

hoses and tag for reassembly.

2 Remove the capscrews that fasten the solenoid valves to the adapter bracket and remove the valves. Replace the solenoid valves as complete assemblies. For reassembly, tighten the capscrews to 18 ft.-lbs. (25 Nm).


6880238

ERVICES

50

LP0448.eps

4.8 Electronic Swing Control (if equipped)

4.8-1 Solenoid Valve Service

1 Disconnect the tubes connected to the solenoid valves fittings. Tag for reassembly.

2 Disconnect the wire ends from the solenoid coils.

3 Remove the capscrews from each valve and remove the valve blocks from the valve mounting bracket. For reassembly, tighten capscrew to 4 ft.-lbs. (5 Nm).

4 Service the valve components and valve in a clean work area. For each valve, remove the solenoid cartridge and fittings. Clean all parts with solvent.


• Install new O-rings and back-up rings on the solenoid cartridges.

WARNING: Before removing hydraulic lines, relieve pressure in the hydraulic system. With the truck off and open the truck auxiliary control valves several times in both directions.

1

2

3

Retainer Nut

Coil

Solenoid Valve

Valve Body

Restrictor Fitting, STOP Solenoid only

LP0449.eps

GA0059.eps

O-Ring O-Ring O-Ring

Backup Rings

54

Solenoid Valve

6880238

ERVICES

51

4.8-2 Stop Position Adjustment1 The attachment boom should stop at the left, middle

and right positions. Wait 3 seconds to swing after stopping OR press the swing override button to continue swinging. NOTE: A full swing should be 7 to 8 seconds.

• If boom stops at middle position, continue with Step 2.

• If boom stops momentarily and then continues at the middle position:

A Reduce the hydraulic input pressure for the swing function.

ORB Adjust both swing valve side counterbalance

cartridges CCW in 1/2 turn increments until boom stops at the middle position.

• If boom does not stop at the middle position:

A Inspect the wiring. Look for loose connection or pinched cables.

B The limit switch end rollers are not fully engaging the deceleration ramp in the middle position. Adjust the limit switch actuators to engage the ramp. The ramp can also be adjusted for precision of the stop position. NOTE: The limit switch plungers must be fully depressed.

2 To continue swing, wait 3 seconds after stopping or the swing override button must be pressed to continue swinging the boom.

To swing boom without stopping in the middle position, press the override button.

• If the boom does not move off the ramp, switch the positive and negative wire connections to the truck power. The timer is polarity sensitive, not the solenoids.

• If boom swings too fast, adjust the restrictor on the STOP Solenoid Valve. Adjust the screw until three threads show past the jam nut. Swing the boom and back out the screw 1/4 turn. Repeat backing the screw 1/4 turn with each swing until the boom slows. The swing boom should gently come to a rest against the mast.

LP0553.eps

LP0390.eps

Limit Switches (Normally Open)

Deceleration Ramp

LP0391.eps

Counterbalance Cartridge Adjust

Adjust restrictor if the boom swings too fast.

Swing Valve

STOP Solenoid Valve

LP0389.eps

Boom swings to left, middle and right positions (some units are left and right positions only).Pressing the override switch allows continuous swing.

Wait 3 seconds or press the override button to continue swinging.

Middle Position

0°

90°

180°

6880238

ERVICES

52

Swing Control Electrical Diagram

STO

P S

ol

STO

P S

w

DE

CE

L S

ol

DE

CE

L S

w

Po

wer

LP0513.eps

+

–

STOPLimit Switch(Normally Open)

DECELLimit Switch(Normally Open)

ESC Control BoxNOTE: Factory-adjusted time delay relay inside. If necessary, see service manual to change setting.

Carriage

STOP Valve

DECEL Valve

Mast

Coil CordPower Supply/Communications Group OR Cable Reel

OverridePushbutton(Normally Open) 180° and Center Stop

Switched

Key

TruckFuse Block

12V Truck Battery

SWING Control Knob

IC Trucks – Use chassis ground.Electric Trucks – Use battery ground.

IMPORTANT: Pushbuttons that are normally closed, are used only on swing units with center stop (90° position).

4.8-3 TroubleshootingNOTE: Refer to diagram shown below.

1 Check the ESC main power fuse/relay. Verify truck voltage is reaching the ESC control box when truck key is turned on.

NOTE: Pushbutton circuit (if equipped) provides power to ESC and is normally closed (NC).

2 Inspect all electrical cables. Look for loose connections, pinched wiring or wrongly-connected cables. Correct as necessary.

NOTE: Cable connector and control box are labeled to show proper connections.

3 Check continuity of solenoid/cable assemblies and limit switch/cable assemblies. Replace if needed.

4 With truck key on, manually operate limit switches. • Listen for 'clicks' at solenoids, indicating solenoid

coil operation.

OR

• Rotate attachment into ramps and check for voltage at control box solenoid output connectors.

5 Look for 3 second time delay between swing deceleration and ability to restart swing. If there is no delay, or attachment will not swing continuously with push button depressed, replace ESC control box.

NOTE: Control box contain factory set time delay, contact Cascade for adjustment procedure.

6880238

PECIFICATIONSS

53

GA0144.eps

5.1 Specifications5.1-1 Hydraulics

Lower Mast Mounts Clean truck axle or pin mounts and inspect for damage. Repair as necessary.

Upper Mast Mounts (tilt cylinders) No tilt function on the layer picker. Mast tilt cylinders are replaced with adjustable links to provide a fixed, mast-vertical configuration for all operations. If adjustable links are not provided, contact OEM for cylinder lockout/immobilization.

Hoses and Fittings• Hoist Function – Hoses and fittings for the HOIST function

should be No. 8 with 0.40 in. (10 mm) minimum ID.

• Clamp, Reach, Swing Functions – Hoses and fittings for theCLAMP, REACH and SWING functions should be No. 6 with0.25 in. (7 mm) minimum ID.

Truck Relief SettingsReach, Clamp, Swing, Hoist

2000 psi (138 bar) Recommended2300 psi (160 bar) Maximum

Truck Flow Volume ➀5C Min. ➁ Recommended Max. ➂

Reach, Clamp

5 GPM(18 L/min.)

7 GPM(26 L/min.)

10 GPM(37 L/min.)

Swing 2 GPM(7 L/min.)

3.5 GPM(13 L/min.)

5 GPM(18 L/min.)

Hoist 7 GPM(26 L/min.)

11 GPM(42 L/min.)

15 GPM(57 L/min.)

➀ Cascade Layer Pickers are compatible with SAE 10Wpetroleum base hydraulic fluid meeting Mil. Spec. MIL-0-5606or MIL-0-2104B. Use of synthetic or aqueous base hydraulicfluid is not recommended. If fire resistant hydraulic fluid isrequired, special seals must be used. Contact Cascade.

➁ Flow less than recommended will result in slower than normaloperating speed.

➂ Flow greater than maximum can result in excessive heating,reduced system performance and short hydraulic system life.

NOTE: Swing function does not apply to Stationary Side Mount models.

swittkop

Sticky Note

L/min values updated

6880238

PECIFICATIONSS

54

5.1-2 Truck Valve FunctionsCheck that lever movement is in compliance with ANSI/ITSDF B56.1 (ISO 3691) standards:

GA0082.eps

Clamp/CloseRetract

Swing Left

Hoist UpSwing Right

Hoist Down

Extend

NOTE: SWING function replaces TILT function (second control lever) on swing model layer picker.

Release/Open

GA0094.eps Hoist Up

Extend

Retract

Release/Open

Clamp/Close

Hoist Down

GA0082.eps

SWING MODEL

STATIONARY SIDE MOUNT MODEL

6880238

PECIFICATIONSS

55

LP0858.eps

5.1-3 Torque Values

6

13

2

5

7

9

10

11 12 13 14

Fastener torque values for the layer picker are shown in the table in both US and Metric units. All torque values are also called out in each specific service procedure section throughout the manual.

NOTE: All fasteners have a torque value range of ±10% of stated value.

Ref. Fastener Location Size Ft.-lbs. Nm

1 Mast Thrust Bearing Shim Capscrew M8 18 25

2 Sheave Retainer Pin Capscrew M10 40 50

3 Mast Thrust Bearing Stub Shaft Capscrew M12 75 85

4 Chain Anchor Jam Nuts 5/8 X 18 UNF 60 80

5 Hose Clamp Capscrews M6 8 10

6 Reach Cylinder Anchor Capscrews M12 80 110

7 Boom Actuator Upper Capscrews 3/4 in. 40 50

8 Actuator Mounting Capscrews 7/8 in. 280 380

9 Swing Control Ramp Capscrews M6 6 8

10 Mast Hoist Valve Capscrews M10 40 50

11 Boom Actuator Lower Capscrews 5/8 in. 160 217

12 Swing Control Mounting Capscrews M10 28 38

13 Ballast Plate Retainer Capscrews M16 165 225

14 Ballast Carriage Capscrews M12 60 80

▲ Double-Torque (tighten, loosen 1/2 turn, retighten)

4

8

6880238

PECIFICATIONSS

56

LP0833.eps

LP0850.eps

16

16

5.1-3 Torque Values (Continued)

17 18

19

22

20

21

Thrust Bearing Type CarriageBack (Driver's) View


15 Clamp Valve Capscrews M8 16 25

16 Cylinder Rod Anchor Nut (Clamp & Reach) 3/4 UNF 165 225

17 Contact Pad Capscrews M12 65 90

18 Arm Load Guard Capscrews M12 65 90

19 Swing Valve Capscrews 3/8 15 20

20 Carriage Retainer Capscrews M12 48 65

21 Carriage Thrust Bearing Shoulder Capscrews M12 22 30

22 IHR Terminal Mounting Bracket Capscrews M8 15 20

15

6880238

PECIFICATIONSS

57

LP0859.eps

LP0429.eps

8STATIONARY SIDE MOUNT

ELECTRONIC SWING CONTROL

PRESSURE/FLOW CONTROL VALVE

13

25

24

23

26

2728

29

5.1-3 Torque Values (Continued)

LP0860.eps


23 Mounting Plate Capscrews M10 28 38

24 Valve Mounting Capscrews M8 14 19

25 Solenoid Mounting Capscrews M6 14 19

26 Solenoid Mounting Plate Capscrews M10 28 38

27 Switch Mount Capscrew M8 14 19

28 Switch Mounting Capscrews M5 14 19

29 Relay Mounting Capscrews M6 6 8

c© Cascade Corporation 2016 06-2016 Part Number 6880238

Do you have questions you need answered right now? Call your nearest Cascade Service Department.Visit us online at www.cascorp.com

AMERICASCascade CorporationU.S. Headquarters2201 NE 201stFairview, OR 97024-9718Tel: 800-CASCADE (227-2233)Fax: 888-329-8207

Cascade Canada Inc.5570 Timberlea Blvd.Mississauga, OntarioCanada L4W-4M6Tel: 905-629-7777Fax: 905-629-7785

Cascade do BrasilPraça Salvador Rosa,131/141-Jordanópolis, São Bernardo do Campo - SPCEP 09891-430Tel: 55-13-2105-8800Fax: 55-13-2105-8899

EUROPE-AFRICACascade Italia S.R.L.European HeadquartersVia Dell’Artigianato 137030 Vago di Lavagno (VR) ItalyTel: 39-045-8989111Fax: 39-045-8989160

Cascade (Africa) Pty. Ltd.PO Box 625, Isando 160060A Steel RoadSparton, Kempton ParkSouth AfricaTel: 27-11-975-9240Fax: 27-11-394-1147

ASIA-PACIFICCascade Japan Ltd.2-23, 2-Chome,Kukuchi NishimachiAmagasaki, Hyogo Japan, 661-0978Tel: 81-6-6420-9771Fax: 81-6-6420-9777

Cascade Korea121B 9L Namdong Ind. Complex, 691-8 Gojan-DongNamdong-KuInchon, KoreaTel: +82-32-821-2051Fax: +82-32-821-2055

Cascade-XiamenNo. 668 Yangguang Rd. Xinyang Industrial ZoneHaicang, Xiamen CityFujian ProvinceP.R. China 361026Tel: 86-592-651-2500Fax: 86-592-651-2571

Cascade India Material Handling Private LimitedNo 34, Global Trade Centre 1/1 Rambaugh ColonyLal Bahadur Shastri Road, Navi Peth, Pune 411 030(Maharashtra) IndiaPhone: +91 020 2432 5490Fax: +91 020 2433 0881

Cascade Australia Pty. Ltd.1445 Ipswich RoadRocklea, QLD 4107AustraliaTel: 1-800-227-223Fax: +61 7 3373-7333

Cascade New Zealand15 Ra Ora DriveEast Tamaki, AucklandNew ZealandTel: +64-9-273-9136Fax: +64-9-273-9137

Sunstream IndustriesPte. Ltd.18 Tuas South Street 5Singapore 637796Tel: +65-6795-7555Fax: +65-6863-1368

6880238_C-Series Layer Picker Service - Cascade Corporation

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