6866472 magnetic layer picker service - cascorp.com€¦ · 30b magnetic . layer picker. manual...

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ERVICE MANUAL SUPPLEMENTS30B Magnetic Layer Picker

Manual Number 6866472

NOTE: This manual covers the magnetic palletizer components only. Refer to Layer Picker Service Manual 230444 for boom/carriage assembly and mast component servicing.

ONTENTSC

i 6866472

PageINTRODUCTION, Section 1

Introduction 1Special Definitions 1

PERIODIC MAINTENANCE, Section 2Swing Model 2

100-Hour Maintenance 2500-Hour Maintenance 21000-Hour Maintenance 32000-Hour Maintenance 3

Fork & Carriage Mount 4100-Hour Maintenance 4500-Hour Maintenance 42000-Hour Maintenance 4

TROUBLESHOOTING, Section 3General Procedures 5

Truck System Requirements 5Tools Required 5Troubleshooting Chart 5

Plumbing 6Hosing Diagram – Palletize and Reach Circuits (Swing Models) 6Hydraulic Schematic - Swing Models 7Hosing Diagram – Palletize Circuit(Fork and Carriage Mount Models) 8Hydraulic Schematic – Fork and Carriage Mount Models 9

Palletize Function 10Supply Circuit Test 10Palletize Circuit Test 10

SERVICE, Section 4Attachment Removal – Carriage and Fork Mount Models 11

Carriage Mount 12Fork Mount 12

Swing Models 13Mast Removal 13Boom/Carriage Assembly 13Reach Cylinder 13Mast Service 13

PageSERVICE, Section 4 (Continued)

Palletizer Assembly Removal 14Palletizer Stripper Pan Service 15Palletizer Assembly Cylinder Service 16

Cylinder Removal 16Gland Cartridge Service 17Cylinder Disassembly 18 Cylinder Inspection 19Cylinder Reassembly 19

Relief Valve 21Valve Removal 21Valve Service 21

SPECIFICATIONS, Section 5Swing Model Specifications 22

Hydraulics 22Auxiliary Valve Functions 22Truck Carriage 22

Carriage Mount Model Specifications 23Hydraulics 23Auxiliary Valve Functions 23Truck Carriage 23

Fork Mount Model Specifications 24Hydraulics 24Auxiliary Valve Functions 24

Torque Values 25

NTRODUCTIONI

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1.1 IntroductionThis manual provides the Periodic Maintenance, Troubleshooting, Service and Specifications for the Cascade Magnetic Layer Pickers.

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:

Swing Model – On the mast.

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.

Nameplate

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 the 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.

Fork Mount Model

Carriage Mount Model

Swing Model

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ERIODIC MAINTENANCEP2.1 Swing Model2.1-1 50-Hour Maintenance

IMPORTANT: 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.

2.1-1 100-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 fasteners, worn or damaged hoses and hydraulic leaks.

• Inspect the stripper pan for damage or wear. Replace as necessary.

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

• Check that mast is vertical and magnetic 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, roller (if equipped) and thrust block wear.

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Stripper Pan

Magnetic Assembly

Swing Boom

Mast

Carriage

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.

2.1-2 500-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.

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

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

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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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Shim Adjustment

Shim to adjust side clearance

2.1-3 1000-Hour MaintenanceAfter each 1000 hours of truck operation, in addition to the 100 and 500-hour maintenance, perform the following procedures:

• Inspect boom arm bearings for wear. Replace as necessary.

2.1-4 2000-Hour MaintenanceAfter each 2000 hours of truck operation, in addition to the 100, 500 and 1000-hour maintenance, perform the following procedures:

• If equipped, replace thrust bearings in mast and carriage.


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2.1-2 500-Hour Maintenance (Continued)• 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 1/16 in. (1.5 mm) maximum at the tightest point throughout the travel of the carriage. Shim behind the thrust bearings for required side-to-side clearance.

• Check torque value on swing boom drive top capscrews. Refer to illustration below. Use alternating cross-pattern and tighten to 160 ft.-lbs. (215 Nm).

• Check torque value on swing drive motor capscrews. Use alternatin cross-pattern and double-torque to 450 ft.-lbs. (610 Nm).

Swing Drive Motor Capscrews

Swing Boom Drive Capscrews

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2.2-3 2000-Hour Maintenance• Carriage Mount Units – After 2000 hours of truck

operation, in addition to the 100 and 500-hour maintenance, 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 & carriage wear gauge 209560 (Class II) and 209561 (Class III).

Fork Pin

Lower Mounting Hooks

Stripper Pan

Stripper Pan


2.2-2 500-Hour MaintenanceAfter each 500 hours of truck operation, in addition to the 100-hour maintenance, perform the following procedures.

• Carriage Mount Units – Check the clearance between the lower mounting hooks and the truck carriage bar:

Quick-Change Hooks – 3/16 in. (4.8 mm) maximumBolt-On Hooks – 3/32 in. (2.4 mm) minimum and 3/16 in. (4.8 mm) maximum.

If adjustment is necessary, refer to Service section 4.1-1, Step 2. Tighten the lower hook capscrews to 125 ft.-lbs. (170 Nm).

Fork MountSide View

Carriage MountSide View

2.2 Fork & Carriage Mount2.2-1 100-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:

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

• Inspect the stripper pan for damage or wear. Replace as necessary.

• Check that the fork lock pins are engaged.

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Pressure Gauge Kit:671212

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 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.

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 Kits:671476 (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 ATTACHMENT 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.

• Pallet hand truck to install palletizer 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.

3.1 General Procedures3.1-1 Truck System Requirements

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.

Palletize Circuit• Cylinder drifts.• Attachment does not engage with load.• Attachment operates erratically or chatters.

To correct these problems, refer to Sections 3.3.

IMPORTANT: Troubleshooting the Swing Model's REACH, SWING or HOIST circuits can be found in the Layer Picker Service Manual 230444.

ROUBLESHOOTING

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3.2 Plumbing3.2-1 Hosing Diagram – Palletize and

Reach Circuits (Swing Models)

RELEASE (Raise Magnetic Head)PRESSURERETURN

NOTE: For ENGAGE (Lower Magnetic Head), reverse the colors shown.

RETRACT BoomPRESSURERETURN

NOTE: For EXTEND, reverse the colors shown.

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ENGAGE(Port 1)

Palletizer Cylinder

Internal Reeving Hose Terminal

Truck Auxiliary Valves



Relief Valve

Extend-RetractCylinder

Revolving Connection

Revolving Connection

RELEASE(Port 3)

RELEASE(Port 4)

RETRACT(Port 2)

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3.2-3 Hydraulic Schematic – Swing Models

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P

Extend-Retract Cylinder

Palletizer Cylinder

ReliefValve

HoistCylinders

HydraulicFuse/Cushion(in cylinder)

RETRACT

ENGAGE

EXTEND

RELEASE

Swing Revolving Connection

Ports

HoistLoweringControlValve

Swing Drive Motor

LEFT RIGHT

Relief Cartridges

Truck AuxiliaryValves

Hose Reel

Mast IHRConnections

4-PositionPressureRelief Valve

Truck TankTruck ReliefTruck Pump

HOISTSWING(if equipped) REACH PALLETIZE

Swing Valve

CounterbalanceCartridges

ROUBLESHOOTING

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3.2-3 Hosing Diagram – Palletize Circuit (Fork and Carriage Mount Models)

RELEASE (Raise Magnetic Head)PRESSURERETURN

NOTE: For ENGAGE (Lower Magnetic Head), reverse the colors shown.

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ENGAGERELEASEPalletizer Cylinder



Relief Valve

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3.2-4 Hydraulic Schematic – Fork and Carriage Mount Models

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Palletizer Cylinder

ReliefValve

ENGAGE

RELEASE

Hose Reel/Mast IHRConnections

PALLETIZETruck Auxilary Valve

Truck TankTruck Relief

Truck Pump

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3.3 Palletize FunctionThere are five potential problems that could affect the PALLETIZE function:

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

• Incorrect hydraulic pressure or flow from the lift truck.

• External leaks.

• Worn/defective cylinder seals.

• Cylinder shell-to-end alignment.

• Cylinder tie rods are loose.

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

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

2 Check the flow volume at the relief valve. Flow must be within the range shown in Specifications, Section 5.1.

3 Lower the magnetic head on a load, holding the lever in the ENGAGE position for a few seconds. Release the lever and check for external leaks at fittings, hoses, valve, cylinder rod and cylinder shell.

3.3-2 Palletize Circuit Test1 Lower the magnetic head (ENGAGE) fully. Turn the

truck off and relieve system pressure by moving the PALLETIZE control lever back and forth several times.

2 Disconnect the hose that runs to the rod end of the cylinder to the valve. Plug the relief valve. Do not disconnect the rod end fitting. Place disconnected hose into the bucket.

3 Turn on truck and actuate the ENGAGE palletizer lever. Check the bucket and verifying one of the following:

• If there is substantial hydraulic flow out of the drain hose, the cylinder has faulty piston seals. Replace the complete unit or service the piston seals. Refer to Section 4.5.

• If there is little or no hydraulic flow out of the hose, the problem is not hydraulic. Refer to Section 3.3.

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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2

Cap supply fitting

Hose end in drain bucket

ENGAGESupply Hose

RELEASESupply Hose

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4.1 Attachment Removal(Carriage and Fork Mount Models only)

4.1-1 Carriage Mount

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 position and install the locking pins in the top holes.

3 Lower the attachment onto a pallet. 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:

• For complete installation procedure, refer to User Manual 6170709.

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ADJUST

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Carriage Bar

Carriage Bar

LH Lower Hook

Lower Hook

Tight against lower carriage bar.

Guide

Locking Pin

LH Lower Hook, Unlocked Position

BOLT-ON HOOKS QUICK-CHANGE HOOKS

WARNING: Before removing any hoses, relieve pressure in the hydraulic system. With the truck off, open the truck auxiliary control valve(s) several times in both directions.

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1 Release

Engage

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4.1-2 Fork Mount

1 Disconnect the truck supply hoses. Plug the hoses and cap the fittings.

2 Lower the attachment onto a pallet.

3 Remove the cotter pin from each side of the fork lock pin. Keep track of the washers.

4 Back truck out of the fork mount slots. Install fork locking pins for storage.

5 For attachment installation, reverse the above procedures with the following exceptions:

• For complete installation procedure, refer to User Manual 6170709.

3

4

Fork Lock Pin

Cotter Pin

Washer


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1 Release

Engage

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NOTE: Manuals are available at www.cascorp.com under the support tab, "Technical Support Manuals" link.

4.2 Swing Models4.2-1 Mast Removal

To remove the mast, refer to the Layer Picker Service manual, part number 230444, Section 4.1.

4.2-2 Boom/Carriage AssemblyTo remove the boom/carriage assembly and service its components, refer to the Layer Picker Service manual, part number 230444, Section 4.4.

4.2-3 Reach CylinderTo remove and service the reach cylinder, refer to the Layer Picker Service manual, part number 230444, Section 4.3.

4.2-4 Mast ServiceTo service the mast, refer to the Layer Picker Service manual, part number 230444, Section 4.5.

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NOTE: To service grayed components refer to Layer Picker Service Manual, part number 230444.

Mast

Reach Cylinder

Boom/Carriage Assembly

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4.3 Palletizer Assembly Removal 1 Lower the palletizer assembly onto a pallet.

2 Disconnect the PALLETIZE function hoses from the relief valve. Tag the hoses for reassembly. Plug the hoses and cap the valve fittings.

3 Swing Model – Disconnect the reach cylinder rod end from the palletizer assembly mounting frame. For reassembly, tighten the spherical retainer against hex washer, to a torque of 165 ft.-lbs. (225 Nm). NOTE: Joint operates with a loose clearance.

4 Remove the two mounting pin retainers and mounting pins connecting the boom bars to the pelletizer assembly mounting frame. For reassembly, tighten the pin retainer capscrews to 20 ft.-lbs. (30 Nm).

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

• Swing Model – Inspect the boom telescoping bars and bearings for damage or wear. Refer to Section 4.2-2.

• Inspect the mounting 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.


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3

4

4

Adjust Stops

Adjust Stops

Fork/Carriage Mount

Swing Model

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4.4 Palletizer Stripper Pan ServiceThis procedure is performed with the palletizer assembly remaining on truck carriage or boom (swing models). Stripper Pan Kit part no. 6182789 is used for this procedure. The kit includes stripper pan and hardware.

1 Lower the palletizer assembly onto a pallet.

2 Remove hardware from the guide pins.

3 Raise the palletizer assembly.

4 Position the palletizer assembly over the new kit stripper pan.

5 Slowly lower the palletizer assembly and position as needed so that the palletizer assembly frame channels align with the stripper pan guide pins.

6 Install new hardware on guide pins. Tighten nuts to 37 ft-lbs. (50 Nm).

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4.5 Palletizer Assembly Cylinder ServiceCascade provides seal kits for servicing the cylinder. If other parts require replacement, a complete cylinder assembly should be replaced. The following kits are available:

• Gland Cartridge Kit, part no. 6177871 – Contains assembled gland with seals.

• Piston Seal Kit, part no. 6177877 – Contains two piston seals and two body O-rings.

4.5-1 Cylinder Removal1 Remove the palletizer assembly from the Carriage/Fork

Mount or boom (swing models) as described in Section 4.3.

2 Disconnect the hoses from the palletizer assembly cylinder. Plug the hoses and cap the fittings.

3 If required, remove the palletizer assembly mounting frame, to gain access to the cylinder. For reassembly, tighten capscrews to 48 ft.-lbs. (65 Nm).

4 At the rod end of the cylinder, loosen the trunnion setscrews.

5 Remove the cylinder from the palletizer assembly frame. For reassembly, tighten capscrews to 75 ft.-lbs. (102 Nm).

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2

Trunnion Setscrew

Trunnion

Cylinder

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4.5-2 Gland Cartridge ServicePerform the following when the gland cartridge is the only part that requires service. Disassembling the cylinder is not required for this service. Gland Cartridge Kit part no. 6177871 is used for this procedure. The kit includes an assembled gland with seals

1 Clamp the cylinder at its base end in a soft-jawed vise. Clamp lightly on the base end only. Do not clamp in middle of shell.

2 Inspect the rod for burrs or damage that would prevent removing the gland cartridge.

3 Remove the gland cartridge from the cylinder rod.

4 Check that the O-ring located in the rod end cap is not faulty or damaged. If the O-ring is damaged, the O-ring on the new gland is required.

5 Lubricate new gland cartridge and its internal seals with petroleum jelly.

6 Slide the new gland cartridge over the piston rod and thread it into the gland retainer. If O-ring is not damaged in rod end cap; O-ring on new gland cartridge is not required.

7 Tighten the gland cartridge firmly against the rod end cap.

IMPORTANT: If required, the gland retainer may need to be removed to aid with aligning gland cartridge against the rod end cap. Remove tie rod nuts and gland retainer and then refer to Section 4.5-5, Steps 9-14, for reassembly.

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2

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67

6Cap O-Ring

Cap O-Ring

Tie Rod Nut

Gland Retainer

Gland Cartridge

Rod End Cap

Gland Cartridge

Rod End Cap

NOTE: This O-ring comes with the replacement gland.

Gland O-Ring (Optional)

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4.5-3 Cylinder Disassembly1 Clamp the cylinder at its base end in a soft-jawed vise.

Clamp lightly on the base end only. Do not clamp the middle of shell.

2 Inspect the rod for burrs or damage that would prevent removing the gland cartridge.

3 Loosen the gland cartridge from the rod.

4 Remove the nuts from the tie rods on the rod end side of the cylinder.

5 Remove the gland retainer and head cap from the cylinder.

6 Remove the rod assembly from the cylinder.

7 Remove the seals or O-rings from the following locations:

• Piston – Clamp the rod assembly in a soft-jawed vise and remove the seals by prying them up. Cut the seal to remove.

• Cylinder Shell – On each side of the cylinder shell, remove the O-ring from the lip.

• Cylinder Rod End Cap – Remove internal O-ring, only if faulty or damaged.

NOTE: Service Tool Kit (part no. 674424) includes two double-ended brass tools that make seal and O-ring removal easy. The tools won’t damage the cylinder components with dents or scratches.

CAUTION: Do not scratch the seal grooves.

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3

4

5

Gland Retainer

Rod End Cap

Base End Cap

Cylinder Shell Remove Rod

Assembly

Gland Cartridge

Rod End Cap O-Ring

Piston Seals

Gland Cartridge

Rod

Nuts

Gland Retainer

Rod End CapCylinder Shell

Base End Cap

Shell O-Rings

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4.5-4 Cylinder Inspection• Inspect the rod, piston and cylinder end cap 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 shell 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 entire cylinder assembly.

4.5-5 Cylinder Reassembly1 Lubricate all new seals and O-rings with petroleum jelly.

2 Install a new seal 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.

IMPORTANT: Note the direction of the U-cup seals. The pressure seal must be installed with the U portion toward the rod side of the piston.

3 Apply a thin film of petroleum jelly cylinder shell OD.

4 Insert the rod assembly (piston first) into the cylinder shell and push the rod assembly through until the second seal groove is exposed.

5 Install the second piston seal onto the exposed groove.

IMPORTANT: Note the direction of the U-cup seals. The pressure seal must be installed with the U portion away from the rod side of the piston.

6 Pull the rod assembly back into cylinder shell.

7 Press the O-rings into the grooves of the end caps.

8 Rock the cylinder shell into the base end cap until metal-to-metal contact occurs.

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7

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5

2

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End Cap O-Ring

Cylinder Shell

NOTE: Only expose the second seal groove.

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9 Screw the gland cartridge with seals into the gland retainer until one thread short of the retainer face contacting the head end cap face.

10 Carefully slide the gland cartridge/retainer assembly over the rod. Position the retainer tie rod holes to line up with the rod cap tie rod holes.

11 Install the tie rods and nuts, tightening to finger tight.

12 Verify that the rod end cap and base end cap are aligned. Retighten the tie rod nuts as necessary

13 Tighten nuts in a alternating cross pattern to 62 ft.-lbs. (84 Nm).

IMPORTANT: Do not torque one tie rod nut completely and then the others.

14 Tighten the gland cartridge firmly against the rod end cap.

4.5-5 Cylinder Reassembly (Continued)9

1013

12

14

Gland Retainer

GlandCartridge/RetainerAssembly

Rod End Cap

Verify rod end cap and base end cap are aligned

GlandCartridge

Head Cap

Tie Rod

Back off gland one thread short

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4.6 Relief Valve4.6-1 Valve Removal

4.6-2 Valve ServiceIMPORTANT: Service the valve in a clean work area.

1 Remove the valve from the frame as described in Section 4.6-1.

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

3 Remove the fittings from the valve.

4 Clean all parts with solvent.


• Install new O-rings and back-up rings on the valve cartridges, as shown.

1 Disconnect the hoses from the relief valve. Cap the hoses and tag for reassembly.

2 Remove the capscrews fastening the valve to the palletizer assembly mounting frame and remove the valve. For reassembly, tighten capscrews to 20 ft.-lbs. (30 Nm).


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


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Crossover Relief Valve Cartridge

Body

O-Rings

Back-Up Ring

Crossover Relief Cartridge

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5.1 Swing Model Specifications5.1-1 Hydraulics

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

should be No. 8 with 0.400 in. (10 mm) minimum ID.

• Palletize, Reach, Swing Functions – Hoses and fittings for the PALLETIZE, REACH and SWING functions should be No. 6 with 0.250 in. (7 mm) minimum ID.

Truck Relief SettingsReach, Palletize, Swing, Hoist

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

Truck Flow Volume ➀30B Min. ➁ Recommended Max. ➂

Reach, Palletize

5 GPM(18 L/min.)

7 GPM(37 L/min.)

10 GPM(56 L/min.)

Swing 2 GPM(18 L/min.)

3.5 GPM(13 L/min.)

5 GPM(13 L/min.)

Hoist 7 GPM(26 L/min.)

11 GPM(42 L/min.)

15 GPM(57 L/min.)

➀ Cascade Magnetic Layer Pickers (Swing Model) are compatible with SAE 10W petroleum base hydraulic fluid meeting Mil. Spec. MIL-0-5606 or MIL-0-2104B. 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.

➁ Flow less than recommended will result in slower than normal operating speed.

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

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

GA0082.eps

EngageRetract

Swing Left

Hoist UpSwing Right

Hoist Down

Extend

NOTE: Swing function replaces Tilt function (second control lever).

Release

GA0082.eps

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GA0381.eps

GA0389.eps

A

Carriage Mount Dimension (A) ITA (ISO)

Minimum Maximum

Class IIClass III

14.94 in. (380.0 mm)18.68 in. (474.5 mm)

15.00 in. (381.0 mm)18.74 in. (476.0 mm)

5.2-2 Truck Valve FunctionsCheck for compliance with ANSI (ISO) standards:

5.2-3 Truck Carriage

5.2 Carriage Model Specifications5.2-1 Hydraulics

GA0126.eps

Hoist Down

Hoist Up

Tilt Forward

Engage

Tilt BackRelease

Truck Relief Setting2000 psi (138 bar) Recommended2300 psi (160 bar) Maximum

Truck Flow Volume ➀Min. ➁ Recommended Max. ➂

30B 5 GPM(19 L/min.)

7 GPM(26 L/min.)

10 GPM(38 L/min.)

➀ Cascade Magnetic Layer Pickers (Carriage Models) are compatible with SAE 10W petroleum base hydraulic fluid meeting Mil. Spec. MIL-0-5606 or MIL-0-2104B. 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.

➁ Flow less than recommended will result in reduced system performance.


Hoses and FittingsHoses and fittings for the PALLETIZE function should be No. 6 hose with 9/32 in. (7 mm) minimum ID.

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GA0463.eps

5.3-2 Truck Valve FunctionsCheck for compliance with ANSI (ISO) standards:

5.3 Fork Model Specifications5.3-1 Hydraulics

GA0126.eps

Truck Relief Setting2000 psi (138 bar) Recommended2300 psi (160 bar) Maximum

Truck Flow Volume ➀Min. ➁ Recommended Max. ➂

30B 5 GPM(19 L/min.)

7 GPM(26 L/min.)

10 GPM(38 L/min.)

➀ Cascade Magnetic Layer Pickers (Fork Models) are compatible with SAE 10W petroleum base hydraulic fluid meeting Mil. Spec. MIL-0-5606 or MIL-0-2104B. 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.

➁ Flow less than recommended will result in reduced system performance.


Hoist Down

Hoist Up

Tilt Forward

Engage

Tilt BackRelease

Hoses and FittingsHoses and fittings for the PALLETIZE function should be No. 6 hose with 9/32 in. (7 mm) minimum ID.

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LP0727.eps

LP0726.eps

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

5.4 Torque ValuesFastener torque values for Magnetic 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: For additional torque values related for boom/carriage assembly and mast components, refer to one of the following Layer Picker Service manual, part number 230444.

Manuals are available at www.cascorp.com under the support tab, "Technical Support Manuals" link.

Ref. Fastener Location Size Ft.-lbs. Nm

1 Adjustable Stop Jam Nuts M12 60 80

2 Valve Capscrews M8 20 30

3 Cylinder Mounting Capscrews 1/2 75 102

4 Mounting Frame Capscrews M12 48 65

5 Palletizer Stripper Pan Nuts 1/2 UNC 37 50

6 Trunnion Capscrews 3/4 150 203

7 Reach Anchor Nut 3/4 UNF 165 225

8 Pin Retainer M8 20 30

9 Lower Hook Capscrews M16 120 165

10 Quick Disconnect Guide Capscrews M16 120 165

11 Carriage Frame Mounting Capscrews M20 325 320

12 Centering Tab Capscrews M16 120 165

13 Upper Hook Capscrews M16 120 165 1

2

3 4

56

79

8

10

11 12 13

Carriage Mount Model only

Swing Model only

c© Cascade Corporation 2016 01-2016 Part Number 6866472

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

6866472 magnetic layer picker service - cascorp.com€¦ · 30b magnetic . layer picker. manual...

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