Cascade is a Registered Trademark of Cascade Corporation
cascade
corporation
ERVICE MANUAL
S
J-Series
Integral Carriages −
Sideshifter, Fork Positioner,
Sideshifting Fork Positioner,
Swing Frame & Slope Frame
Manual Number 6052504
ONTENTS
C
i
6052504
Page
INTRODUCTION, Section 1
Introduction 1
Special Definitions 1
PERIODIC MAINTENANCE, Section 2
100-Hour Maintenance 2
500-Hour Maintenance 2
1000-Hour Maintenance 2
Swing Frame and Slope Frame 3
Hook-Type Fork Positioner Attachments 3
TROUBLESHOOTING, Section 3
General Procedures 4
Truck System Requirements 4
Tools Required 4
Troubleshooting Chart 4
Plumbing 5
Hosing Diagram – Sideshift and Fork Position 5
Hydraulic Schematics 5
Fork Position Function 6
Supply Circuit Test 6
Fork Position Cicuit Test 6
Sideshift Function 7
Supply Circuit Test 7
Sideshift Circuit Test 7
Electrical Circuit 8
SERVICE, Section 4
Sideshift/Fork Position Frame 9
Removal and Installation 9
Bearing Service 10
Mechanical Swing Wedge Bearing Service 11
Valve 12
Fork Position Valve Removal 12
Fork Position Valve Service 12
Sideshift Cylinder 13
Removal and Installation 13
Cylinder Disassembly 14
Cylinder Inspection 14
Cylinder Reassembly 15
Fork Positioner Cylinder 17
Removal and Installation 17
Cylinder Disassembly 18
Cylinder Inspection 18
Cylinder Reassembly 19
Flow Restrictor Adjustment 20
Solenoid Valve 20
Coil Service 20
Valve Service 20
SPECIFICATIONS, Section 5
Specifications 21
Hydraulics 21
Auxiliary Valve Functions 21
Torque Values 22
NTRODUCTION
I
6052504
1
1.2 Special Definitions
The statements shown appear throughout this Manual
where special emphasis is required. Read all WARNINGS
and CAUTIONS before proceeding with any work.
Statements labeled IMPORTANT and NOTE are provided
as additional information of special significance or to make
your job easier.
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.
1.1 Introduction
This manual provides the Periodic Maintenance,
Troubleshooting, Service and Specifications for Cascade
J-Series Integral Fork Positioner/Sideshifter, Swing Frame
and Slope Frame.
In any communication about the attachment, refer to the
product I.D. number stamped on the nameplate as shown.
If the nameplate is missing, the numbers can be found
stamped on the top left surface of the attachment.
IMPORTANT: All hoses, tubes and fittings on these
attachments are JIC.
NOTE: Specifications are shown in both US and (Metric)
units.
MAXIMUM STRUCTURAL CAPACITY
OF ATTACHMENT ONLY IS:
CATALOG
NUMBER
SERIAL
NUMBER
ADDITIONAL
EQUIPMENT
SYSTEM PRESSURE
PSI
BAR
INCH
LOAD
CENTER
mm
LOAD
CENTER
LBS
AT
Kg
AT
R
E
C
M
A
X
M
A
X
R
E
C
cascade
�
corporation
WEIGHT
Kg
FOR TECHNICAL ASSISTANCE CONTACT:
SERVICE: 1-800-227-2233 PORTLAND, OREGON USA
PARTS: 1-888-227-2233 SPRINGFIELD, OHIO USA
667635R6
CAPACITY OF TRUCK AND ATTACHMENT COMBINATION MAY BE LESS
THAN ATTACHMENT CAPACITY SHOWN.
CONSULT TRUCK NAMEPLATE.
WEIGHT
LBS.
35E-PPS-A001
PTL 604920-1R0
35E-PPS-A001
PTL 604920-1R0
FP1194.eps
Nameplate
IMPORTANT: Information in this manual is based
on a general attachment. Some functions are not
shown. Contact Cascade for specific information.
6052504
ERIODIC MAINTENANCE
P
2
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 procedures:
Check for loose or missing capscrews, worn or
damaged hoses, and hydraulic leaks.
Check fork shafts for bends, damage or wear. Replace
if bent. Consult Cascade if damaged or worn.
2.2 300-Hour Maintenance
After each 300 hours of truck operation, in addition to the
100-hour maintenance, perform the following procedures:
Tighten Cascade backrest (if equipped) capscrews to
the following torque values:
M12 Capscrew – 75 ft.-lbs. (100 Nm)
M16 Capscrew – 145 ft.-lbs. (195 Nm)
For other backrests, see OEM recommendations.
If equipped with zerk fittings – Apply general purpose
chassis grease to upper and lower bearings.
Inspect frame retainers for wear. Replace if necessary.
Tighten lower frame retainer capscrews to 165-200 ft.-lbs.
(225-275 Nm).
Inspect fork shaft and front of lower frame bar for
grease contamination. Remove contaminated grease
from fork shaft and lower frame bar. Apply a general
purpose chassis grease to the fork shaft. Apply a
general purpose chassis grease or Slip-Plate (or a
'paint-on' graphite equivalent) to the lower frame bar.
2.3 1000-Hour Maintenance
After each 1000 hours of truck operation, in addition to
the 100 and 300-hour maintenance, perform the following
procedures:
Inspect sideshift upper and lower bearings for wear.
If the frame is rubbing the carriage or lower bearing
capscrews, replace the entire bearing set (see Service
Manual for repair procedures).
Inspect forks for wear.
NOTE: Cascade fork safety kit 3014162 is available with
wear calipers, inspection sheets and safety poster. Also
available Cascade fork hook & carriage bar wear gauge
209560 (CL II), 209561 (CL III) and 6105257 (CL IV).
Inspect sideshift cylinder pivot pins and clevis pins for
wear. Replace part as necessary.
Inspect fork position cylinder anchor nuts for wear.
Replace if necessary.
NOTE: Anchors operate with a loose clearance.
Tighten lower bearing capscrews to 200 ft.-lbs. (270 Nm).
Tighten fork shaft retainers capscrews (if equipped) to
49 ft.-lbs. (66 Nm).
•
•
•
•
•
•
•
•
•
•
•
•
WARNING: After completing any service
procedure, always test the Fork Positioner/
Sideshifter through five complete cycles
to make sure the attachment operates
correctly before returning it to the job.
FP0736.eps
Shaft Retainer
capscrews
Fork Shaft Upper Bearing
Sideshift Cyinder
Clevis Pin Mounts
Lower
Frame Bar
Lower Bearing
Front View
Back (Driver's) View
FP1218.eps
Backrest Capscrews
(if equipped)
Fork Positioner
Cylinder Anchors
Lower Frame
Retainer Capscrews
6052504
ERIODIC MAINTENANCE
P
3
SS0817.eps
2.4 Swing and Slope
Attachments
In addition to the previous page maintenance schedule,
where applicable, the following maintenance procedures
must be completed on swing and slope attachments:
300 Hours – Apply general purpose chassis grease to
pivot pin zerk fittings and cam rollers.
1000 Hours – Inspect swing and slope frame pivot
points for wear.
1000 Hours – Inspect wedge bearings (Mechanical
swing frame) for wear.
1000 Hours – Inspect swing and slope cylinder
pivot pins and clevis pins for wear. Replace part as
necessary.
•
•
•
•
Cylinder
Pivot Pins
Frame
Pivot Pins
Cam Rollers
Wedge
Bearings
FP1212.eps
Upper Fork
Carrier Bearings
Lower Fork
Carrier Bearings
FP Cylinder
Lug
Capscrews
Fork Carrier
Capscrews
Fork Pad Capscrews
2.5 Hook-Type Fork
Positioner Attachments
In addition to the previous page maintenance schedule,
where applicable, the following maintenance procedures
must be completed on hook-type fork positioner
attachments:
300 Hours – Apply general purpose chassis grease to
fork carrier bearings.
300 Hours – Tighten capscrews as follows:
FP Cylinder Lug – 13-15 ft.-lbs. (18-20 Nm)
Fork Pad – 500 ft.-lbs. (678 Nm)
Fork Carrier – 28 ft.-lbs. (38 Nm)
NOTE: Apply Loctite 242 to FP Cylinder Lug and Fork
Pad capscrews.
300 Hours – Apply general purpose chassis grease or
Slip-Plate (or a 'paint-on" graphite equivalent) to the fork
slider bars.
•
•
•
Fork Slider
Bars
ROUBLESHOOTING
6052504
T
4
3.1 General Procedures
3.1-1 Truck System Requirements
Truck hydraulic pressure should be within the pressure
range as shown in Section 5.1. PRESSURE MUST NOT
EXCEED 2500 psi (170 bar).
Truck hydraulic flow should be within the volume range
as shown in Section 5.1
Truck hydraulic fluid supplied to the attachment must
meet the specifications as shown in Section 5.1.
•
•
•
3.1-2 Tools Required
In 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
Assorted fittings, lines, drain hoses and quick-couplers
as required.
•
•
•
3.1-3 Troubleshooting Chart
WARNING: Before servicing any
hydraulic component, relieve pressure in
the system. Turn the truck off and move
the truck auxiliary control valves several
times in both directions.
After completing any service procedure, test the
attachment through several cycles. First test the
attachment empty to bleed any air trapped in the
system to the truck tank. Then test the attachment
with a load to be sure it operates correctly before
returning 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.
Determine All The Facts – It is important that all
the facts regarding the problem are gathered before
beginning service procedures. The first step is to
talk to the equipment operator. Ask for a complete
description of the malfunction. The following
guidelines can then be used as a starting point to
begin troubleshooting procedures:
Fork Position Function
• Forks open and close unevenly.
• Forks will not open and close.
To correct one of these problems, see Section 3.3.
Sideshift Function
• Attachment sideshifts too fast or too slow.
• Attachment will not sideshift.
To correct one of these problems, see Section 3.4.
Other Functions
Contact Cascade, see back cover.
GA0013.eps
GA0014.eps
AC0127.eps
Flow Meter Kits: 671476 – 37 L/min (10 GPM)
671477 – 75 L/min (20 GPM)
(2) No. 8-12
JIC/ O-Ring
(2) No. 6-8 JIC Reducer
Flow Meter
Pressure Gage Kit: 671212
Pressure Gauge★
No. 6-6 Hose★
No. 6 and No. 8
JIC Swivel Tee
No. 4. No.
6★ and No. 8
JIC/O-ring
No. 6-8 JIC
Reducer
No. 4-6 Pip/JIC★
Quick-Disconnect Couplers
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)
★ NOTE: Diagnostics Kit 394382
includes items marked.
6052504
ROUBLESHOOTING
T
5
4.2 Plumbing
4.2-1 Hosing Diagram –
Sideshift and Fork Position
FP0733.eps
CLOSE
Forks
OPEN
Forks
Relief
Valve
Fork Positioning
Cylinders
Sideshift
Cylinder
SIDESHIFT LEFT, CLOSE FORKS
PRESSURE
RETURN
NOTE: For SIDESHIFT RIGHT, SPREAD
FORKS reverse the colors shown.
SIDESHIFT Truck
Auxiliary Valve
FORK POSITION
Truck Auxiliary Valve
4.2-2 Hydraulic Schematic
FP0732.eps
Flow
Restrictor
Flow
Restrictor
Relief
Valve
Sideshift Cylinder
Hose Reel or
IHR
Terminals
SIDESHIFT Truck
Auxiliary Valve
FORK POSITION
Truck Auxiliary Valve
Truck Pump
Truck Relief
Valve
Truck Tank
SSR SSL
OPEN
CLOSE
ROUBLESHOOTING
6052504
T
6
3.3 Fork Position
Function
There are five potential problems that could affect the fork
positioning function:
Forks and fork carriers binding on bearings
Incorrect hydraulic pressure or flow.
External leaks.
Loose electrical connection or defective solenoid coil or
valve (if equipped).
Worn/defective cartridge valves or cylinder seals.
3.3-1 Supply Circuit Test
1 Check the truck pressure at the carriage hose terminal.
Pressure must be within 100 psi (7 bar) of that specified
in the truck service manual. PRESSURE MUST NOT
EXCEED 2500 psi (170 bar) to the fork positioner/
sideshifter. See Section 5.1 for recommended
operating pressure.
2 Check the flow volume at the carriage hose terminal.
See Section 5.1 for recommended flow volume.
3 Fully spread forks. Hold the lever in the OPEN position
for 2 seconds. Release the lever. Check for external
leaks at fittings, hoses and valve.
3.3-2 Fork Position Circuit Test
1 If equipped, press the solenoid button. Listen for a
'click' at solenoid valve. If no sound is heard, check the
fuse, wiring and coil. See Section 3.5.
IMPORTANT: Solenoid operated valves must be
plumbed so that the solenoid is energized during the
fork positioning function.
2 Fully open and close forks. If the forks move at different
speeds, adjust the flow restrictors for equal fork speed.
See Section 4.5-5.
3 Turn the truck off. Connect a 5000 psi (345 bar)
pressure gauge to the OPEN line below the valve.
4 Start the truck. Fully spread forks. Hold the lever in the
OPEN position for a few seconds.
5 Release the lever. Watch the pressure gauge:
If the pressure drop is less than 150 psi (10 bar)
initially and additional drop does not exceed 25 psi
(2 bar) per minute, the problem is not hydraulic. See
Section 3.3, above.
If the pressure drop is more than 150 psi (10 bar)
initially, one of the relief valve's cartridges is faulty.
Replace both cartridges.
6 Fully close forks. Hold the lever in OPEN position for
a few seconds. If the pressure still drops more than
150 psi (10 bar), the cylinders are faulty and should be
serviced. See Section 4.5.
•
•
•
•
•
•
•
WARNING: Before removing hydraulic
lines or components, relieve pressure in the
hydraulic system. Turn truck off and open
the truck auxiliary control valve(s) several
times in both directions.
FP1195.eps
FP1196.eps
2
3
2
4
Flow Meter
Flow Restrictor
Pressure
Gauge
Back (Driver's) View
Front View
6052504
ROUBLESHOOTING
T
7
3.4 Sideshift Function
There are five potential problems that could affect the
sideshifting function:
Binding due to bending damage, wear, lack of
lubrication. See Periodic Maintenance, Section 2.
Incorrect hydraulic pressure or flow to sideshift cylinder.
External leaks.
Lower mounting hooks installed incorrectly. Refer to
User Manual 6082563 Installation Section.
Worn or defective cylinder seals.
3.4-1 Supply Circuit Test
1 Check the pressure supplied by the truck at the carriage
hose terminal. Pressure must be within the range
shown in Specifications, Section 5.1. PRESSURE TO
THE FORK POSITIONER/ SIDESHIFTER MUST NOT
EXCEED 2500 psi (170 bar).
2 Check the flow volume at the carriage hose terminal.
Flow must be within the range shown in Specifications,
Section 5.1
3 Fully sideshift left and right, holding the lever in each
SIDESHIFT position for a few seconds. Release the
lever and check for external leaks at fittings, hoses,
valve and cylinders.
3.4-2 Sideshift Circuit Test
1 If equipped, press the solenoid button. Listen for a
'click' at the solenoid valve. If no sound is heard, check
the fuse, wiring and coil. See Section 3.5.
IMPORTANT: Solenoid operated valves must be
plumed so that the solenoid is not energized during the
sideshifting function.
2 Turn the truck off. Relieve system pressure. Disconnect
the sideshift base end supply hose from the internal
reeving or hose terminal fitting. Cap the supply fitting
and place the hose end in a drain.
3 Start the truck and actuate the SIDESHIFT LEFT lever
for 5 seconds:
If there is substantial hydraulic flow out of the drain
hose, the sideshift cylinder is faulty and requires
service.
If there is no hydraulic flow out of the hose, the
problem is not hydraulic. See Section 3.4, above.
•
•
•
•
•
•
•
WARNING: Before removing hydraulic
lines or components, relieve pressure in the
hydraulic system. Turn truck off and open
the truck auxiliary control valve(s) several
times in both directions.
FP1197.eps
3
2
Sideshift base
end hose
Back (Driver's) View
ROUBLESHOOTING
6052504
T
8
3.5 Electrical Circuit
(Solenoid Equipped Attachments)
Use the electrical schematic and diagram shown and
follow the steps below:
1 Check the control knob circuit fuse. Replace if
necessary.
2 Check for loose electrical connections at the truck
ignition switch, control knob button, solenoid coil
terminal and diode.
3 Remove the diode from the solenoid coil terminal. Test
with an ohmmeter for high resistance in one direction
and no resistance in the other direction. If there is no
resistance in both directions, replace the diode.
NOTE: When replacing the diode, the banded (+) end
must connect to the positive (+) side of the coil and
wiring as shown.
4 Disconnect the electrical leads from the solenoid coil
terminals. Use a voltmeter to determine if voltage
is present at the electrical leads when the button is
pressed.
If there is no current to the solenoid, troubleshoot
the electrical circuit for shorts.
If there is current to the solenoid, test for coil
continuity.
5 Test the coil continuity by placing an ohmmeter test lead
on each solenoid coil terminal (ohmmeter on Rx1 scale).
If there is an ohmmeter reading, the coil is good.
If the coil is good, but the solenoid does not 'click'
when the control knob button is pressed, the
solenoid cartridge may be jammed.
If there is no ohmmeter reading, the coil is defective.
Replace coil.
•
•
•
•
•
CL0258.eps
CL0257.eps
7.5 amp
Fuse
White
Black
Knob
Button
(Normally
Open)
Diode
Solenoid Coil
Diode
7.5 amp
Fuse
Black
White
Solenoid Coil
User supplied wire
6052504
ERVICE
S
9
4.1 Sideshift/ Fork
Position Frame
4.1-1 Removal and Replacement
NOTE: The Sideshift/Fork Position frame, with forks in
place, may be removed from the integral carriage bars to
service the sideshifter bearings.
6 For installation, reverse the above procedures with the
following exceptions:
Clean and inspect carriage bars for damage and
smoothness. Bars should be parallel and ends
should be flush.
Clean all bearing areas of built-up dirt and grease.
Inspect bearings for wear and replace if necessary
(see Section 5.1-2).
•
•
•
WARNING: Before disconnecting hoses,
relieve pressure in the attachment hydraulic
system. Turn the truck off and move the
truck auxiliary valve control lever several
times in both directions.
1 Disconnect the supply hoses to the fork positioner
valve and sideshift cylinder. Cap hoses and tag for
reassembly.
2 Remove the clevis pins and remove the sideshift
cylinder from the frame.
3 Backrest may be removed or left in place to assist in
lifting frame from carriage. For Cascade backrests
reassembly, tighten backrest capscrews to 145 ft.-lbs.
(195 Nm).
4 Remove the lower retainers. For reassembly, tighten
capscrews to 120 ft.-lbs. (165 Nm).
5 Attach an overhead hoist and slings to the frame. Lift
away from the truck carriage.
NOTE: Bearings may remain on the carriage bars.
WARNING: Check the attachment weight
(located on the nameplate) to make sure the
overhead hoist is at least the rated capacity
of the attachment.
FP1198.eps
4
2
FP1199.eps
5
Upper
Bearings
Lower
Bearings
6052504
ERVICE
S
10
4.1-2 Bearing Service
1 Remove the Sideshift/Fork Position frame from the truck
carriage as described in Section 4.1-1.
2 Remove and inspect the upper bearings. If any bearing
is worn to less than .4 in. (10 mm) thickness, replace all
bearings.
IMPORTANT: Make sure upper bearings are properly
positioned and seated on the upper integral carriage
bar, as shown. Proper lower hook clearance requires
that all bearings be properly positioned on the top
carriage bar.
3 Remove and inspect the lower bearings. If any bearing
is worn to less than .4 in (10 mm) thickness, replace all
bearings.
4 For reassembly, reverse the above procedures with the
following exceptions:
Use grease to hold the upper bearings in position on
the carriage bar when replacing the frame.
Tighten lower bearing capscrews to 202 ft-lbs.
(274 Nm).
•
•
FP1200.eps
2
3
4
6052504
ERVICE
S
11
FP1205.eps
4.2 Mechanical Swing
Wedge Bearing Service
WARNING: Before disconnecting hoses,
relieve pressure in the Attachment hydraulic
system. Turn the truck off and move the
truck auxiliary valve control lever several
times in both directions.
1 Disconnect the supply hoses to the swing cylinder. Cap
hoses and tag for reassembly.
2 Remove the clevis pin from the swing cylinder rod end.
3 Remove the clevis pins from the push rod assembly and
remove the push rod assembly from the wedges.
4 Remove the retainers from the cam pins and remove the
cam rollers from the frame.
5 Rotate the swing frame to one side. Slide out the
opposite side wedge.
6 Replace the upper and lower wedge bearings.
7 Reinstall wedge and rotate the swing frame to the
center.
8 For the opposite side, repeat steps 5 and 6.
9 For reassembly reverse the steps 1-4 with the following
exceptions:
If the swing frame slops or binds between the cam
rollers and wedges, adjust the push rod assembly
ends to extend or shorten.
•
4
5
6
8
5
2
3
Retainer
Cam Roller
Cam Pin
Push Rod
Assembly
Wedge
Wedge
Bearings
6052504
ERVICE
S
12
4.3 Valves
NOTE: Not all valves are covered. Contact Cascade to
replace valve components.
4.3-1 Fork Position Valve Removal
WARNING: Before servicing any hydraulic
component, relieve pressure in the system.
Turn the truck off and move the truck
auxiliary control valves several times in both
directions.
1 Disconnect the hoses from the valve. Tag hoses for
reassembly.
2 Disconnect the tubing at the bottom of the valve. Plug
the tubing ends.
3 Remove the capscrews fastening the valve to the frame
and remove the valve. For reassembly, tighten the
capscrews to 15 ft.-lbs. (22 Nm).
4 For reassembly, reverse the above procedures with the
following exceptions:
Service that valve as describe in Section 4.3-2.•
4.3-2 Fork Position Valve Service
IMPORTANT: Service the valve in a clean work area.
1 Remove the valve from the sideshift frame as described
in Section 4.3-1.
2 Remove the crossover relief valve cartridges from the
valve. Remove the O-rings and back-up rings from the
cartridges.
3 Remove the fittings from the valve.
4 Clean all parts with solvent.
5 For reassembly, reverse the above procedures with the
following exceptions:
Replace O-rings and back-up rings on relief valve
cartridges as shown.
•
FP0731.eps
2
3
Crossover Relief
Valve Cartridge
Body
FP0730.eps
O-Rings
Back-Up Rings
5
FP1207.eps
Valve
Crossover Relief Cartridge
6052504
ERVICE
S
13
4.4 Sideshift Cylinder
4.4-1 Removal and Installation
NOTE: The following procedures can be performed with
the Sideshift/Fork Position frame mounted on the truck.
1 Disconnect the hoses from the cylinder ports and tag for
reassembly.
2 Remove the clevis pins from the cylinder ends and
remove the cylinder from the sideshifting frame.
3 For reassembly, reverse the above procedures with the
following exceptions:
Service the cylinder as described in Section 4.4-2.
Operate the sideshifter through several full cycles to
clear the system of any entrapped air. Check fittings
and hoses for leaks.
•
•
WARNING: Before disconnecting hoses,
relieve pressure in the attachment hydraulic
system. Turn the truck off and move the
truck auxiliary valve control lever several
times in both directions.
FP0773.eps
2
1
SIdeshift
Rod End
Sideshift
Base End
Clevis Pins
6052504
ERVICE
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14
SS0088.eps
6
4.4-2 Cylinder Disassembly
NOTE: Use a soft-jawed vise for all cylinder disassembly
and assembly procedures.
1 Clamp the cylinder so that the vise jaws contact only the
extreme end of the cylinder base. Do not clamp on the
shell.
2 Threaded Retainers – Use a pin-type spanner wrench
or special socket to screw out piston retainer.
Snap Ring Retainers – Fully extend cylinder rod.
Remove the spiral snap from the retainer.
Tap the retainer into the shell approximately 2 in. (50
mm). Pry out the circular retaining ring from it's groove
on the opposite side from the split ends.
CAUTION: Do not scratch cylinder bore.
3 Remove the rod assembly from the cylinder shell.
4 Clamp the rod assembly in a vise on the clevis end as
shown.
CAUTION: Never clamp directly on the rod sealing
surface.
5 Remove the piston nut from the rod. Remove the piston
from the cylinder rod.
6 Place the piston or retainer in a soft-jawed vise to
remove seals. Pry the seals and O-rings up with a brass
seal removal tool (part no. 674424) and cut the seals
and O-rings to remove them.
CAUTION: Do not scratch the seal grooves.
FP0743.eps
SS0061.eps
1
2
5
4
Pin-Type
Spanner
Wench
Threaded
Retainer
Piston
Retainer
SS0059.eps
SS0336.eps
1
Spiral Snap Ring
2
NOTE: Service Tool
Kit 674424 includes
two double edged
brass tools to ease
seal and retaining
ring removal.
6052504
ERVICE
S
15
4.4-3 Cylinder Inspection
Inspect the rod, piston and retainer for nicks or burrs.
Minor nicks or burrs may be removed with 400-grit
emery cloth. If they cannot be removed, replace the
parts.
Inspect the cylinder bore and remove any minor nicks
or burrs with a butterfly. If they cannot be removed,
replace the part.
NOTE: Minor nicks are those that will not pass
hydraulic fluid under pressure.
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.
•
•
•
FP0738.eps
Piston Nut
Piston Shell
Rod Retainer
NOTE: Snap Ring
Retainer not shown
6052504
ERVICE
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16
4.3-4 Cylinder Reassembly
1 Polish the piston and retainer chamfer angles with
400-grit emery cloth to ease seal installation.
2 Note the direction of the pressure seals. Pressure
seals must be installed with the lip toward the high
pressure side of the cylinder.
3 Lubricate new seals and O-rings with O-ring lube or
petroleum jelly.
4 Install a new pressure seal and back-up ring (if
equipped), wear ring (if equipped) on the piston. If
equipped, install a new O-ring in the piston.
5 Install a new pressure seal, wiper, O-ring and back-up
ring on the retainer, as shown.
6 Clamp the rod at the clevis end in a soft-jawed vise.
CAUTION: Do not clamp on the cylinder rod sealing
surface.
7 Threaded Retainers – Apply a thick film of petroleum
jelly to the retainer ID. Install the retainer on the rod.
Use a seal loader as required to prevent damage to the
seals.
8 Install the piston on the rod. Tighten the nut as shown.
9 Apply a thick film of petroleum jelly to the cylinder
shell and piston OD. Install the rod assembly into the
cylinder shell. Use a piston/seal loader as required to
prevent damage to the seals.
10 Threaded Retainers – Use a pin-type wrench to screw
the retainer into the shell. Tighten the retainer as shown.
Snap Ring Retainers – Tap retainer into shell far
enough to install the circular retaining ring in its groove.
Fully extend rod. Install the spiral snap ring on the
retainer.
SS0063.eps
SS0061.eps
SS0334.eps
1,4
8
9
6
7
Nut
Piston
Retainer
Piston/Seal
Loader
Piston/Rod Assembly
FP0739.eps
Wear Ring
Back-up Ring
O-Ring
Piston U-cup
Pressure Seal
Note Seal
Direction
4
5
5
Wiper
Back-up Ring
O-Ring
Pressure
Seal
Torque Piston Nut
200-250 ft.-lbs.
271-339 Nm.
Torque Retainer
350-400 ft.-lbs.
475-542 Nm.
TYPE 1
6052504
ERVICE
S
17
SS0822.eps
TYPE 2
TYPE 3
SS0823.eps
Piston U-cup
Pressure Seal
Note Seal
Direction
Pressure Seal
O-Ring
Back-up
Ring
Wiper
Wear Ring
Torque Piston Nut
100-120 ft.-lbs.
271-339 Nm
Retaining Ring
Spiral Snap Ring
4
5
5
Piston U-cup
Pressure Seal
Note Seal
Direction
Pressure Seal
O-Ring
Wiper
Wear Ring
Torque Piston Nut
100-120 ft.-lbs.
271-339 Nm
Retaining Ring
Spiral Snap Ring
4
5
5
O-Ring
6052504
ERVICE
S
18
5 Disconnect the hydraulic lines from the cylinder to be
removed. Plug the lines and cap the cylinder ports.
Tag lines for reassembly.
6 Disconnect the cylinder base end from the frame by
removing the cotter pin, locking cap and spherical nut.
Lift the cylinder away from the frame.
NOTE: Some cylinders have a cotter pin and clevis pin
assembly.
7 For reassembly, reverse the above procedures with the
following exceptions:
Service cylinder as described in Section 4.5-2.
Lubricate threads and spherical nuts with chassis
grease.
Install hex beveled washer on cylinder rod end.
NOTE: Beveled side faces lug, as shown.
Tighten spherical nuts to 160 ft.-lbs. (220 Nm).
NOTE: Nut tightens against hex washer, providing a
loose operating clearance. Lubricate anchor joints
with chassis grease.
Install locking caps using new cotter pins, if equipped.
Secure cylinder base ends with dowel pin, if
equipped.
•
•
•
•
•
•
4.5 Fork Position Cylinders
4.5-1 Removal and Installation
1 If equipped, remove the backrest to provide access to
the cylinder head end anchors. For cascade backrest
reassembly, tighten backrest capscrews to:
M12 Capscrew − 75 ft.-lbs. (100 Nm)
M16 Capscrew − 145 ft.-lbs. (195 Nm)
Refer to the truck service manual for truck
manufacturer's backrest.
2 Position the forks to mid range. Disconnect the cylinder
rod ends from the lugs by removing the cotter pin,
locking cap and spherical nut.
3 Retract the cylinder rods until they disengage from the
lugs.
4 Slide the forks to maximum frame width to provide room
to remove the cylinders.
WARNING: After completing this service
procedure, test the attachment through five
complete cycles. First test empty, then test
with a load to make sure the attachment
operates correctly before returning it to the
job.
WARNING: Before disconnecting
hydraulic lines, relieve pressure in the
attachment hydraulic system. Turn the
truck off and move the auxiliary control
levers several times in both directions.
FP1208.eps
4
5
1
Lug
Cotter Pin
Spherical Nut,
Locking Cap
Cylinder
Rod End
Hex Washer
(beveled side
toward lug)
Cotter pin
and clevis
pin assembly
shown
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