SERVICE MANUAL / PARTS LIST

Transcription

1 SERVICE MANUAL / PARTS LIST APPLIANCE CLAMP SOFT TOUCH MODEL #05 PATENT NO. 9,630,8 CONTENT: PAGE Lift Truck Requirements General Installation Procedures General Inspection & Maintenance -3 Clamp Assembly 4 Arm Group Assembly 5-7 Floating Pad Assembly 8-9 Hydraulic Assembly 0 Cylinder Assembly Clamp Adjustments Control Valve 3 Clamp Force Control Valve 4-5 Narrow Range Control Valve 6 Arm Slide & Shim Replacement 7 Trouble Shooting Guide 45 Hazel St. Kelso WA 9866 (800) Fax (360)

2 LIFT TRUCK REQUIREMENTS CAPACITY Capacity shown on the Clamp name plate is for the Clamp only. The combined truck and Clamp capacity is provided by the lift truck manufacturer. CLAMP HYDRAULICS Recommended Truck Pressure: 300 to 400 PSI (59 to 65 bar) Hydraulic fluid: petroleum based hydraulic fluid only. Hydraulic supply group: includes hoses and take-up - one for each function. Auxiliary valve: function (Side Shift & Clamp) = a double auxiliary valve. Oil Volume Settings: Side Shift = 3 GPM Clamp Open/Close = 7 GPM NOTE: Three Position Force Selector must be disabled. GENERAL INSTALLATION PROCEDURES. Make sure that the attachment centering lug is completely seated in truck carriage center notch.. Clearance between the lower retainers that hold the attachment to the truck lower carriage bar should be as shown below..3" (3. mm) MAXIMUM Truck Lower Carriage Bar Lower Retainer 3. Attach truck supply group (take-up) to clamp valve on attachment base. 4. Standing clear of the clamp attachment, cycle the attachment in and out several times. Use caution because partially filled hydraulic lines may cause erratic movement. GENERAL INSPECTION AND MAINTENANCE. Check all hydraulic fittings, hoses, cylinders and valves for leakages - repair or replace as required.. Check bladder/water pressure. If out of operating range adjust as required using the LORON hand pump #909 and pure propylene glycol antifreeze mixed : with water. Check clamp force and adjust. Time Schedule: Check pressure and clamp forces every 3 weeks Water pressure: 4-6 PSI 3. All bolts should be checked and tightened as required. 4. Check lower retainer clearance-see item in General Installation Procedures above.

3 Drawing reference 998. CLAMP ASSEMBLY- # QTY PART # DESCRIPTION 999 Frame 74. Cylinder Assembly Load Backrest Flat Slide Angle Slide Shim 7 8 C.080 Bolt 8 4E.08 Lock Washer Spherical Bearing Rod Centering Seal Cotter Pin 380 Cylinder Rod Washer Lower Retainer Lower Load Backrest 5 4 C.08 Bolt 6 69 Slide Button 7 86 Cylinder Guard 8 4 5GN.0608 Bolt 9 4 F.06 Washer Cover Weldment 5G.05 Bolt 4E.05 Lock Washer 3 4 C.088 Bolt 4 4 4E.0 Lock Washer

4 CLAMP ASSEMBLY- Drawing reference

5 Drawing reference 64.3 ARM GROUP ASSEMBLY # QTY PART # DESCRIPTION 7 Right Hand Arm Weldment 74 Left Hand Arm Weldment 3 09 Contact Pad (Lower) Retaining Nut 5 6 Right Hand Tip Plate 6 8 Left Hand Tip Plate 7 0 C.080 Bolt 8 0 C.08 Bolt Spring Washer Tip Plate Upper 0 Contact Pad (Upper)

6 Drawing reference 8. FLOATING PAD ASSEMBLY- # QTY PART # DESCRIPTION Air Tank Valve 9 95 Hose Clamp Hose 4 96 Pressure Gauge Elbow Fitting 6 9 Branch Tee Hose 8 93 Run Tee Hose Hose 90.0 Hose Hose 3 99 Hose Clip 4 5G.056 Bolt Bladder Hose Hose Hose 9 4 9G.04 Bolt 0 47 Clamp Bar Hose Clamp 8 5GN.0508 Bolt Cover Hose Hose Guide 5 5G.05 Bolt Direction Valve Assembly -Ref Pipe Elbow 8 50 Spring Gauge Stainless Wire Tie 30 3 Hose Clamp 3 5G.0608 Bolt Clamp Valve 93 See Hydraulic Assembly C C3 C4 Bellows Cylinder Air Bleed Bladders Air Bleed 3 Fill Valve 085 Valve Assembly High Pressure Hydraulic Circuit 5 Low Pressure Hydraulic (Water) Slave/Force Sense Circuit

7 Drawing reference 8. FLOATING PAD ASSEMBLY

8 Drawing reference 8. FLOATING PAD ASSEMBLY Note: Use two 9 gauge stainless steel wire ties (878) at each bladder connection. Twist to tighten and clip to reduce ends. 7

9 Drawing reference 9 HYDRAULIC ASSEMBLY- # QTY PART # DESCRIPTION 93 Clamp Valve 5G.054 Bolt Straight Thread Adapter Hose Directional Valve Assembly Swivel Union Tee Fitting Adapter Fitting Pipe to Swivel 8 3 In-Line Check Valve Adapter Fitting JIC to Pipe Hose O-Ring Tee Branch Fitting Swivel Fitting Hose Hose O-Ring Elbow Fitting Hose Hose Restrictor Fitting Lock Washer 0 5G.06 Bolt 5G.0608 Bolt MCD Bar Flat O-Ring Straight Restrictor Fitting 8 SS 3 SS 8

10 Drawing reference 9 HYDRAULIC ASSEMBLY- Maximum Clamp Force Control Open Force Control Clamp Open/Close 4 Clamp Force Adjustment Side Shift Force Control See End View SS/SS W W Tack in place to lock valve assembly. 9

11 Drawing reference 74. CYLINDER ASSEMBLY Part # R E S NET STROKE # QTY PART # DESCRIPTION 75. Tube Weldment 77. Rod 3 48 Seal Kit (Items 4-0) Poly-Pak "B" Wear Ring Rod Seal Rod Wiper O-Ring Back-Up Ring O-Ring 7D.0 Nut Self Locking Lock Wire Piston Gland Washer Cylinder R=Retracted Length E=Extended Length S=Basic Stroke Cylinder Service Prior to assembly lubricate seals, cylinder bore and rod with STP. Inspect all parts for scratches, nicks and gouges - replace all damaged components. Inspect cylinder bore and rod for scoring - replaced if scored. Avoid damage to seal grooves - use a dull screwdriver for seal removal. Torque piston nut to 0 FT/LBS. (5.3kg-m). 0

12 CLAMP ADJUSTMENTS CLAMP FORCE CHECK/ADJUSTMENT. Check water pressure. If out of operating range fill with LORON hand pump # 909. NOTE: Use pure Propylene Glycol Antifreeze mixed to with water.. Check the clamp force. CLAMP CONTROL VALVE ADJUSTMENT NOTE: When looking at the clamp control valve from the front of the clamp, the clevis pin should be directly in front of the shut off valve stem, or slightly to the left, when the clamp will not close. To check the pin position, turn the force control screw in until the clamp just starts to move, at which point the clevis pin should be directly in front of the valve stem. Air Bleed OPEN FORCE CHECK/ADJUSTMENT Open the arms against a force fixture and adjust for desired maximum force. SIDE SHIFT FORCE ADJUSTMENT. Clamp on the heaviest load that will be handled.. Adjust the side shift force down until the arms stop. 3. Turn the adjusting screw one turn in. Clamp Control Valve Fill Valve Water Pressure Gauge Air Bleed

13 CONTROL VALVE Drawing reference 93 (A) 67 Pressure Reduce/Relief Valve Torque 5-0 FT/LBS Seal Kit 065 (B) 887 Flow Divider Torque 0- FT/LBS Seal Kit 047 I B Facing Truck E (H)(G) 406. & (F) 406. Relief Valve Torque 0-5 FT/LBS Seal Kit 064 C D Facing Clamp A H F G (C)(D)(E) 44 Check Valve Torque FT/LBS Seal Kit 059 HYDRAULIC SCHEMATIC C C C3 C4 NOTE: Lubricate threads & seals prior to assembly. #6 #6 #6 #6 #6 SS G QTY PART # DESCRIPTION #6 SS 67 Pressure Reducer Valve E D C 0383 Flow Divider I F 406. Relief Cartridge 406. Relief Cartridge H B ORIFICE 6 " NPT Orifice Plug A 3 44 Check Valve #6 #6

14 Drawing reference 085. CLAMP FORCE CONTROL VALVE # QTY PART # DESCRIPTION G.0844 Bolt 09 Mounting Plate Weldment Directional Valve 4 4E.04 Lock Washer 5 7D.08 Jam Nut Wheel 7 09 Air Spring 8 C.044 Bolt 9 7D.0 Hex Nut 0 38 Wheel Housing 097 Spring 098 Spring Tension Cap 3 57 Spring Cap Clevis Pin Cotter Pin Nylon Washer 7 5G.0408 Set Screw Washer Nylon Washer See Note Pg Reference 89 see floating pads assembly

15 Drawing reference 76 NARROW RANGE CONTROL VALVE # QTY PART # DESCRIPTION Hose Adapter Fitting Relief Valve O-Ring Adapter Fitting Modified Valve Body Swivel Nut Elbow O-Ring Elbow Fitting Spring Collar 0 7D.04 Nylock Nut C.046 Bolt 760 Direction Valve Cartridge Connector Fitting Swivel Nut Tee Fitting 5 5G.04 Bolt Actuator Arm Straight Thread Adapter Straight Thread Adapter 4 Stop Bar 4E.05 Lock Washer 3 5G.0508 Bolt Angle 5 5G.0408 Bolt Hex Plug Fitting Cam Bar 8 5G.04 Bolt 8 7 Detail N N 4 5 Front View 4

16 Drawing reference 76 NARROW RANGE CONTROL VALVE M M Back View View M-M 5

17 ARM SLIDE & SHIM REPLACEMENT. To replace the slides, the arms need to be in the fully open position. Release system pressure prior to removing the arms by turning the truck off and working the side shift and clamp function controls several times.. Support the arm with an overhead crane or lift truck. Be sure to secure the chain or sling in a manner that prevents the arm from falling out of the chain or sling when hanging free of the clamp. 3. Remove the cotter pin, slotted nut and spherical bearing from the end of the clamp cylinder rod. Keeping hands and feet clear, and carefully slide the clamp arm off of the clamp frame. 4. Inspect slides and slide buttons for wear. Slides may be rotated end-to-end and reused if excessively worn on the outer end only. Extra shims may be used to tighten operating clearance on slightly worn slides. Replace any slides worn to less than.06" (.5mm) thick or any slide that is deeply scored or broken. Block: For L0 Clamp Models " x " x 3" Long (50.8mm x 50.8mm x 76mm) For L35 Clamp Models.5" x.5" x 3" Long (57.mm x 57.mm x 76mm) Clamp Arm 5. To aid in replacing the slides a block may be fashioned of wood or another convenient material to the dimensions shown above. The block is inserted to the end of the arm to hold the slides, shims, and buttons in position while the arm is inserted over the arm bars on the clamp frame. The block is expelled out the opposite end of the arm as the arm is pushed onto the frame. Prior to installing the arm the block may be used to determine the number of shims to place under the slides. Adjust the clearance between the slides and the block to provide approximately.06" (.5mm) running clearance between the slides and arm when installed. 6. Keeping hands and feet clear, carefully slide the clamp arm onto the clamp frame. Be sure the arm moves freely without excessive binding. If the arm is to loose or too tight add or remove shims as required. 7. Install the spherical bearing, slotted nut and cotter pin onto the end of the clamp cylinder rod. Be sure to leave.03"-.06" (.7mm to.5mm) clearance to allow the cylinder to "float" on its mountings. 6 Clamp Frame Arm Bar

18 TROUBLE SHOOTING GUIDE LOADS SLIPPING OR DROPPING POSSIBLE CAUSES SOLUTION. Clamp force set too low.. Internal leakage in cylinder. 3. Load too heavy for the clamp capacity. 4. Load may not by stacked correctly or may need to be unitized. 5. Bent arms or contact pads. 6. Damaged / leaking hydraulic hose. Adjust clamp force.. Replace cylinder seals. If tube, pistons or rod is scored replace with new parts. 3. Consult factory. 4. Restack or unitize load (shrink wrap). 5. Consult factory. 6. Replace damaged hose. POSSIBLE CAUSES CRUSHING LOADS SOLUTION. Clamp force set too high.. Bent arms or contact pads. 3. Leak in the bladder system.. Adjust clamp force.. Consult factory. 3. Check for leaks and repairs. ARM CHATTERING OR ERRATIC MOVEMENT POSSIBLE CAUSES SOLUTION. Bent clamp arms.. Nylon slides sticking. Note: Sticking slides can cause inconsistent force measurements. 3. Nylon slides worn, broken or missing.. Consult factory.. Clean slides if necessary, the slides are self lubricating. 3. Replace damaged slides, shims, and retaining buttons. 7