229603_70F Clamp Service Manual
Contents
1. Order As Shown 1c16 037 eps 229603 23 S ERVICE 52 Arms 5 2 1 Arm Assembly Removal and Installation The following procedures can be performed with the attachment mounted on the truck 1 Position the arms to frame width Lower the clamp to position the forks or arms 1 2 in 13 mm above the floor 2 Remove the cylinder rod nut on the arm to be removed Extend the cylinder rod fully or till the arm is clearly outside the frame width 3 Retract the cylinder rod fully from the anchor bracket 1 mm Clearance 1 2 in 13 mm Above Floor 1c16 056 eps 5 4 Attach an overhead hoist and chain to the arm assembly Position the chain clear of the arm bearing surfaces CAUTION Use a second chain to stabilise the arm if required WARNING Make sure your overhead hoist has a rated lifting capacity of at least 2000 Ibs 900 kg 5 Slide the arm assembly out of the frame 6 For reassemble reverse the above procedures 7 Tighten the nylock nut up fully then back off the nut 1 4 turn 1 mm clearance Prevent the rod turning by using a wrench on the rod end wrench flats 24 229603 E ERVICE 9524 Arm Bearing Removal and Installation 1 Remove the arm assemblies from the attachment as described in Section see page 20 Using a 10 mm diameter punch Insert the punch in the holes located in the front of the arm carri2. 2 Screw Out anti clockwise increase flow speeds up arm Screw in clockwise decrease flow slows arm down l Ic16 019 eps 10 229603 NSTALLATION 1 1 Clamp Cycle function e With no load cycle each Clamp function Several times 9 Check for operation in accordance with ITA ISO standards 9 Lift a maximum load check for smooth arm movement e Check for leaks at fittings valve manifold and cylinders WARNING Make sure all personnel are clear of the Clamp during testing SIDESHIFTING RIGHT A Release Arms B Clamp Arms C Sideshift Right NON SIDESHIFTING D Not Used SIDESHIFTING LEFT A Release Arms yi A Release Arms B Clamp Arms EN ENS AAA B Clamp Arms C Not Used So A C Not Used D Not Used D Sideshift Left R Auxiliary Valve Functions Tilt fi Hoist down ilt forwarg ac fatale KETA Hoist up Tilt back 229603 11 P ERIODIC MAINTENANCE 31 100 Hour Maintenance Every time the lift truck is serviced or every 100 hours of truck operation whichever comes first complete the following maintenance procedures e Inspect the cylinder anchor nuts for correct hold e Apply wheel bearing grease to the spherical portion of the cylinder anchor nuts e Arm bearing life can be extended with periodic inspection Inspect T section for
3. 5 1 Clamp Removal 1 Extend the arms to outside the width of the frame WARNING Before removing any hoses relieve pressure in the hydraulic system Turn the truck off then open the truck auxiliary control valve s several times in both directions 2 Disconnect and plug the hoses to the attachment Tag the hoses for reassembly 3 Disconnect the Lower Hooks Bolt On Type Remove the lower mounting hooks For reassembly tighten the capscrews to a torque of Class Mounting 105 115 ft Ibs 140 155 N m Quick Change Type Pull out the retaining pin slide the hook down and reinstall the pin in the lower hole For reassembly slide the hook up and install the pin in the top hole 4 Lower the clamp onto a pallet Tilt the mast forward and lower the carriage to disengage the upper hooks NOTE Attachments with load arms other than forks Do not require additional stabilizing weight 5 For installation reverse the above procedures or consult the Installation Instructions refer to section Section 2 QUICK CHANGE LOWER HOOKS Guide y qd002 eps ET Left Hook Locking Pin Sideshift Left Sideshift Right Clamp Open As seen from drivers seat lc16 055 eps BOLT ON LOWER HOOKS C pep ees OT 588 Remove Lower Hooks in
4. 3 Remove the cartridges from the valve body Ki 4 Remove the remaining plugs and fittings i 5 O rings and back up rings from the UNE es 6 Clean all parts with kerosene or cleaning solvent Back Up Rings 3 7 For reassembly reverse the above procedures except as follows The cartridge valve back up rings and O rings must be installed as shown to avoid seal damage during reassembly e Lubricate cartridges and seals with petroleum jelly prior to reassembly 1c16 057 eps q Q q 100 CO 26 229603 E ERVICE 5 3 2 Check Valve Service With Regeneration 2500 3200 kg Clamps IMPORTANT Service the Check Valve in a clean work area 1 2 3 4 5 6 7 Remove the valve from the clamp Remove the special fitting Remove the cartridges from the valve body Remove the remaining plugs and fittings Remove the O rings and back up rings from the cartridges Clean all parts with kerosene or cleaning solvent For reassembly reverse the above procedures except as follows The cartridge valve back up rings and O rings must be installed as shown to avoid seal damage during reassembly Lubricate cartridges and seals with petroleum jelly prior to reassembly Q O rings 4 Back up rings 5 O rings 2 Sof OOk ee Back up rings 2 Q 229603 27 ERVICE 5 3
5. ISO Maximum 15 00 in 381 0 mm 18 74 in 476 0 mm 23 50 in 597 0 mm box02 eps 6 1 3 Auxilliary Valve Functions Tilt Forward ht Release Sideshift Hoist Down Left bees ess GAO082 eps Hoist Up Sideshift Right Tilt Back J Clamp GAO080 ill HOSES AND FITTINGS All supply hoses must be at least No 6 minimum Recommended No 9 All fittings must have an orifice size of 9 32 in 7 mm minimum box03 eps 229603 31 S PECIFICATIONS 6 1 4 Torque Values 32 Fastener torque values for the Series 4 Clamps are shown in the table below in both U S and Metric units All torque values are also called out in each specific Service procedure section throughout the Manual REF Description Size ft lbs Nm 1 Top mounting Hook M 16 242 330 e M 20 477 650 2 Centering Bar M 12 75 100 3 Valve Mounting Bolts M 8 15 20 4 Lower mounting Bolts M 16 195 285 e M 20 235 320 e 5 Cylinder Nuts Rod Tighten then loosen 1 4 turn 6 Clinder Nuts Base Tighten then loosen 1 4 turn e Use Locktite 242 blue 1 mm 1c16 073 eps 229603 Do you have questions you need answered right now Call your nearest Cascade Service Department
6. connect a 3500 psi 240 bar pressure gauge to the test port on the main valve or install a gauge and T fitting into line as per diagram if NO TEST PORT is available 3 Start the truck Hold the clamp control handle in the clamp position for a few seconds 4 Return the handle to neutral Watch the gauge pressure reading e Ifthe pressure drops more than 150 psi 10 bar initially and additional drop exceeds 25 psi 2 bar per minute the sideshift left cartridge is faulty and requires service e Ifthe pressure does not drop more than 150 psi 10 bar initially and additional drop does not exceed 25 psi 2 bar per minute the second cylinder is faulty WITH TEST PORT 1600 Kg clamps 1c16 067 1 eps It is recommended to perform a similar test for the second cylinder before servicing Cylinder Pressure Test NOTEST PORT 1 Connect one of the hydraulic lines to its cylinder The other line must remain plugged 2 Insert gauge into line as shown 3 Start the truck Hold the clamp control handle in the clamp position for a few seconds 4 Return the handle to neutral Watch the gauge pressure reading e If the pressure drops more than 150 psi 10 bar initially and additional drop exceeds 25 psi 2 bar per minute the sideshift left cartridge is faulty and requires service e If the pressure does not drop more than 150 psi 10 bar initially and additional drop does not exceed 25psi 2 bar
7. in the table Tools Required Metric In addition to a normal selection of hand tools you will need e A flow meter capable of measuring hydraulic flow to 20 GPM 75 L min The parts shown are included in Cascade Flow Meter Kit Part No 671477 e Apressure gauge capable of measuring pressure to 2500 psi 175 bar The parts shown are included in Cascade Pressure Gauge Kit Part No 671212 e Assorted fittings and a No 6 hose as shown to adapt the gauge and flow meter to the components being tested Hydraulic Specifications 1600 Kg Pressure Maximum ane 0 Recommended 140 bar 2 GPM Flow Minium pue Recommended GEI 18 GPM Maximum 2 49L min Supply Hose and Fitting Size bod pru Minimum Orifice Size No 8 Clamp 13 22 in 10mm Flow less than minimum will result unequal arm move ment e Flow greater than maximum can result in excessive heating reduced system performance and short hydraulic system life Hydraulic Oil Cascade attachments are compatible with SAE 10W petroleum base oil per Mill Spec MIL 0 5606 or MIL 0 2104B Use of synthetic or aqueous base hydraulic oil is not recommended Contact Cascade if fire resistant hydraulic oil must be used Flow Meter Kit 671477 2 No 8 12 JIC O Ring Flow Meter Sap bee GA0013 ill 2 No 6 8 JIC Reducer Pressure Gauge Kit 671212 Pressure
8. m a pes 1c16 037 eps e NSTALLATION r Connect Hoses as shown in Step 3 Q Q lc16 045 eps lc16 044 eps Install solenoid control knob 8 Solenoid equipped units Button toward Ns driver Adapter Truck control valve handle CL0240 eps Install wiring Solenoid equipped units 7 5 Amp Fuse ions S CL0257 eps CLO258 eps User supplied wire Solenoid Coil 229603 9 f Nstaitarion 1 0 Prior to Operation NOTE Some 70F clamps utilize a regenerative hydraulic circuit in the arm opening mode In this case the arms will open at a faster speed than when closing Check for equal arm travel If the travel is unequal the restrictor cartridges can be adjusted as follows Plunger A Loosen the jam nuts on the restrictor cartridges Screw in the plungers until they bottom out Then screw out each plunger three full turns B Activate the arms to the fully open position C Activate the arms to close until one arm bottoms out Measure the amount of stroke remaining in the opposite arm Jam Nut D if the unequal closing movement exceeds 50 mm 2 in screw the plunger in 1 2 turn on the cylinder that bottomed first E Repeat steps b through d until unequal closing movement is less than 2 in Arm Speed Adjustment Slow Arm Fast Arm
9. 592 651 2500 Fax 86 592 651 2571 Sunstream Industries Pte Ltd 18 Tuas South Street 5 Singapore 637796 Tel 65 6795 7555 Fax 465 6863 1368 07 2001 Cascade India Material Handling Private Limited No 34 Global Trade Centre 1 1 Rambaugh Colony Lal Bahadur Shastri Road Navi Peth Pune 411 030 Maharashtra India Phone 91 020 2432 5490 Fax 91 020 2433 0881 Part Number 229603
10. Cof G ATTACHMENT COMBINATION MAY BE LESS THAN ATTACHMENT CAPACITY CAPACITY AT LOAD CENTRE REFER TO TRUCK CAPACITY PLATE 229603 3 2 1 NSTALLATION Truck System Requirements Truck Relief Valve Setting 2300 psi 160 bar maximum 2000 psi 140 bar recommended Truck Flow Volume Capacity Min Recommended Max O 3200 Lbs 5 2 GPM 10 GPM 13 GPM 1600 Kg 19 L min 28 L min 49 L min 5500 Lbs 5 2 GPM 10 GPM 13 GPM 2500 Kg 19 L min 28 L min 49 L min 7000 Lbs 7 8 GPM 14 GPM 17 GPM 3200 Kg 29 L min 52 L min 63 L min Hydraulic Oil Cascade attachments are compatible with SAE 10W petroleum base oil per Mil Spec Mil 0 5606 or MIL 0 2104B Use of synthetic or aqueous base hydraulic oil is not recommended Contact cascade if fire resistant hydraulic oil must be used Flow less than minimum will result in equal arm movement reduce systen performance and short hydraulic system life Low greater than maximum can result in excessive heating box01 Minimum Carriage Mount Dimension A ITA ISO Maximum Class Il 14 96 in 380 0mm 15 00 in 381 0 mm Class Ill 18 68 in 474 5mm 18 74 in 476 0 mm Class IV 14 96 in 595 5mm 23 50 in 597 0 mm box02 eps Auxiliary Valve Functions Check for compliance with ANSI standards Tilt Forward Release Sideshift Hoist Down Left ee es 844 Hoist Up Sideshift Tilt
11. Right Clamp Back 4 229603 WARNING Rated capacity of the truck attachment combination is a responsibility of the original truck manufacturer and may be less than that shown on the attachment nameplate Consult the truck nameplate GA0080 ill Carriage Clean carriage bars and inspect for damaged notches box03 eps D Hydraulic Oil Cascade attachments are compatible with SAE 10W petroleum base oil per Mil Spec Mil 0 5606 or MIL 0 2104B Use of synthetic or aqueous base hydraulic oil is not recommended Contact cascade if fire resistant hydraulic oil must be used 2 Flow less than minimum will result in equal arm movement 8 Low greater than maximum can result in excessive heating reduce systen performance and short hydraulic system life NSTALLATION 22 Recommended Hydraulic Supply Options 70F Clamps provide the best performance with one of the hydraulic supply arrangements shown below Refer to Cascade Hose and Cable Reel Selection Guide Part No 212119 to select the correct hose reel for the mast and truck The hose and fitting requirements are e All hoses for clamp functions should be at least No 8 hose with 13 32 in 10mm minimum I D e All hoses for sideshift functions should be at least No 6 hose with 9 32 in 7mm minimum 1 D e All fittings should have a minimum internal diameter of 9 32in 7mm Non Sideshift
12. any damage or sharp edges caused through impacting or foreign matter caught in the C sections Oylinder u Centering Top e Check for worn damaged or leaking hoses Nuts Hose Fittings Bracket Hook e Check arm speed and uniform arm travel clamps fitted with regenerative valves should operate to the following speeds if clamp is plumbed as per the chart in section 2 2 OPEN 5 seconds CLOSED 6 7 seconds NOTE these values may vary depending on frame width of clamp A pp 32 500 Hour Maintenance 1 it cm After each 500 hours of lift truck operation in addition to the 100 hour maintenance procedures perform the WARNING After completing any service procedure always test the Clamp through five complete cycles First test the Clamp empty then test with a load to make sure the Clamp operates correctly before returning it to the job following e Tighten the top and lower hook capscrews Use the torque specifications shown in Section 6 1 4 IPIS ddp e Check for wear and tear to bolt on or weld on accessories ie bale arm forks repair or replace as required Lower Lower Hook Hook 33 1000 Hour Maintenance In addition to the 100 hour and 500 hour maintenance Arm Casting Arm Bearings procedures perform the following e Inspect the arm bearings If the bearings are worn in any area to a thickness l
13. per minute the second cylinder is faulty It is recommended to perform a similar test for the second cylinder before servicing NO TEST PORT 2500 and 3200 Kg clamps install a gauge as shown install a T fitting into line as shown 1c16 068 1 eps IMPORTANT Before removing pressure gauge with truck turned off momentarily actuate clamp open circuit This will relieve pressure trapped by check valves in clamp circuit 20 229603 _ T ROUBLE SHOOTING 4 6 4 6 1 4 6 2 Check Valve Check Valve Test WITH TEST PORT 1 Disconnect the hydraulic lines at the rod end of both cylinders Cap the ports and plug the lines 2 Position the arms mid stroke Turn the truck off and connect a 3500 psi 240 bar pressure gauge to the test port on the main valve or install a gauge and T fitting into line as per diagram if NO TEST PORT is available 3 Start the truck Hold the clamp control handle in the clamp position for a few seconds 4 Return the handle to neutral Watch the gauge pressure reading e If the pressure drops more than 150 psi 10 bar initially and additional drop exceeds 25 psi 2 bar per minute the check valve is faulty and requires service e If the pressure does not drop more than 150 psi 10 bar initially and additional drop does not exceed 25 psi 2 bar per minute one or both cylinders require service Proceed with the troubleshooting check list to isolate the faulty compon
14. 0 6 and No 8 Gauge No 6 6 Hose JIC Swivel Tee X A GAO0014 ill 7 No 4 6 Pipe JIC No 6 8 JIC No 4 No 6 Reducer and No 8 JIC O Ring Diagnostic Quick Coupler No 4 and No 6 Male Straight or JIC Thread Wu O ring Coupler N No 6 Female Straight Thread O ring Coupler ACO127 ill 229603 13 lll ouscesuoorme Clamp Circuit one Get All The facts Clamp drops load after it has been picked up Befo re You beg l n el ak not carry load up to its rated Working On The Clamp Clamp arms have uneven travel It is important that you gather all the facts regarding Clamp arms t slowly the problem before you begin service procedures The P dra best way is to talk with the operator Ask for a complete Clamp arms will not move description of the malfunction The following guidelines will help you decide where to be in your troubleshooting To correct these problems see Sections 4 3 1 and procedures 2 Sideshift Circuit e Clamp drops the load when sideshifting e Clamp sideshifts left and right at different speeds To correct these problems see Sections 4 4 1 and Valve Identification amp Test Port Location Non Sideshifting 1600 Kg Clamps Sideshifting 2500 3200 Kg Clamps valve ID eps 2 Clamp Hoist Tilt Sideshift Before removing any hydraulic lines r
15. 039 eps Sideshift Right Sideshifting Double Internal Hose Reeving Sideshift Left Sideshift Right Clamp Sideshift Left Open Flush hydraulic supply hoses 4 A Install hoses using union fittings B Operate auxiliary valves for 30 sec in both directions C Remove union fittings at A OO Ic16 040 eps Sideshifting with Hose Reel 229603 7 p NsTALLaTion Mount Clamp on truck carriage A Centre the lift truck behind the attachment B Tilt the mast forward C Engage the mounting hook tab with the closest upper carriage bar notch and raise the truck carriage into position behind the attachment D Lift attachment 2in 5cm off the pallet ITA Class Il 0 32 0 36 in 8 9 m ITA Class II 0 60 0 66 in 15 17 mm 80 i 1c16 043 eps Slide hook up to engage bar install pin in locked position upper hole QUICK CHANGE TYPE Lower Carriage Bar 6 Install and engage lower hooks Inspect hooks for excessive clearance Reverse guides to reduce clearance See Step 2 e 5 36i O 5 mm Max 8 229603 qd003 eps Tighten Capscrews Class Mounting 165 ft Ibs 225 Nm e So XO OS
16. 2 Check for loose electrical connections at the truck ignition switch control knob button solenoid coil terminals and diode 3 Remove the diode from the solenoid coil terminale 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 be connected to 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 depressed e If there is no current to the solenoid troubleshoot the electrical circuit for shorts e If there is current to the solenoid test for coil continuity 5 Test for coil continuity by placing an ohmmeter test lead on each solenoid coil terminal ohmmeter on Rx1scale e If there is an ohmmeter reading the coil is good e If the coil is good but the solenoid does not click when the control knob button is depressed the solenoid cartridge may be jammed Refer to Section 5 6 e If there is no ohmmeter reading the coil is defective and should be replaced Refer to Section 5 6 Install wiring Solenoid equipped units Diode Solenoid Coil Knob is 3 Amp Fuse Button RA g T serv027 eps m oO User supplied wire Solenoid Coil 22 229603
17. 3 Removing Regeneration IMPORTANT Service the Valve in a clean work area This process can be done with the valve on the clamp 1 Remove hose from clamp close cl fitting Remove special long fitting from valve 2 3 Remove the spool fitting It may be necessary to power the open op line to force out spool 4 5 Insert Blanking Fitting into valve body Note open end must face out Replace special long fittings Reconnect hose line e Open Close times can be increased by up to 2 3 seconds when regeneration is removed NOTE Open end must be facing out 28 229603 Before removing any hydraulic lines relieve pressure in the hydraulic system Turn the truck off then open the truck auxiliary control valves several times in both directions S 5 4 5 4 1 5 4 2 ERVICE Cylinders Cylinder Service The following procedures can be performed with the attachment mounted on the truck Cylinder Removal 1 Extend or remove the arms outside the width of the frame Remove the nylock nuts retaining the cylinder rods to the arm lugs Retract the cylinder rods until they come out of engagement with the arm lugs Relieve hydraulic system pressure actuate all auxillary levers several times to relieve pressure in the lines this is not necessary on hoist lever Disconnect the hyraulic lines from the cylinder ports Plug the lines and cap the cylinder ports Remove t
18. Attachment Valve Truck Auxiliary Valve H CLAMP ARMS RELEASE ARMS Pressure Return a 229603 17 4 3 4 3 1 4 3 2 ROUBLE SHOOTING Clamp Function e There are five potential problems that could affect the CLAMP function e Incorrect load handling Refer to the Operator s Guide for suggested procedures Incorrect hydraulic pressure or flow from the lift truck External leaks Defective solenoid coil or valve if equipped e Worn defective cartridge valves or cylinder seals Supply Circuit Test 1 Check the truck pressure at the carriage hose terminal The pressure must be within 100 psi 7 bar of specified truck pressure TRUCK PRESSURE MUST NOT EXCEED 2300 PSI 160 Bar See section 6 1 for recommended operating pressure 2 Check the flow volume at the hose terminal See Section 6 1 for the recommended flow volumes 3 Start the truck Close the arms fully Holding the lever in the CLAMP position for a few seconds Release the lever and check for external leaks at fittings hoses and valve Clamp Circuit Test Press the solenoid button if equipped and listen for a click at the solenoid valve If no sound is heard check the fuse wiring and coil see section 4 5 IMPORTANT Solenoid operated valves must be plumbed so that the solenoid is energised during the CLAMP RELEASE function 2 Open and close the arms fully 3 Position the a
19. E S ERVICE MANUAL 70F Clamps Manual Number 229603 Cascade Corporation Cascade is a Registered Trademark of Cascade Corporation C ONTENTS PAGE PAGE INTRODUCTION Section 1 SERVICE Section 5 Introduction 3 Clamp Removal 23 Special Definisions 3 Arms 24 INSTALLATION Section 2 Arm Removal and Installation 24 Truck System Requirements 4 Arm Bearing Removal 25 Clamp Installation 5 Valves 26 Recommended Hydraulic Supply Options 5 Check Valve Service Non Regeneration 26 Installation Proceedure 6 Check Valve Service With Regeneration 27 Adjusting Arm Speed 10 Regeneration Removal 28 Prior to Operation Clamp Functions 11 Cylinders 29 PERIOD MAINTENANCE Section 3 Cylinder Removal 30 100 Hour Mantenance 12 Cylinder Dismantle and Reassembly 32 500 Hour Mantenance 12 SPECIFICATIONS Section 6 1000 Hour Mantenance 12 Hydraulics 31 2000 Hour Mantenance 12 Truck Carriage 31 TROUBLESHOOTING Section 4 Torque Values 32 General Proceedure 13 Truck Requirements 13 Tools Required 13 Troubleshooting Chart 14 Valve Identification amp test Port Location 14 Plumbing 15 Hydraulic Circuit Non Regenerative 16 Hydraulic Circuit Non Regenerative 16 Hosing Diagram 17 Clamp Function 18 Supply Circuit Test 18 Clamp Circuit Test 18 Sideshift Function 19 Supply Circuit Test 19 Sideshift Circuit Test 19 Cylinders 20 Cylinder Pressure
20. Test With Test Port 20 Cylinder Pressure Test NoTest Port 20 Check Valve 21 Check Valve With Test Port 21 Check Valve No Test Port 21 Electrical Circuit 22 2 229603 1 1 1 2 NTRODUCTION Introduction This manual provides instructions for installing a Cascade 70F Clamps Follow the suggested installation proceddures for best results If you have any questions or need more informatiuon contact your near est Cascade Service Department see back cover Read the WARNING Statements placed throughout this manual to emphasize safety during clamp installation IMPORTANT Field alterations impair performance or capability and could result in loss of warranty Consult Cascade for any required modifications 1c16 053 np eps Special Instruction Definitions CAUTION A statement preceded by CAUTION is information that should be acted upon to prevent Machine Damage 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 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 Nameplate MODEL Ne o 7OF CFS TC PART No cascad Cascade Mate SERIAL No C4 MAS HOR Cof G Phone 03 9357 0899 Facsimile 03 9357 0186 fT VERT
21. Visit us online at www cascorp com AMERICAS Cascade Corporation U S Headquarters 2201 NE 201st Fairview OR 97024 9718 Tel 800 CASCADE 227 2233 Fax 888 329 8207 EUROPE AFRICA Cascade Italia S R L European Headquarters Via Dell Artigianato 1 37050 Vago di Lavagno VR Italy Tel 39 045 89891 11 Fax 39 045 8989160 ASIA PACIFIC Cascade Japan Ltd 2 23 2 Chome Kukuchi Nishimachi Amagasaki Hyogo Japan 661 0978 Tel 81 6 6420 9771 Fax 81 6 6420 9777 Cascade Australia Pty Ltd 1445 Ipswich Road Rocklea QLD 4107 Australia Tel 1 800 227 223 Fax 61 7 3373 7333 1 1 C73 CTM Cascade Corporation 2001 Cascade Canada Inc 5570 Timberlea Blvd Mississauga Ontario Canada LAW 4M6 Tel 905 629 7777 Fax 905 629 7785 Cascade Africa Pty Ltd PO Box 625 Isando 1600 60A Steel Road Sparton Kempton Park South Africa Tel 27 11 975 9240 Fax 27 11 394 1147 Cascade Korea 121B 9L Namdong Ind Complex 691 8 Gojan Dong Namdong Ku Inchon Korea Tel 82 32 821 2051 Fax 82 32 821 2055 Cascade New Zealand 15 Ra Ora Drive East Tamaki Auckland New Zealand Tel 64 9 273 9136 Fax 64 9 273 9137 Cascade do Brasil Rua Jo o Guerra 134 Macuco Santos SP Brasil 11015 130 Tel 55 13 2105 8800 Fax 55 13 2105 8899 Cascade Xiamen No 668 Yangguang Rd Xinyang Industrial Zone Haicang Xiamen City Fujian Province P R China 361026 Tel 86
22. elieve pressure in the hydraulic system Turn the truck off then open the truck auxiliary control valves several times in both directions 14 229603 2 ROUBLESHOOTING 42 Plumbing 421 Hydraulic Circuit Sideshifting Clamps Non Regeneration Rear Mount Cylinders 2 Attachment Valve Sideshift Check Valves 2 SSR OP CL 2 Port Hose Reels 2 or 1 L Internal Hose Reeving 1 1 Truck Truck Auxiliary Q NU Auxiliary Valve X NI Valve Sideshift Clamp Truck Pump e Truck Tank 1c16 058 eps 229603 15 E T ROUBLESHOOTING 43 Plumbing 431 Hydraulic Circuit Sideshifting Clamps With Regeneration Rear Mount Cylinders 2 Sideshift Q C C o Check u os Attachment Valve Valve 2 Clamp Check Valve Relief S Shift Regeneration Directional Valve Relief 1 e Clamp SL S SSR eb v3 r 1 l be LI JI N S 2 Port Hose Reels 2 or Internal Reeving 0 0 e T 4 l 7 M Q Q Truck Auxiliary Truck v Valve Auxiliary Clamp Valve Sideshift Truck Relief Truck Tank hyds T eps lt Truck Pump 16 229603 75 ROUBLESHOOTING 421 Sideshifting Clamps Hosing Diagram
23. ent Check Valve Test NOTEST PORT 1 Disconnect the hydraulic lines at the rod end of both cylinders Cap the ports and plug the lines 2 Insert guage into line as shown Start the truck Hold the clamp control handle in the clamp position for a few seconds 4 Return the handle to neutral Watch the gauge pressure reading e If the pressure drops more than 150 psi 10 bar initially and additional drop exceeds 25 psi 2 bar per minute the check valve is faulty and requires service If the pressure does not drop more than 150 psi 10 bar initially and additional drop does not exceed 25 psi 2 bar per minute one or both cylinders require service Proceed with the troubleshooting check list to isolate the faulty component IMPORTANT Before removing pressure gauge with truck turned off momentarily actuate clamp open circuit This will relieve pressure trapped by check valves in clamp 2 Test Port ex Cap Oylinder Port Cap Hose Cap Oylinder Port Cap Hose 1 WITH TEST PORT 1600 Kg clamps 1c16 068 eps Cap Oylinder Port Cap Hose 2 ap Cylinder Ports and hoseends C 1c16 068 3 eps NO TEST PORT 2500 and 3200 Kg clamps 229603 21 T ROUBLE SHOOTING 47 Electrical Circuit Solenoid equipped Clamps Use the electrical schematic and diagram shown and follow the steps below 1 Check the control knob circuit fuse Replace if necessary
24. ers drive the bearing retainer plugs out of the arm Using a piece of flat stock 50 x 20 mm Drive the one piece bearing out of the arm carrier untill sufficient material is exposed to remove it by hand or with a pair of multi grips To replace bearing Clean the inside of the arm carrier of any contaminants and spay with a light coating of lubricant STP Note the position of the offset bearing retaining holes in the new bearing these must align with the holes in the arm carrier Insert the leading edge of the new bearing into the arm carrier and drive the bearing into place using a piece of board to protect the bearing end Insert the bearing retainer plugs as shown with the plug insertion tool The plug face should be set 1 mm below the inside face of the bearing NOTE If plugs are damaged or worn replace as plugs must be tight in the arm carrier and engage the bearing by at least 4 5 mm For reassemble reverse the above procedure except for the following special instructions for cylinder anchor nuts Bearing Plug Hole Plug 1c16 036 eps Plug Tool Plug must be inserted with chamfer first 229603 25 ERVICE 53 Valves 5 3 1 Check Valve Service Non Regenerative 1600 kg Clamps IMPORTANT Service the Check Valve in a clean area O Rings 3 1 Remove the valve from the clamp 6 7 2 Remove the special fitting
25. ess than 040 in 1 mm they must be replaced See Section 5 2 34 2000 Hour Maintenance After each 2000 hours of lift truck operation in addition to the 100 hour 500 hour and 1000 hour maintenance procedures perform the following procedures e Replace all arm bearings See Section 5 2 Ic16 049 eps e Tighten the frame mounting plate capscrews Use the torque specification shown in Section 6 1 4 Bale Arm 12 229603 E T ROUBLESHOOTING 4 1 4 1 1 4 1 2 General Procedures WARNING Before servicing any hydraulic amp component relieve pressure in the system Turn the truck off and open the truck auxiliary valves several times in both directions A After completing any service procedure always test the function through several cycles First test the attachment empty to bleed air trapped in the system to the truck system Then test the attachment with a load to be sure it operates correctly before returning it to the job Stay clear of the load while testing Do not raise the load more than 3 in 7cm off floor while testing Truck Systems Requirements e The lift truck must supply sufficient hydraulic pressure to handle the heaviest load PRESSURE MUST NOT EXCEED 2300 PSI 160 BAR e Hydraulic flow should fall within the volume range shown in the table e The truck hydraulic system must supply hydraulic oil to the attachment that meets the specification shown
26. he nylock nuts retaining the cylinder to the frame lugs Lift the cylinders away from the clamp frame For reassembly reverse the above procedures except for the following special instructions for the cylinder anchor nuts NOTE The rod end nut MUST not be tight against the arm base lug This looseness allows for cylinder align ment during clamping amp C Hoist Tilt Sideshift N qa0082 1 eps Before removing any hydraulic lines relieve pressure in the hydraulic system Turn the truck off then open the truck auxiliary control valves several times in both directions 1c16 069 eps 229603 29 B ERVICE 543 Cylinder Dismantle and Reassembly 1 Clamp cylinder in a soft jawed vise Clamp at the extreme base end only 2 Remove the retainer by using a pin type spanner wrench DO NOT use a punch as this may cause damage to the retainer nut Remove the rod assembly from the cylinder 4 Clamp the rod assembly on the wrench flats Never clamp directly on the rod sealing surface 5 Remove the nut fastening the piston to the rod Remove the piston 6 Place the piston or gland nut in a soft jawed vise to remove the seals Pry the seals up with a blunt screwdriver Cut the seal to remove them 7 Replace all the seals in order as shown NOTE direction of seals in housing 8 For installation reverse the above proceedure except for the following special instructions e Lubricate all seal
27. ing A or B RH or TH YHINLINE 2 post hose reel group OR C Mast single internal hose reeving group Sideshifting A or B RH or TH YHINLINE 2 post hose reel group OR C Mast single internal hose reeving group 229603 5 mE NSTALLATION 23 Installation Procedure Remove banding B Remove bolt on lower mounting 1 Prepare Attachment hooks if equipped C For clamp which are not self upported by arms Extend the arms and attach slings as shown Set the clamp vertical 1c16 038 eps WARNING Make sure your overhead hoist has a rated capacity of at least 116 097 eps 4000 Ibs 1800 kg pres aee Remove pin and drop hooks into unlocked position B Re install pin in lower hole 2 Unlock Quick Change lower mounting hooks qd001 eps 5 8 in 16mm offset on top pro f vides max clear ance NOTE Guides can be reversed to reduce hook to carriage clearance See lower hook installation Step 6 Left Hook Locking Pin 6 229603 NSTALLATION Prepare hoses A Determine hose lengths required for hydraulic supply configuration of truck WARNING Do not remove the fitting from the valve clamp CL port B Cur hoses to length install end fittings or quick disconnect kits 4 For No 6 hose connection use a 6 8 reducer Sideshift Right Clamp Sideshift Left Open OO Ic16
28. lease 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 2 bar per minute Then the sideshift Left check valve cartridge may be faulty Replace the cartridge If the pressure drop is less Sideshift Right and hold the lever for a few seconds 6 Release the lever and watch the pressure gauge f the pressure drop is more than 150 psi 10 bar initially and additional drop exceeds 25 psi 2 bar per minute Then the Sideshift Right check valve cartridge may be faulty Replace the cartridge f the pressure drop is less the problem is not hydraulic see Section 4 1 3 WARNING Before installing the pres sure gauge relieve pressure in the hydraulic system Turn the truck off then open the truck auxiliary control valves several times in both directions 2 Flow Meter OO 1c16 066 eps WITH TEST PORT 1600 Kg clamps 1c16 067 2 eps gauge as shown Installa T fitting into line as shown c16 068 1 eps 229603 19 E T ROUBLE SHOOTING 4 5 4 5 1 4 5 2 WARNING Before removing any hoses relieve pressure in the hydraulic system Turn the truck off then open the truck auxi Cyl n d e rs iry contol valves several times in both Cylinder Pressure Test wirH TEST PORT 1 With all the lines connected to the cylinders 2 2 Position the arms mid stroke Turn the truck off and
29. rms mid stroke Turn the truck off and connect a 3500 psi 240 bar pressure gauge to the test port on the main valve 4 Start the truck and close the arms fully holding the lever in the clamp position for a few seconds 5 Release the lever and watch the pressure gauge e f the pressure drop is less than 150 psi 10 bar initially and additional drop does not exceed 25 psi 2 bar per minute Then the problem is not hydraulic See section 4 1 3 9 f the pressure drop is more than 150 psi 10 bar initially and additional drop exceeds 25 psi 2 bar per minute Then the clamp check valve cartridge may be faulty Replace the cartridge 6 Close the rams fully and hold the lever in the CLAMP posi tion for a few seconds If the pressure still drops as before the cylinder seals are faulty and must be replaced 18 229603 WARNING Before removing any hoses relieve pressure in the hydraulic system Turn the truck off then open the truck auxiliary control valves several times in both directions 2 Flow Meter QQ 1c16 065 eps 3 Test Gauge VN o o T 4 4 4 4 1 4 4 2 ROUBLE SHOOTING Sideshift Function e There are five potential problems that could affect the SIDESHIFT function e Incorrect load handling Refer to the Operator s Guide for
30. s and O rings with petroleum jelly or STP e When installing the cylinder rod nut tighten to 90 55 125 Nm e When installing the cylinder gland nut tighten to 75 55 100 Nm CAUTION Do not scratch the seal grooves Direction Em of seals cyl204 ep H 30 229603 i cyl205 eps EN S PECIFICATIONS 61 Specifications 6 1 1 Hydraulics 2300 psi 160 bar maximum Truck Flow Volume Truck Relief Valve Setting 2000 psi 140 bar recommended 3200 Kg 29 Limin 52 L min Capacity Min Recommended Max 3200 Lbs 5 2 GPM 10 GPM 13 GPM 1600 Kg 19 L min 28 L min 49 Limin 5500 Lbs 5 2 GPM 10 GPM 13 GPM 2500 Kg 19 L min 28 L min 49 Limin 7000 Lbs 7 8 GPM 14 GPM 17 GPM 63 L min 612 Truck Carriage D Hydraulic Oil Cascade attachments are compatible with SAE 10W petroleum base oil per Mil Spec Mil 0 5606 or MIL 0 2104B Use of synthetic or aqueous base hydraulic oil is not recommended Contact cascade if fire resistant hydraulic oil must be used Q Flow less than minimum will result in equal arm movement Low greater than maximum can result in excessive heating reduce systen performance and short hydraulic system life box01 Minimum perm Class III 18 68in 474 5mm Class IV 14 96 in 595 5mm Class II 14 96 in 380 0mm Carriage Mount Dimension A ITA
31. suggested procedures e Incorrect hydraulic pressure or flow from the lift truck e External leaks e Defective solenoid coil or valve if equipped e Worn defective cartridge valves or cylinder seals Supply Circuit Test Check the truck pressure at the carriage hose terminal The pressure must be within 100 psi 7 bar of specified truck pressure TRUCK PRESSURE MUST NOT EXCEED 2300 PSI 160 Bar See section 6 1 for recommended operating pressure 2 Check the flow volume at the hose terminal See Section 6 1 for the recommended flow volumes 3 Start the truck Close the arms fully Holding the lever in the SIDESHIFT position for a few seconds Release the lever and check for external leaks at fittings hoses and valve Sideshift Circuit Test 1 Press the solenoid button if equipped and listen for a click at the solenoid valve If no sound is heard check the fuse wiring and coil see section 4 5 IMPORTANT Solenoid operated valves must be plumbed so that the solenoid is energised during the CLAMP RELEASE not sideshift function 2 Open and close the arms fully 3 Position the arms mid stroke Turn the truck off and con nect a 3500 psi 240 bar pressure gauge to the test port on the main valve or install a gauge and T fitting into line as per diagram if NO TEST PORT is available 4 Start the truck clamp and raise a load clear of the floor Sideshift Left and hold the lever for a few seconds 5 Re
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