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1. N 0 S Y RC0182 eps 25 Q ERVICE 44 Drive Motor 4 4 1 Drive Motor Removal and Installation 1 Remove the attachment from the lift truck as described in Section 4 1 WARNING Before removing hydraulic lines relieve pressure in the hydraulic 2 Remove the drive group from the attachment as system Turn the truck off and open the described in Section 4 3 1 truck auxiliary control valves several times 3 Remove the fill plug and drain the lubricant from the in both directions drive group 4 Lay the drive group pinion down on two 4 x 4 in 10 x 10 cm wood blocks placed on both sides of the pinion gear A If equipped Adapter plate is on 5 Remove the four capscrews and special lockwashers motors with Cascade part no less then fastening the check valve assembly to the drive motor 608XXXX Keep track of the two O rings between the check valve Drive Motor assembly and drive motor For reassembly tighten the capscrews to 15 ft lbs 20 Nm O Rings Adapter Check Valve 6 Remove the three capscrews fastening the adapter plate to the gearcase housing Tap on the drive motor with a rubber mallet to separate the drive motor adapter plate assembly if equipped from the gearcase housing T If equipped with adapter plate remove the four capscrews fastening adapter plate to the drive motor separate the motor from the adapter plate Fill Plug two locations 8 For reassembly reverse the a
2. zl 7 A i m A Truck Flow Volume Min Recommended Max 38F Clamp 5 GPM 10 GPM 12 GPM 19 L min 38L min 45 L min Rotate 5 GPM 10 GPM 15 GPM 19 L min 38 L min 57 L min 5 GPM 19 L min 10 GPM 38 L min 15 GPM 45F 60F 66F 57 L min 77F 90F 100F 10 GPM 15 GPM 20 GPM 120F 38 L min 57 L min 76 L min 130F 150F 15 GPM 20 GPM 25 GPM 160F 57 L min 76 L min 95 L min Cascade Roll Clamps are compatible with SAE 10W petroleum base hydraulic fluid meeting Mil Spec MIL O 5606 or MIL O 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 Flow less than recommended will result in a rotate soeed less than 2 RPM Flow greater than maximum can result in excessive heating reduced system performance and short hydraulic system life Hoses and Fittings e ROTATE Function Hoses and fittings should be No 8 with 13 32 in 10 mm minimum D e CLAMP Function Hoses and fittings should be No 8 with 13 32 in 10 mm minimum D except for internal reeving arrangements where hoses and fittings may be No 6 minimum with 9 32 in 7 mm minimum I D 56 674512 R7 _ S PECIFICATIONS 5 1 2 Auxiliary Valve Functions Tilt Rotate CCW Forward Swing Exten
3. 2300 psi 12 880 Nm 160 bar 216 000 in lbs 2300 psi 24 405 Nm 160 bar Rated at 15 GPM 56L min flow E Rated at 20 GPM 75L min flow Rated at 24 GPM 91L min flow A High Speed Option 147 000 in lbs 2300 psi 16 610 Nm 160 bar 15 ROUBLESHOOTING T 35 Electrical Circuit Solenoid equipped attachments Use the schematics 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 terminals 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 be connected to the coil and wiring as shown ALL CLAMPS Except 77F swing frame early model 12V 2 4 2 8 Ohm 24V 9 5 11 Ohm 36V 24 28 Ohm 48V 40 46 Ohm Pushbutton 7 5 AMp Pushbutton attached to control lever with heat shrink tubing Fi 77F SWING FRAME EARLY MODEL White 7 5 AMp Pushbutton Fuse L Black 16 Pushbutton attached to control lever with heat shrink tubing 4 Disconnect the electrical leads from the solenoid coil terminals Use a voltmeter to determine if there is voltage at the electrical lead terminals when the control
4. Shuttle Check Valve Adjustment 1 Rotate the attachment to the bilge horizontal position with the short arm down 2 Activate the SWING function and check for smooth extend and retract at equal moderate speeds If attachment moves upward suddenly when SWING EXTEND function is activated adjust cartridge labeled Swing Extend Adjust see illustration Loosen nut and turn adjustment screw counterclockwise CCW to reduce swing speed or clockwise CW to increase swing speed If attachment moves downward suddenly when SWING RETRACT function is activated adjust cartridge labeled Swing Retract Adjust see illustration Loosen nut and turn adjustment screw counterclockwise CCW to reduce swing speed or clockwise CW to increase swing speed Snap Valve Two Piece Ring Seals RC2494 eps Back Up Rings SEQUENCE VALVE CARTRIDGE O Rings RC2502 eps Back Up Rings FLOW DIVIDER CARTRIDGE GA0203 eps Back Up Ring SHUTTLE CHECK VALVE CARTRIDGE O Rings RC0454 eps Back Up Rings RELIEF VALVE CARTRIDGE Revolving Connection SWR Swing Retract Adjust SWE Swing Extend Adjust RCO784 eps NOTE Typical revolving connection front view Clamp rotated to bilge position short arm down 674512 R7 S ERVICE 4 6 8 Split Arm Relief Pressure Adjustment Type 1 Full Arm Travel C
5. 2 bar per minute the cylinder check valve cartridge or piston seals may be faulty Continue troubleshooting e lf both gauge pressures do not drop more 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 3 Position both arms at midstroke to relieve cylinder pressure Remove swap and reinstall the cylinder check valve cartridges Long Arm Cylinders While clamped on a medium to full size roll close the long arm fully Watch the gauge pressure readings Short Arm Cylinders Rotate the Roll Clamp to the 45 degree position Close the short arm fully and hold the handle in the CLAMP position a few seconds to develop full truck system pressure Watch the gauge pressure readings e Ifthe gauge pressure on the cylinder continues to drop more than 150 psi 10 bar initially and additional drop exceeds 25 psi 2 bar per minute the cylinder piston seals are faulty see Section 4 7 e lf the gauge pressure on the cylinder does not drop more than 150 psi 10 bar initially and additional drop does not exceed 25 psi 2 bar per minute the check valve now in the other cylinder is faulty and requires replacement see Section 4 7 4 45F 160F m Long Arm Cylinder Test Port Pressure Gauge 2 D Re ee Arye he w RC2005 eps 38F 674512 R7 _ T BOQUBLESHOOTING 3 3 3 3 3 4 Swing Circuit Test
6. 845 bar Cascade Part No 671212 e Assorted fittings hoses and quick disconnect couplers as required 3 1 3 Troubleshooting Chart 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 Clamp Circuit e Clamp drops roll after it has been picked up e Clamp will not carry rolls to its rated capacity e Clamp arms will not function properly To correct one of these problems see Section 3 3 e Split arms will not clamp rolls equally To correct this problem see Section 4 6 3 or 4 6 4 Rotate Circuit e Clamp will not rotate e Clamp will not rotate rolls up to its rated capacity e Clamp rotates in one direction only To correct one of these problems see Section 3 4 e Clamp will not stop smoothly with 180 degree stop valve or electronic rotational control To correct this problem see Section 4 10 or 4 11 Swing Circuit e Clamp swings slowly or not at all To correct this problem see Section 3 3 3 674512 R7 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 t
7. CAUTION Bushings may be damaged if installed without a proper bushing driver Bushing Driver Dimensions A B Bushing I D Driver O D Bushing Bushing Bushing Bushing 9 D 1 23 in 1 11 in 1 48 in 1 36 in 31 2 mm 28 2 mm 387 6 mm 34 5 mm 1 48 in 1 23 in 1 73 im 1 48 in 37 6 mm 31 2 mm 43 9 mm 37 6 mm 38F 45F 60F 66F 77F 90F 100F and larger Eroin 120 0 1 98 in 1 48 in 43 9 mm 381 2 mm 50 38 mm 37 6 mm 674512 R7 Connector Pin Swing frame Pivot Pins Retainers Spacer RC0324 eps RC0362 eps 45 ERVICE S 4 9 3 Rotation Bearing Assembly Capscrew Torque Inspection 500 Hour Inspection Every 500 hours perform the following inspection 1 Check the accessible baseplate capscrews above the upper mounting hooks for proper torque value as follows tighten each capscrew CW until torque is 10 ft los 14 Nm above torque value listed below Mark each capscrew after checking 38F 100F 75 ft lbs 100 Nm 120F 160F 220 ft lbs 300 Nm e lf any baseplate capscrews rotate are loose or broken go to 2000 hour inspection criteria and replace complete set of baseplate fasteners as described in Section 4 9 4 e f capscrews do not rotate continue with bearing Capscrew inspection in Step 2 2 Check three bearing capscrews for proper torque value as follows Remove the access plug from the back of the baseplate and rotate
8. J gt Closing Free Arm ou ifi i i Adjustable Orifice if equipped a as Relief Valve Flow Divider S Sequence Valve LY a oes oy 4 i al er Shuttle Valve Pre Type 0 8 ee 674512 R7 _ T BOQUBLESHOOTING 3 2 5 Swing Frame Clamp Hydraulic Schematic Long Arm Cylinders CAUTION Outer most hose on 4 port hose reel must connect to OPEN Typical All Cylinders Test Port Check Valve at a i Sr ere Short Arm Cylinders if equipped 3 Q Ea Valves SWE Counterbalance Rotator port on attachment Solenoid Operated Control Valve 77F Serial Numbers 675414 675467 674512 R7 OPEN CLAMP 4 Port Hose Reel oe ee or Internal jm Reeving Truck Auxiliary Valve CLAMP Drive Motor Solenoid Operated Control Valve All Models except as shown Hose Reel Truck Auxiliary Valve ROTATE and SWING RC2466 eps _ T BQUBLESHOOTING 3 2 6 Swing Frame Clamp Split Long Arm Hydraulic Schematic Various split long arm hydraulic circuits revolving connections used Test Port Check Valve Saf Re oa gt ___ Long Arm 7 sculecedh Cylinders eos aad r 5 Q Typical All Cylinders O Revolving Connection split Long Arm Circuit Components ma Swin me S g variations shown e Cylinder below CL CL Counterbalance OP Valves 2 OP Flow Divide
9. Pry the seals up with a brass seal removal tool and cut to remove CAUTION Do not scratch the seal grooves Check Cartridge Piston Nut Piston Rod Shell assembly Retainer ZA Aa A Aaa a pee A Paitin Ie 4 8 2 Cylinder Inspection e nspect the rod piston and retainer for nicks or burrs Remove minor nicks or burrs with 320 grit emery cloth If they cannot be removed replace the parts e Inspect the cylinder shell bore and remove any minor nicks or burrs with a butterfly hone 320 grit If the nicks or burrs cannot be removed replaced the part e 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 674512 R7 43 S 4 8 3 Piston Seals 44 ERVICE Cylinder Reassembly Polish the piston and retainer chamfer angle with 400 grit emery cloth to facilitate seal installation Clean all parts thoroughly 2 Lubricate all new seals and O rings with O ring lube or petroleum jelly 3 Install new seals and O rings on the piston and retainer Hook one side of the seal in the groove and carefully work it over the piston or retainer as shown Note the direction of the U cup seals Pressure seals must always be installed with the lip toward the high pressure side of the cylinder 4 Install the composite wear ring on the piston 5 Install the retainer and then the
10. bilge positions e lf rotation does not stop at vertical or bilge positions proceed to Troubleshooting Section 4 11 3 e lf attachment stops in vertical and horizontal bilge positions proceed to Step 2 e lf rotation does not stop at exact vertical or bilge positions limit switches may be adjusted as described in Step 4 Wait 3 seconds to rotate attachment again verifying it again stops in the vertical or horizontal bilge positions Press and hold override pushbutton and verify that the attachment will rotate continuously without stopping e f continuous rotation does not occur when holding pushbutton proceed to Troubleshooting Section 4 11 3 Inspect limit switch end rollers for full engagement on deceleration ramps and stop capscrews If required adjust limit switch position and or stop capscrew to precisely locate stop position within 0 5 in 13 mm 4 11 3Stop Troubleshooting NOTE Reference schematic on facing page i Check ERC main power fuse relay control lever pushbutton NOTE Pushbutton is normally closed NC providing power to ERC Verify the 12V 96V is reaching ERC control box when truck key is turned on Inspect all electrical cables Look for and correct loose connections pinched wiring or wrongly connected cables NOTE Cable connectors and control box are labeled to show proper connections Check continuity of solenoid cable assemblies and limit switch cable assemblies and
11. from the body Burrs or paint chips pulled through the bore will permanently damage the valve body GO Remove the shaft from the body 4 Remove the end block from the shaft Remove the relief cartridge if equipped For reassembly apply Loctite 2 1 red to the capscrews and tighten to 15 ft lbs 20 Nm 5 Remove the two piece seals from the body using a brass hook type seal removal tool Cascade Part No 674424 CAUTION Do not scratch grooved surfaces 6 Clean all parts with clean solvent or kerosene and inspect the following areas e Check shaft sealing surface Remove minor surface imperfections with 320 grit emery paper Sand radially around shaft Break edges on outer end of shaft and snap ring grooves If severely worn replace shaft e Check seal grooves in body Remove minor nicks or projections with 320 grit emery paper If severely worn replace body T For reassembly reverse previous procedures with the following exceptions for the two piece seals e Install new O rings between shaft and end block FIXED FRAME REVOLVING CONNECTIONS End Block Capscrews 674512 R7 m Clean all traces of oil and moisture from seal grooves inside revolving connection body using a non petroleum based cleaner Example electronic contact cleaner Clean hands thoroughly to remove all traces of oil and moisture prior to 2 piece seal installation Install square rubber rings into revolving connection body
12. grooves Install Teflon rings over rubber rings IMPORTANT Use a seal installation tool or form seal rings into a kidney shape as shown to install Avoid sharp bends Use finger pressure to smooth rings into grooves Lubricate shaft and body with hydraulic fluid prior to reassembly Use seal shaft loader and apply gentle pressure to install shaft in body Rotate body to ease installation Seal FIXED FRAME Installation Tool BODY Cascade Part No 599514 RC0372 eps Teflon Ring Square Two Piece Seals Rubber Ring Rear Snap Ring 7 O Rings Form seals into Kidney shape to install Body RC0488 eps gt RC01973 eps Front Two Piece _ 7 NO Pd Seals 45F 100F 37 S 4 6 6 Split Arm Revolving Connection Service NOTE Various revolving connections and cartridges are used with Split Arm Clamps see Section 3 2 Hydraulic Schematics for versions All are serviced in a similar manner A typical example is shown below 4 6 7 Swing Frame Counterbalance 38 ERVICE 1 Remove disassemble and service the revolving connection using the same procedures as described in previous Sections 4 6 3 4 6 4 and 4 6 5 2 Use illustration opposite when installing new Back up rings and O rings on the cartridges Snap Ring End Block FIXED FRAME SPLIT ARM REVOLVING CONNECTION Clamp Relief Valve if equipped sequence Valve Shuttle Spool Valve
13. handles several times in both directions 4 Place a drip pan under the cylinder and disconnect the hoses from the cylinder ports Plug the hose ends and tag for reassembly 5 Service the cylinder as described in Section 4 8 4 7 2 Cylinder Removal Long or Short Arm 1 Close the arm attached to the cylinder being removed Rotate the Clamp to the vertical roll handling position 2 Remove the cylinder rod anchor pins from both cylinders For reassembly tighten the anchor capscrews to 35 ft lbos 45 Nm WARNING Before servicing hydraulic components relieve pressure in the attachment hydraulic system Turn the truck off and move the auxiliary control handles several times in both directions 3 Swing the arm inward Place a drip pan under the cylinders and disconnect the hoses from the cylinder ports Plug the hose ends and tag for reassembly 4 Remove the cylinder base anchor pins Note the location of shims For reassembly tighten the anchor capscrews to 35 ft lbs 45 Nm 5 Service the cylinder as described in Section 4 8 RC0308 eps 40 674512 R7 Q ERVICE 4 7 3 Cylinder Removal Swing Frame 1 Position the swing cylinder rod to midstroke Rotate the attachment to the vertical roll handling position WARNING Before removing hydraulic hoses relieve pressure in the attachment hydraulic system Turn the truck off and move the auxiliary control val
14. housing CoO N oa A GO N Apply Loctite sealant 242 blue or equivalent to the four holes of the housing and the four capscrews Wipe away any excess sealant Install the four capscrews and tighten in a criss cross pattern to 250 in lbs 28 Nm IMPORTANT Capscrews must be clean and dry Output Shaft RRO861 eps 674512 R7 29 S 30 ERVICE 9 Turn the housing over and clamp across the flange with 10 11 12 13 14 15 the output shaft taper facing down Lubricate the O rings and install into the housing geroler set and endcap grooves Align the output shaft timing dot with the screw hole that is aligned to the port surface Use the scribe mark to help with the alignment Use the drive splines to align the geroler star point with the capscrew hole as shown CAUTION Geroler spacers can fall out Assemble together the endcap with O ring geroler set with O ring drive short spline end into geroler set and spacer IMPORTANT Make sure O rings are properly seated Install endcap assembly onto housing while aligning the scribe marks and capscrew holes Make sure the drive engages with output shaft Install the capscrews into the end cap Tighten the Capscrews using a criss cross pattern to 240 in lbs 27 Nm Timing Dot on Output Shaft screw hole that is aligned with port surface A Port Surface RRO627 eps splined Drive 10 gt RO675 eps G
15. piston on the cylinder rod Tighten the piston retaining nut to the following torque value 38F 110 ft lbs 150 Nm 45F 225 ft lbs 305 Nm 60F 66F 77F 450 ft lobs 610 Nm 90F amp larger 400 450 ft lbs 545 610 Nm 6 Place the piston loader furnished with the seal kit into the cylinder shell Assure that the loader covers all the cylinder shell threads but does not contact the thread relief chamfer Trim the loader stop fins if more engagement is needed CAUTION The piston will not enter the cylinder shell properly if the loader contacts the thread relief chamfer 7 Apply a thick film of petroleum jelly to the inside of the cylinder shell piston loader and piston seals Using a rubber mallet tap the piston rod assembly through the loader into the cylinder shell 8 Remove the loader by cutting down one side and pulling it out of the cylinder bore 9 Screw the retainer into the cylinder shell and tighten to the following torque value 38F 200 ft los 270 Nm 45F 400 ft lbs 540 Nm 60F 66F 77F 450 ft lbs 610 Nm 90F amp larger 450 ft lbs 610 Nm 4 Chamfer Angle 3 fa Wear RC1982 eps Ring Stop Fins S Cylinder Shell Piston Seal a Loader RC0320 eps Thread Refief chamfer Piston Rod Assembly 45F 100F Seal 38F Seal Retainer Seals aaa ae 1 1 Retainer 674512 R7 Q
16. replace if needed With truck key on manually operate limit switches and listen for clicks at solenoids indicating solenoid coil operation Or rotate Clamp into ramps and check for voltage at control box solenoid output connectors Look for 3 second time delay between rotation decelerating and ability to restart rotation If there is no delay or Clamp will not rotate continuously with pushbutton depressed replace ERC control box NOTE Control box contains adjustable time delay contact Cascade for adjustment procedure 674512 R7 Rotational Control stops Clamp at vertical positions A top B bottom and C bilge position To continue rotation after stopping wait 3 seconds OR press override button For continuous rotation press and hold button AC0231 eps Limit Switches Normally Open Early Model AC0242 eps Stop Capscrew Deceleration Ramp Limit Switches Normally Open Late Model AC1214 eps Deceleration Stop Ramp 53 ERVICE STOP Limit Switch alii Open Q DECEL Limit Switch Normally Open 54 Truck Battery Rotational Control Electrical Hookup DECEL Solenoid top Rotator Drive Valve Block STOP Solenoid side Cable Junction Box NOTE Factory adjusted time delay relay inside If necessary Contact Cascade to change setting Fuse 7 5A 12V 2 O 3z nN OW On aJ J a Aa WU W een a nna A D H ea G C
17. the attachment to the predominant vertical roll handling position Locate the three capscrews closest to the access hole and tighten each capscrew CW until torque is 10 ft lbs 14 Nm above torque value listed below Mark each capscrew after checking 38F 100F 75 ft lbs 100 Nm 120F 160F 220 ft Ibs 300 Nm e lf any bearing capscrews rotate are loose or broken go to 2000 hour inspection criteria and replace complete set of bearing fasteners as described in section 4 9 4 e f capscrews do not rotate inspection is complete 2000 Hour Inspection Every 2000 hours perform the following inspection NOTE Remove attachment from truck to provide access to all baseplate capscrews Remove baseplate shown or use access hole to provide access to all bearing capscrews see Section 4 9 4 1 Check all capscrews as follows tighten CW until torque is 10 ft los 14 Nm above torque values listed above Mark each capscrew after checking e f any capscrews rotate are loose or broken replace complete set of rotation bearing fasteners as described in Section 4 9 4 e f capscrews do not rotate inspection is complete 46 Baseplate Capscrews Baseplate RC2320 eps Bearing Baseplate Capscrews 2 RC2319 eps Access Plug Faceplate Rotation Bearing Baseplate removed RC2316 eps 674512 R7 Back Driver s Views ERV
18. the body bore for grooves and scratches If the 9 FIXED FRAME SHAFT For reassembly reverse the above procedures with the following exceptions Lo ZN e Install new back up rings and O rings on the shaft and counterbalance valve cartridges as shown e Lubricate the shaft and counterbalance valve cartridges with O ring lube or petroleum jelly prior to reassembly Shaft oy RCO803 eps SWING FRAME suet WV up Rings SWING FRAME REVOLVING CONNECTION Snap Ring D O Q Counterbalance J S Valve Cartridge N FIXED FRAME REVOLVING CONNECTION O Rings Back up Rings 674512 R7 35 S ERVICE 4 6 4 Seals in Body Revolving 36 Connection Service Remove the revolving connection from the attachment as described in Section 4 6 1 Seals 2 Remove the front snap ring from the shaft CAUTION Remove all burrs and paint from exposed shaft Surface prior to removal from the body Burrs or paint chips pulled through the bore will permanently damage the valve body Remove the shaft end block assembly from the body Remove the end block from the shaft NOTE For reassembly orient block and shaft as shown Apply Loctite 271 red to the capscrews and tighten to 15 ft lbs 20 Nm Remove the O rings and back up rings from the body and counterbalance valve cartridges using a hook type brass seal removal tool Cascade Part No 674424 NOTE Do not scratch grooved surfaces Clean a
19. 4 Clean the revolving connection and adjacent parts with clean solvent or kerosene 5 Remove the snap ring from the front of the revolving connection shaft CAUTION Remove all burrs and paint from exposed shaft surface prior to removal from the body Burrs or paint chips pulled through the bore will permanently damage the valve body Bracket 6 Remove the shaft from the body if equipped Snap Ring 7 Remove and replace the shaft seals as described in section 4 6 3 8 For reassembly reverse the above procedures RCO799 eps 34 674512 R7 ERVICE 4 6 3 Seals in Shaft Revolving Connection Service Remove the revolving connection from the attachment as described in Section 4 6 1 2 Remove the snap ring from the revolving connection shaft CAUTION Remove all burrs and paint from exposed shaft surface prior to removal from the body Burrs or paint chips pulled through the bore will permanently damage the valve body COUNTERBALANCE VALVE CARTRIDGE RC2504 eps Back up Rings 3 Remove the shaft from the body Back up Rings 4 Swing Frame Clamps Remove the counterbalance valve cartridges 5 Remove the O rings and back up rings from the shaft and counterbalance valve cartridges 6 Remove the fittings from the shaft and body Clean all parts with clean solvent or kerosene bore is worn replace the body 7 8 Inspect
20. C for 2 hours Apply the fillet holding a close arc Do not oscillate or use a wash bead pattern Let the welds slow cool Hardfacing Surface Backing Plate D 95 jn V 6 mm Q lan L J fy D Sy ODBE ia 6 Remove slag and inspect the welds The following defects are not allowed undercut overlap stress cracks and porosity 7 Clean the weld area and repaint RC0007 eps 674512 R7 19 Q ERVICE 4 2 3 4 2 4 20 Contact Pad Removal and Installation 1 Rotate the Clamp to the vertical roll handling position Lower the unit until the contact pads lightly touch the ground NOTE If bolt on pad surfaces are to be replaced remove and replace at this point Tighten capscrews to 15 ft lbs 20 Nm 2 Remove the clevis pins fastening the links to the contact pad 3 Remove the pipe plug retainers or drive pin retainer from the contact pad pivot points and drive out the pivot pins 4 Remove the contact pad Pad links can be removed from the arm by rotating 90 degrees and pulling out Long arms links are held in by a spring 5 38F Assure pad opener springs are installed as shown Replace as required 6 For reassembly reverse the above procedures with the following exceptions e Inspect the arm tips and pivot pins for wear and repair replace as necessary Refer to Section 4 2 3 e 38F Install drive pin type retainer 2 mm below outside surface of contact pad Assure pin is an i
21. Check sample of baseplate capscrews for proper torque value See Sections 4 9 3 and 4 9 4 for checking and replacement procedures e Check sample of bearing capscrews for proper torque RCO749 eps value See Sections 4 9 3 and 4 9 4 for checking and replacement procedures Arm Cylinder Left Side and Swing Frame e Tighten mounting hook capscrews See Section 4 1 4 for specific Roll Clamp Model torque specifications Pivot Joints e Tighten rotator drive assembly capscrews to 75 ft lbs 105 Nm Capscrew torque must be checked initially WARNING Baseplate and bearing e Lubricate rotator bearing assembly with multi purpose n extreme pressure NLGI 2 grease Whitmore Omnitask OE ee canon or equivalent Rotate Clamp one full turn during procedure hours Failure to keep the capscrews tightened can result in attachment damage and serious injury e Check rotator drive gearcase lubricant level Lubricant should be up to bottom of fill plug hole If necessary fill with Cascade Rotator Drive Lubricant Part No 656300 Rotator Drive or SAE 90 wt gear lube AGMA mild 6 EP Gear Oil Bearing Capscrews Capscrews Baseplate Replace plug Access all through Capscrews ane in baseplate e Inspect all arm frame and cylinder pivot bushings for wear and replace if necessary Refer to Sections 4 7 5 and 4 9 2 for wear limits e Inspect all load bearing structural welds on arms swing frame pivots arm pivots
22. E S ERVICE MANUAL F Series Fixed amp Swing Frame Paper Roll Clamps Manual Number 674512 R7 Cascade Cascade is a Registered Trademark of Cascade Corporation C ONTENTS INTRODUCTION Section 1 Introduction Special Definitions PERIODIC MAINTENANCE Section 2 100 Hour Maintenance 500 Hour Maintenance 2000 Hour Maintenance TROUBLESHOOTING Section 3 General Procedures Truck System Requirements Tools Required Troubleshooting Chart Plumbing Hosing Diagram Fixed Frame Hosing Diagram Swing Frame schematic Fixed Frame schematic Split Long Arm schematic Swing Frame schematic Swing Frame Split Long Arm Dual Drive with Brake Clamp Function Supply Circuit Test Clamp Circuit Test swing Circuit Test Rotation Function Supply Circuit Test Rotation without Load Rotation with Load Electrical Circuit SERVICE Section 4 Attachment Removal Arms Arm Assembly Wear Tile Replacement Contact Pad Arm Tip Repair Drive Group Removal Installation Disassembly and Service Reassembly Drive Motor Removal and Installation Disassembly Inspection Reassembly Rotator Drive Valves Check Valve Service Dual Drive Brake Valve Page NO DO COIN RIBR W WI IQ a OIOGIAIA gt AIAIOOIM MNININI IOO 17 18 18 19 20 20 ge 22 ee 24 26 26 F 29 29 31 31 32 SERVICE Section 4 continued Revolving Connection Removal and Installation Shaft Only Service Seal in Sha
23. ERVICE 4 9 4 9 1 4 9 2 Base Unit Swing Frame Service 1 Rotate the attachment to the vertical roll handling position 2 Remove the arms from the attachment as described in Section 4 2 1 3 Remove the clamp and swing cylinders as described in sections 4 7 2 and 4 7 3 4 Remove the pin connecting the swing casting and rollers to the swing frames For reassembly tighten the retainer capscrews to 35 ft lbs 45 Nm 5 Remove the swing frame pivot pins and spacers see note below Note the location and quantity of shims removed For reassembly tighten the retainer capscrews to 35 ft los 45 Nm NOTE It is recommended that all Clamps be equipped with spacers at the swing frame pivot points as shown Kits listed below include spacers for the swing frame arms and cylinder base pivots Clamp Model Spacer Kit 45F 681774 60F 66F 681775 77F 90F amp larger 681776 6 For reassembly reverse the above procedures Frame Bushing Service NOTE Bushings require replacement if bushing to pin clearance exceeds 1 16 in 1 6 mm 1 Swing Frame Clamps Remove the swing frames from the faceplate as described in Section 4 9 1 Fixed Frame Clamps Remove the arms from the Clamp as described in Section 4 2 1 2 Remove the bushings from the frames using a bushing driver NOTE Bushing drivers can be machined using the dimensions shown in the chart below 3 Install new bushings in the frames See chart below
24. ICE S 4 9 4 Rotation Bearing Assembly Removal and Installation 1 Remove the attachment from the lift truck as described in Section 4 1 2 Remove the drive group as described in Section 4 3 1 3 Remove the upper mounting hooks For reassembly tighten the capscrews as follows 38F 45F 110 ft lbs 150 Nm 60F 66F 77F CLIII 110 ft los 150 Nm 60F 66F 77F CLIV 195 ft lbs 265 Nm 90F amp larger 260 ft lbs 860 Nm 4 38F 45F Clamps Remove the revolving connection keeper bracket For reassembly tighten the capscrews to 8 ft lbs 10 Nm 5 Remove the capscrews fastening the baseplate to the bearing assembly For reassembly tighten capscrews using the following technique WARNING Install short capscrews in counterbored holes only Use lockwashers if supplied in kit A Baseplate Capscrews A Apply Loctite 242 blue to clean and dry capscrews Clean and dry the threaded holes in the bearing Threads must be clean and dry for new Loctite to Cure properly B Tighten using the alternating cross pattern shown to one half the final torque value shown below C Tighten using the alternating cross pattern to the final torque value then double torque by backing off 1 2 turn and immediately retightening to the final torque value shown below 38F 100F 75 ft lbs 100 Nm 120F 160F 220 ft Ibs 300 Nm CAUTION Do not reuse old capscrews or washers Use ne
25. N 609XXXX or greater Make a scribe across the drive motor inline with the capscrew and drive motor s port surface Clamp drive motor in a soft jawed vise across the flange with the output shaft downward Remove all capscrews from the end cap Remove altogether the end cap geroler set and spacer plate The splined drive should remain in place with this group Remove the O rings from the end cap geroler set and housing Turn the drive motor over clamping the housing across the port area with the flange upward 674512 R7 Output Shaft Housing O Ring amp Housing Capscrews 7 End Cap RR0840 eps Geroler Set Spacer 27 Q ERVICE 9 Remove the four Loctited capscrews from the flange with a X10 Torx Socket Do not use an impact wrench CAUTION Thread sealant used on the capscrews may require a small amount of heat to the housing to remove the capscrews Use a temperature indicator to prevent overheating the housing Flange 10 Turn the flange 45 degrees clockwise OB 11 Remove the flange and output shaft by pushing the output shaft from under the housing and pulling up on the tapered portion of the output shaft 12 Remove the flange and thrust bearing from the output shaft 13 Remove the load bearing race and flange seal from the flange 14 Remove the wiper seal and pressure seal from the flange using a seal removal tool or modified screwdrive
26. Swing Frame Clamp Only 1 Clamp a vertical roll of the approximate weight capacity of the Clamp Rotate 90 degrees to position the short arm down Extend the swing cylinder fully to swing the frame upward e lf the roll drifts downward the revolving connection counterbalance valve may require service see section 4 6 4 e f the roll does not drift down continue troubleshooting 2 Retract the swing cylinder to lower the roll e lf the roll drops suddenly the counterbalance valve requires adjustment see Section 4 6 7 3 Raise the roll and rotate 180 to position the long arm down Retract the swing cylinder fully to swing the frame upward e lf the roll drifts downward the revolving connection counterbalance valve may require service Refer to section 4 6 4 e Ifthe roll does not drift down continue trouble shooting 4 Extend the swing cylinder to lower the roll e lf the roll drops suddenly the counterbalance valve requires adjustment Refer to Section 4 6 7 Revolving Connection Sequence Valve Cartridge Troubleshooting For Type O and some early revolving connections with sequence valve cartridges roll clamp arms may be effected by the sequence valve cartridge The following circumstances may aid in troubleshooting e lf the arms will not move the sequence valve cartridge may be stuck in the closed position or faulty Refer to section 4 6 6 for replacement procedure e f the arms clamp uneven and do n
27. Use Loctite 242 Blue A Double Torque tighten loosen 1 2 turn retighten Apply Loctite 271 Red T ITA ININ 60F 66F ITA IlI ITA IV 90F 100F 120F RC3710 eps RC0436 eps 674512 R7 BLANK Do you have questions you need answered right now Call your nearest Cascade Service Department 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 37030 Vago di Lavagno VR Italy Tel 39 045 8989111 Fax 39 045 8989160 ASIA PACIFIC Cascade Japan Ltd 2 23 2 Chome Kukuchi Nishimachi Amagasaki Hyogo Japan 661 0978 Tel 81 6 6420 977 1 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 cascade cm Cm TM Cascade Corporation 2012 Cascade Canada Inc 5570 Timberlea Blvd Mississauga Ontario Canada L4W 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 Ne
28. a 77F Solenoid Valve RC0681 eps Truck Auxiliary Valve CLAMP NOTE For SWING EXTEND reverse the colors shown 6 674512 R7 _ T BOQUBLESHOOTING 3 2 3 Fixed Frame Clamp Hydraulic Schematic Typical All Cylinders Test Port Check Valve zi or ET Ca Oo e E Long Arm Short Arm Cylinders Cylinders if equipped a Q CL aq EL D Revolving Y C ti p onnection OP OF 1 4 7 CL CL at ae a Clamp Relief CLAMP if equipped Rotator Drive Motor l Motor Check Valve CW 2 Port H Hose Reel or Internal Reeving L H I Truck Auxiliary Valve ROTATE Truck Auxiliary Valve CLAMP Truck P ad i 2 Truck Tank RC2477 eps 674512 R7 7 _ T ROUBLESHOOTING 3 2 4 Fixed Frame Clamp Split Long Arm Hydraulic Schematic Typical All Cylinders Various split long arm hydraulic circuits revolving connections used Test Port Check Valve Short Arm Cylinders if equipped Long Arm Cylinders CL Split Long Arm Circuit Components variations shown below Wy Revolving LL Shuttle SD Connection OP Spool Valve gor A OP sy Sequence P Valve a e SDO ace Flow Divider at a Ge Rotator A Drive Motor Type 0 Shuttle Check Valve Cross Over Relief if Check Valve equipped NOTE Truck components N N not shown Adjustable Relief Valve Flow Divider p
29. achment Tag hoses for reassembly Rotate CCW ToLo S Rotate CW RCO758 eps Cate Lower Hooks nul Migi Rotate CCW Rotate CW RC0441 eps Open 3 Disconnect the lower hooks Bolt On Hooks Remove the lower mounting hooks For reassembly tap hooks tight against lower carriage bar and tighten the capscrews to CL Il Ill 38F 45F 60F 66F 110 ft lbs 150 Nm CL IV 60F 66F 77F 195 ft lbs 265 Nm CL IV 90F 100F and higher 260 ft lbs 850 Nm Quick Change Hooks Pull out the locking pins and drop the lower hooks to the unlocked position Reinstall the pins in the lower holes For reassembly slide the hooks up to the locked position and install the locking Swing pins in the top holes Open Retract tutti RC0446 eps 4 Set the attachment on a pallet Tilt the mast forward and lower the carriage to remove the attachment from the truck WARNING Hose connected to OPEN port must use outer most 5 For installation reverse the above procedures with the hose on 4 port hose reel following exceptions e Refer to Fixed Frame Roll Clamp Installation 674510 or Swing Frame Roll Clamp Installation 674511 for complete installation procedures BOLT ON HOOKS QUICK CHANGE HOOKS Carriage Bar RC0368 eps RC0367 eps LH lower LH lower Hook in unlocked position Locking P
30. and cylinder pivot areas for Rotator oe visual cracks Replace components as required Drive e Inspect wear tile arm tips and contact pads for wear Fill Plug and damage Replace or repair as needed Refer to sections 4 2 2 and 4 2 4 23 2000 Hour Maintenance After each 2000 hours of truck operation in addition to the 100 and 500 hour maintenance perform the following procedures e Check all rotation bearing capscrews for proper torque value See Section 4 9 3 and 4 9 4 for checking and replacement procedures RCO750 eps e Inspect all arm and cylinder pivot pins for wear and Back Driver s View Mounting Hook Capscrews replace if necessary Refer to Section 4 9 2 674512 R7 ROUBLESHOOTING General Procedures 3 1 1 Truck Requirements e Truck hydraulic pressure should be within the range shown in Specifications Section 6 1 Pressure to the Clamp must not exceed the following 45F 160F 2300 psi 160 bar 38F 2600 psi 180 bar e Truck hydraulic flow should be within the range shown in Specifications Section 5 1 e Hydraulic fluid supplied to the attachment must meet the requirements shown in Specifications Section 5 1 3 1 2 Tools Required In addition to a normal selection of mechanic s hand tools the following are required e In line Flow Meter Kits 10 GPM 87 L min Cascade Part No 671476 OR 20 GPM 75 L min Cascade Part No 671477 e Pressure Gauge Kit 2 kits required 5000 psi
31. arriage Bi B _ i Relay 12V 96V a Unswitched T T Switched Truck Fs Bock FO NOTES 1 All cables are 2 conductor with Deutsch type connectors 2 Electrical Supply Relay preferred for Rotational Control Only Power Bus Relay preferred for multiple accessories 3 Refer to the following documents for additional help ERC Installation Instructions Part No 6048228 Relay Installation Instructions Part No 6006270 Power Bus Relay Installation Instructions Part No 6048228 Coil Cord Power Supply Communications Group ROTATE Control Lever Override Push Button if equipped Normally Closed of Power Bus Relay 12V output only NOTE Fuses inside Main Power 20A Circuits 7 5A OR Unswitched T gt Switched Truck Fuse Block K AC0662 eps 12V Truck Battery IC Trucks Use chassis ground Electric Trucks Use battery ground 674512 R7 Q ERVICE 412 Solenoid Valve 4 12 1 All Clamps Except 77F Models with serial numbers 675414 675467 1 2 3 Remove the cover from the valve assembly Disconnect the wires and diode from the coil terminals Loosen the end cover capscrews Remove the end cover and coil Note the position of the coil terminals in relation to the valve body Install the new coil and end cover Assure that the terminals are positioned correctly For reassembly reverse the above procedu
32. bove procedures except as follows e Apply Loctite 515 sealant Cascade Part No 668184 to both sides of the drive motor adapter plate gasket if equipped Apply sealant to the threads of the four drive motor capscrews Install the gasket and adapter plate to the drive motor Tighten capscrews to 40 ft lbs 55 Nm e Apply sealant to both sides of the adapter plate gearcase or motor gearcase gasket Apply sealant to the threads of the three adapter plate capscrews Install the drive motor adapter plate assembly and gasket to the gearcase housing Tighten the capscrews to 65 ft lbs 90 Nm e Fill the drive group with fill with 56 fluid ounces 540 ml Cascade Gear Lube Part No 656300 or SAE 90 wt gear lube AGMA mild 6 EP Gear Lube 26 674512 R7 Q ERVICE 4 4 2 Drive Motor Disassembly Cascade provides service replacement parts for the seals indicated with a A below Due to cost if other parts need replacement the complete drive motor assembly should be replaced 1 Wiper Seal A JO AQ Remove the drive motor from the drive group as described in Section 4 3 1 IMPORTANT Clean the outside of the drive motor and service in a clean dust free work area Use a soft jawed vise for all service procedures Remove O rings from housing Flange 608XXXX or less _ Thrust Bearing Load Bearing Race Flange Seal amp Pressure Seal A Brass Shim amp Capscrews 4 Flange O1 fe GO
33. d Hoist zl fa esas 4r F GA0082 eps Hoist Up Clamp Tilt Rotate CW Back Swing Retract 5 1 3 Truck Carriage Carriage Mount Dimension A ITA ISO Minimum Maximum Class II 14 94 in 380 0 mm 15 00 in 381 0 mm Class Ill 18 68 in 474 5 mm 18 74 in 476 0 mm Class IV 23 44 in 595 5 mm 23 50 in 597 0 mm 674512 R7 57 5 1 4 Torque Values PECIFICATIONS Fastener torque values for the F Series Roll Clamp are shown in the table below in both US and Metric units All torque values are also called out in each specific service procedure throughout the manual NOTE All fasteners have a torque value range of 10 of stated value Fastener Location Location CIMA 5 8 xs 110 150 rs Tee oui Cl4 60F 77F 75 M20 195 265 P C14 a a M20 260 360 ie Hook Spacer Capscrew 5 8 M16 110 150 38F 77F Bie Hook Spacer Upper Capscrew 5 8 M16 mjs 95 38F 45F 5 8 M16 110 150 ae 60F 66F 25 Vo 75 100 p p 77F 3 8 M10 15 20 M12 90 ae i 100F 50 M12 105 p 120F 160F 75 M20 n 380 38F 100F 50 M12 80 108 Se 120F 150F 15 280 380 p 160F M20 394 534 ee eee eet a a 9 vavenouning Capen Tsw 0 T 30 10 mormono Capen an 0 Sina a A 12 Sateo oneanea case mo e 10 oa 13 16o oeae sonics somo s e A4 Pia Pin Reiner Capen Tae oy 35 4 A5 ewsioacancene Taema 16 roe Biock Mounino Capscen 75 v20 30 40 M
34. d 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 674512 R7 ERIODIC MAINTENANCE 21 100 Hour Maintenance Every time the lift truck is serviced or every 100 hours five complete cycles First test the clamp of truck operation whichever comes first complete the empty then test with a load to make sure the following maintenance procedures clamp operates correctly before returning it to the job WARNING After completing any service procedure always test the clamp through e Check for loose or missing bolts worn or damaged hoses and hydraulic leaks Contact Pad Contact Pad Rotator Bearing e Check the edges of the contact pads for wear or sharp Edges Pivar doii Assembly Grease nicks that could damage or tear paper rolls Grind the Fitting Botator edges smooth Dre e Check the contact pad pivot joints for wear and replace Fill Plug or repair as necessary Refer to Section 4 2 e Lubricate plungers on 180 degree stop valve if fitted e Check that load holding hydraulic system is functioning properly Clamp Force Indicators 830141 832442 and 200645 for paper roll clamps are available for this test meni lh e Check decals and nameplate for legibility 22 500 Hour Maintenance After each 500 hours of truck operation in addition to the 100 hour maintenance perform the following procedures e
35. e 1 Remove the attachment from the lift truck as described in Section 4 1 2 Disconnect the hoses and tubes from the front and rear of the revolving connection Tag for reassembly 3 Remove the capscrews fastening the revolving connection to the faceplate For reassembly tighten capscrews as noted in the illustration opposite 4 Remove the revolving connection from the faceplate 5 For reassembly reverse the above procedures with the following exceptions e Service revolving connection in a clean work area Refer to Sections 4 6 2 through 4 6 6 e Position shaft end block so that CLAMP OPEN fittings are on the left side driver s view or the TOP stamping if marked is upward TOP stamping Sai wing ol Extend o E RC2479 eps Open Swing Retract Back Driver s View 674512 R7 TYPICAL MOUNTINGS Front Views FLANGE A Tighten to gt AO ft Ibs 55 Nm 6 6 LONG ARN Q ao W W WD Wed LAORS ABD Tighten to ft lbs 10 N EYE PIN ens ve BRACKET PIN ou 2 Tighten to 8 ft lbs 10 Nm RC1972 eps Q ERVICE 4 6 2 Shaft Service Seals in shaft type only 1 Remove the attachment from the lift truck as described in Section 4 1 2 45F Clamps Remove the revolving connection keeper N bracket For reassembly tighten the capscrews to 8 ft lbs 10 Nm 3 Disconnect the hoses from the shaft end block only and cap the fittings
36. e WARNING Before removing hydraulic lines relieve pressure in the hydraulic system Turn the truck off and open the truck auxiliary control valves several times in both directions 1 Disconnect the hydraulic tubes to the LH drive break valve Tag tubes for reassembly 2 Remove the four capscrews fastening the brake valve to the LH drive group Keep track of the two O rings between the check valve and drive motor For reassembly tighten the capscrews to 24 ft lbs 30 Nm 3 Remove the plugs fittings and valve cartridge 4 Clean all parts with clean solvent Remove any burrs or sharp edges with emery cloth 5 For reassembly reverse the above procedures except as follows e Install new O rings and Back up rings on the valve cartridge Fittings Shuttle y Cartridge Valve Body Cartridges RC4086 eps 32 GA0203 eps Back Up Rings Check Valve Cartridge O Rings GA0426 eps Back Up Ring 674512 R7 Q ERVICE 46 Revolving Connection 4 6 1 Removal and installation WARNING Before removing any hydraulic lines relieve pressure in the attachment hydraulic system Turn the truck off and move the auxiliary control valves several times in both directions Connection RC0785 eps NOTE Revolving Connections vary in mounting style and configuration See typical examples opposit
37. e torque by backing off 1 2 turn and immediately retightening to the final torque value shown below 38F 100F 75 ft lbs 100 Nm 120F 130F 135 ft lbs 180 Nm 160F 220 ft Ibs 300 Nm CAUTION Do not reuse old capscrews or washers Use new hardware kit when installing a new bearing assembly Alternating cross pattern tightening sequence RC2330 eps 8 Attach two eyebolts to the bearing assembly as shown Attach an overhead hoist and lift the bearing assembly away from the faceplate 9 check the condition of the felt seal for the center hole Replace if necessary 10 For reassembly reverse the above procedures with the following exceptions e When installing the rotation bearing assembly on the faceplate align and position the heat treated overlap zone R on the ring gear with the outer race grease fitting as shown 38F 30 degrees above horizontal 45F 60F 66F 34 degrees above horizontal 77F 160F 38 degrees above horizontal e Apply multi purpose extreme pressure NLGI No 2 grease Whitmore OmniTask or equivalent to the teeth of the bearing assembly ring gear e After remounting the attachment apply chassis grease to the bearing assembly grease fitting Rotate the attachment slowly during the procedure Faceplate LOL YN 7 Voy M YY My S Felt Seal RC0328 eps Grease Fitting Heat Treat Zone Faceplate RC0331 eps Bac
38. ed on the front of the faceplate top or side IMPORTANT All hoses tubes and fittings on these attachments are JIC NOTE Specifications are shown in both inch and Metric units where applicable All fasteners have a torque value range of 10 of stated value Nameplate Locations mot m ATTACHMENT CAPACITY LIFT TRUCK ATTACHMENT ocom POUNDS INCH LOAD AT E CENTER SERIAL NUMBER 674870 CAPACITY OF TRUCK AND ATTACHMENT COMBINATION MAY BE LES S THAN ATTACHMENT CAPACITY SHOWN CATALOG 60F RCP 459 abel PF ABOVE CONSULT TRUCK NAMEPLATE RECOMMENDED SYSTEM PRESSURE 2000 PSI ADDITIONAL Sete MAXIMUM SYSTEM PRESSURE 2300 PSI ADDITIONAL cascade EQUIPMENT FOR TECHNICAL ASSISTANCE PARTS AND SERVICE CONTACT ADDITIONAL 1 800 227 2233 EWZEL PORTLAND OREGON USA RC0720 eps 12 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 precede
39. er NOTE Bushing drivers can be machined using the dimensions shown in the table CAUTION Bushings may be damaged if installed without a proper bushing driver e Adjust belt tension by fully opening both arms and attaching the long arm belt anchor bar to the set of holes that allow the belt to lay flat against the frame NOTE Belt anchor bars have offset holes which allow additional tension adjustment Adjust Long Arm Belt flat j Anchor Bar against frame A SWING FRAME CLAMP 50 Bushing Driver Dimensions A B Bearing I D Driver O D 38F 45F 1 11 1n 28 2 mm 1 36 in 34 5 mm 60F and larger 1 23 in 31 2 mm 1 48 in 37 6 mm 7 in 1 5 in 178 mm 38 mm E B A eooo RC0362 eps Adjust Long Arm Belt flat Anchor Bar against frame RC0685 eps FIXED FRAME CLAMP 674512 R7 Q ERVICE 410 180 Degree Hydraulic Stop Group rT Valve 4 10 1 Stop Valve Service WARNING Before removing hydraulic lines relieve pressure in the hydraulic system Turn the truck off and open the truck auxiliary control valves several times in both directions 1 Disconnect the hydraulic hose and tubing from the stop valve fittings 2 Remove the 90 degree fitting that extends through the baseplate 3 Remove the capscrews and remove the stop valve from the baseplate For reassembly tighten the capscrews to 35 ft lbs 50 Nm 4 Remove the end gland nuts plungers and s
40. eroler Set Short Spline splined Drive Spacer Plate 674512 R7 Q ERVICE 45 Rotator Drive Valves 4 5 1 Check Valve Service WARNING Before removing hydraulic lines relieve pressure in the hydraulic system Turn the truck off and open the truck auxiliary control valves several times in both directions 1 Disconnect the hydraulic hoses to the drive group valve Tag hoses for reassembly 2 Remove the four capscrews fastening the check valve to the drive group Keep track of the two O rings between the check valve and drive motor For reassembly tighten the capscrews to 18 24 ft lbs 25 30 Nm 3 Remove the plug fittings check valve internal parts early or cartridges later 4 Clean all parts with clean solvent or kerosene Remove any burrs or sharp edges with emery cloth 5 Inspect the internal ball seats for imperfections that would keep the balls from seating fully 6 For reassembly reverse the above procedures except as follows e Note the correct direction of the internal conical RC0214 eps springs Spring Type e Install new O rings and Back up rings on the check valve cartridges as shown Cartridge Type SPRING TYPE CARTRIDGE TYPE Body S O RC0197 eps 6 Check Valve Cartridges S os Check Cartridge O Rings RC2519 eps Back Up Rings 674512 R7 ERVICE S 4 5 2 Dual Drive Brake Valv
41. essure If not possible lower relief settings equally and test until system resets Start step 6 procedure again to maximize clamped arm pressure Check that the clamp pressures are approximately equal see step 5 Tighten the jam nut on each relief cartridge 4 Relief A controls Split Long Arm A Relief B controls Split Long Arm B 9 674512 R7 WARNING Make sure all personnel are clear of the attachment during testing Split Long Arm Cylinder RC0349 eps Test Port Plug Pressure Gauge IMPORTANT If truck is equipped witha 3 or 4 pressure selection valve adjust split arm relief cartridges while pressure selection valve is at its lowest supply setting Split Long Arm A Revolving Connection e Split Long Arm B RC3074 eps Short Arm 39 Q ERVICE 47 Cylinders 4 7 1 Servicing Cylinders on the Clamp 1 Close the arm attached to the cylinder being serviced Rotate the attachment to the vertical roll handling position 2 Remove the cylinder rod anchors from both cylinders For reassembly tighten the anchor capscrews to 35 ft lbs 45 Nm 3 Retract the cylinder rods Swing the cylinder to be serviced outward to expose the cylinder rod and retainer WARNING Before servicing hydraulic components relieve pressure in the attachment hydraulic system Turn the truck off and move the auxiliary control
42. est 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 Flow Meter Kits 671476 10 GPM 37 L min 671477 20 GPM 75 L min 2 No 8 12 JIC O Ring Flow Meter GA0013 eps 2 No 6 8 JIC Reducer Pressure Gauge Kit 671212 mee ule No 6 and No 8 wil No 6 j Hose JIC Swivel Tee r fp 7s orgs GA0014 eps No 6 8 J No 4 No No 4 6 Reducer 6 manas JIC O Ring Quick Disconnect Couplers Male Straight Thread O Ring Coupler No 4 Part No 212282 4 No5 Part No 210378 No 6 Part No 678592 Female JIC Thread 7 HUM Coupler No 4 Part No 210385 No 6 Part No 678591 AC0127 eps NOTE Diagnostics Kit 394382 includes items marked _ T BQUBLESHOOTING 32 Plumbing 3 2 1 Fixed Frame Clamp Hosing Diagram oi SA Rotator Drive CCW Dual Drive Box RC4071 eps Long Arm C O Cylinders Short Arm Cylinders if equipped O S 2 Port Hose Reel NOTE Short arm cylinders operate only when the attachment is rotated to the 45 degree position Revolving Connection 2 Port Truck Auxiliary Valve ROTATE Hose Reel O o
43. etal to 70 F 21 C 45F 906 06 2712 12 0 50 minimum and tack weld the new tubes to the arm tips 23 0 15 68 8 30 12 7 Use the recommended weld procedures listed below 60F 9 06 06 20 46 12 0 50 6 Install the contact pad and pivot pins on the arms 66F 23 02 15 722 2 30 12 7 Check the tube alignment and realign as required 77F Remove the contact pad and pins 10 06 06 32 204 12 0 56 90F 26 94 15 81 64 30 14 2 7 Finish weld the tubes to the arm tips using the following 100F and larger weld procedures e Protect threaded end of tubes from weld spatter e Preheat arm tip base metal as follows 38F 90F 150 F 66 C 100F 400 F 205 C Start weld this side n Monitor and maintain arm tip heat at locations shown using suitable temperature indicating devices 0 40 in 10 mm e Weld sequence Start weld on side indicated Terminate each weld at center of tube e WELD METHOD A FCAW Flux Core Arc Weld Attach ground wire to arm Weld using AWS E7OT 1 1 16 in 1 6 mm or 5 64 in 2 mm diameter wire with 100 CO2 shielding gas at 35 50 CFH Set welding amps per manufacturer s recommendations Apply weld holding a close arc Do not oscillate or use a wash bead pattern emperature e WELD METHOD B SMAW Stick Welding Measurement Attach ground wire to arm Weld using E 7018 Areas low hydrogen 1 8 in 3 2 mm or 5 32 in 4 mm electrodes Set weldi
44. ft Service Seals in Body Service Two Piece Seals in Body Service Split Arm Connection Service Counterbalance Valve Adjustment Split Arm Relief Pressure Adjustment Type 1 Cylinders Servicing Cylinders on Attachment Cylinder Removal Long or Short Arm Cylinder Removal Swing Frame Cylinder Check Valve Service Cylinder Bushing Service Cylinder Service Cylinder Disassembly Cylinder Inspection Cylinder Reassembly Base Unit swing Frame Service Frame Bushing Service Rotation Bearing Torque Inspection Rotation Bearing Removal and Installation Adjustable Bumper Service 180 Degree Hydraulic Stop Group Stop Valve Service Stop Position Adjustment Electronic Rotational Control Group ERC Stop Valve Service Stop Position Adjustment Stop Troubleshooting solenoid Valve Service All Clamps Early Swing Frame Clamps SPECIFICATIONS Section 5 Specifications Hydraulics Auxiliary Valve Functions Truck Carriage Torque Values Page 33 33 34 35 36 37 38 38 39 40 40 40 41 At 41 43 43 43 44 45 45 45 46 47 4 51 51 54 52 52 53 53 55 55 55 56 56 T Fi 58 674512 R7 _ NTRODUCTION 11 Introduction This manual provides the Periodic Maintenance Troubleshooting Service and Specifications for Cascade F Series Paper Roll Clamps 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 stamp
45. he right hand drive group Rotate a load requiring approximately 1 3 of attachment maximum torque e lf the higher gauge reading is substantially less than truck pressure measured at the junction block hose terminal the RH motor gerotor set may need repair Refer to Section 4 4 2 e lf the higher gauge is close to truck pressure measured at the junction block hose terminal and no rotation occurs The RH motor output shaft or drive may need repair Continue troubleshooting e lf the higher gauge is close to truck pressure measured at the junction block hose terminal and rotation occurs The LH motor output shaft or drive box may need repair Continue troubleshooting 2 Remove the motor from the drive box assembly as described in Section 4 4 3 Reinstall the hoses to the rotator motor fittings Actuate the rotate circuit e f the rotator motor shows rotational output the drive box may require service Refer to Section 4 3 2 e f the rotator motor shows little or no rotational output the rotator motor requires service Refer to Section 4 4 2 674512 R7 Model Maximum Torque Capacity 38F 63 000 in los 2300 psi 7 120 Nm 160 bar x 80 000 in lbs 23000 psi ROR OGT 9 040 Nm 160 bar 77F 98 000 in los 2300 psi 11 073 Nm 160 bar m 128 000 in lbs 2300 psi ld 14 462 Nm 160 bar 145 000 in lbs 2300 psi 16 383 Nm 160 bar 114 000 in lbs 2300 psi 12 880 Nm 160 bar 114 000 in lbs
46. in 674512 R7 17 Q ERVICE 4 2 18 Arms 4 2 1 Arm Assembly Removal and Installation 1 Open the arm to be removed to mid range position Rotate the attachment to the vertical roll handling position Remove the cylinder rod anchor pins from both cylinder rods Retract the cylinders For reassembly tighten the anchor capscrews to 35 ft lbs 45 Nm swing the arm being removed inward to contact the other arm Rotate the attachment 90 degrees to position the arm being removed on top 4 Attach an overhead hoist to the arm and take up slack 5 6 in the chain Remove the arm pivot pins and spacers if equipped Note location of shims Lift away arm assembly For reassembly tighten the arm pivot pin capscrews to 35 ft lbs 45 Nm NOTE Clamps built after 6 87 are equipped with spacers at the arm pivot points It is recommended that all Clamps be equipped with these spacers Kits listed below include spacers for the swing frames arms and cylinder base pivots Clamp Model Spacer Kit 45F 681774 60F 66F 681775 77F 90F 100F 681776 and larger For reassembly reverse the above procedures Cylinder Rod Anchor Pins RC0332 eps WARNING Check the attachment weight located on the nameplate to make sure the overhead hoist and chains or straps are at least the rated capacity of the attachment RC0333 eps 674512 R7 Q ERVICE 4 2 2 Wear Tile Re
47. ircuit IMPORTANT Revolving connection with relief valve controlled split arm circuit must be adjusted for proper arm movement as follows 1 2 8 Confirm that the truck relief setting is between 2000 2600 psi 140 180 bar Rotate the Clamp to the vertical roll handling position 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 Install 5000 psi 345 bar pressure gauges to each split long arm cylinder test port No 4 O ring fitting required Open the long arms Clamp a short roll 30 in diameter min or Clamp force indicator between the short arm pad and lower split long arm pad Build pressure until the upper arm begins to move Release the lever and note the gauge pressure Rotate the Clamp 180 degrees Repeat step 4 for the opposite split long arm Both pressures should be within 50 psi 3 5 bar If not adjust the relief cartridge screw out CCW on the arm with the higher pressure to equal the arm with the lower pressure NOTE 1 turn approximately 400 psi 28 bar At half throttle compare the gauge pressure with truck relief pressure Adjust both relief cartridges equally using 1 8 turn steps Verify that the unclamped arm moves after the clamped arm stops and re syncs upon opening Adjust the clamped arm pressure to approximately 200 psi 14 bar lower than truck relief pr
48. irst bearing retained by an additional snap ring see illustration next page 11 Press the pinion gear out of the housing pinion bearing Remove seal 12 Clean and inspect all components Remove all dried sealant or threadlocker residue Replace all worn items Remove any burrs or sharp edges with emery cloth RC2111 eps NOTE Iwo types of large pinion bearing used Sealed bearing and bearing with separate seal shown 674512 R7 23 ERVICE S 4 3 3 Drive Group Reassembly Build up the pinion worm gear assembly vertically with the pinion gear down 1 Standard Pinion Position the seal against the pinion gear spring side facing housing Apply Loctite 271 red to clean and dry bearing seating area as shown Press a non sealed housing bearing onto the pinion shaft IMPORTANT Earlier design uses a sealed bearing Pry out bearing seals when using an external seal Remove excess Loctite Heavy Duty Pinion No external seal is used Position the first bearing and snap ring on the pinion shaft Apply Loctite 271 red to the second bearing seating area as shown Press the second bearing onto the pinion shaft Remove excess Loctite CAUTION Verify that the Loctite does not squeeze into the seal or bearings 2 Preheat worm gear to 200 F Install the key worm gear cover plate pinion bearing and snap ring on the pinion 3 Apply Loctite 271 red to clean and dry housing seating area and shoulder for the housing
49. k Driver s View 674512 R7 Q ERVICE 4 9 5 Adjustable Bumper Service 1 Rotate the Clamp to the vertical roll handling position Raise approximately 2 ft 60 cm off the ground Cylinder Pivot Pin Retainers Tiedown 2 Remove the top and bottom cylinder pivot pin retainers Capscrews For reassembly tighten the retainer capscrews to 35 ft lbs 50 Nm Cylinder 3 Pull the pivot pins out of engagement with the bumper 4 rollers approximately 2 in 5 cm CAUTION Do not completely remove the cylinder pivot amp pins Co s 4 Remove the tiedown capscrews from the arms For reassembly tighten the capscrews to 15 ft lbs 20 Nm 5 Remove the capscrews fastening the belt anchor bars to the arms Remove the belt For reassembly tighten the capscrews to 35 ft lbs 50 Nm j FIXED FRAME CLAMP Belt Anchor Bar Capscrews La RC0683 eps Bumper Rollers Cylinder Pivot Pin Retainers Tiedown Capscrews Cylinder Belt Anchor Bar Capscrews J Ss is X T os P oe SWING FRAME CLAMP ee 674512 R7 49 Q ERVICE 4 9 5 Adjustable Bumper Service Continued 6 For reassembly reverse the above procedures with the following exceptions e Inspect bumper belt roller surface for wear and replace if necessary Remove by splitting surface down the side with a screwdriver e Install new bushings into the rollers using a bushing driv
50. knob button is depressed e fthere is no current to the solenoid troubleshoot the electrical circuit for opens or shorts e fthere is current to the solenoid test for coil continuity and proper rating 5 Test for coil continuity and rating by placing an ohmmeter test lead on each solenoid coil terminal ohmmeter on Rx1 scale e lf there is a reading the coil is good Check for proper ohm value for the truck e Ifthe 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 4 12 e lf there is no ohmmeter reading the coil is defective and should be replaced Refer to Section 4 12 Control Knob with Pushbutton Solenoid Solenoid Coil Valve RCO736 eps Diode IMPORTANT Banded end must connect to positive side of circuit Cable Control Knob with Pushbutton Diode IMPORTANT Banded end must Solenoid connect to positive Coils side of circuit Control LK Valve RC0O747 eps 674512 R7 Q ERVICE 41 Attachment Removal 1 Rotate the attachment to the vertical roll handling position Extend the arms outside the width of the frame WARNING Before removing hydraulic lines relieve pressure in the Attachment hydraulic system Turn the truck off and move the auxiliary control valves several times in both directions iil TUT 2 Disconnect and plug the hydraulic supply hoses to the att
51. laces with a feeler gauge or Pastigage thread and determine the minimum gap Choose a combination of end cover shims equal to the minimum gap measured plus the next higher 005 in 0 12 mm increment See examples below For 025 029 in measured gap use 030 in total shim thickness For 010 014 in measured gap use 015 in total shim thickness For 009 or less use one 010 in shim since a minimum of one 010 in shim is required for proper seal NOTE Shim Service kit 670578 contains the shims listed A minimum of one 010 shim is required to seal against leakage Qty Part No Color Thickness 1 671758 Blue 020 in 50 mm 1 671757 Brown Clear 015 in 38 mm 1 67 0574 Pink 010 in 25 mm 1 674513 Yellow 005 ins 13 mm Remove the end cover Apply Loctite 515 sealant Cascade Part No 668184 to both surfaces of the shims and the capscrews Install the shim pack and end cover Tighten the capscrews to a torque of 65 ft lbs 90 Nm Remove excess sealant With the gearcase laying flat fill with 56 fluid ounces 540 ml of Cascade Gear Lube Part No 656300 or SAE 90 wt gear lube AGMA mild GEP Gear Lube Install the cover plate and gasket Install the four cover plate capscrews and tighten to 15 ft lbs 20 Nm Install the center hole plug Reinstall the drive group on the rotator baseplate as described in Section 4 3 1 Cover plate 674512 R7 RC0180 eps Housing fa
52. ll parts with clean solvent or Kerosene and inspect the following areas e Shaft sealing surface Remove minor surface imperfections with 320 grit emery paper Sand radially around shaft Break sharp edges on front of shaft If severely worn replace shaft e Body grooves Remove minor nicks or projections that may damage seals during installation If severely worn replace body For reassembly reverse the above procedures with the following exceptions Back up Rings e Install new back up rings and O rings as shown e Lubricate shaft and body with O ring lube or petroleum jelly Use shaft seal loader rotate body during installation JBBTE FIXED FRAME BODY RC0781 eps Back up Rings SWING FRAME BODY he RC0831 eps SWING FRAME REVOLVING CONNECTION gt Body O Rings WP AJ gt Back up a s Snap Rings LY 44 Ring i AI Counter AD balance G Mp D Z e Valve 0 N4 amp i Cartridges gt ACC 5 FIXED FRAME Z 5 g g Og REVOLVING CONNECTION Z ZX NA Bo Y o gt CG 2 g d 7 IA T Z CF gD 29 T Wiz Q a Fa j O Rings Cg s Back up 4 a Rings 674512 R7 ERVICE S 4 6 5 Two Piece Seals in Body Revolving Connection Service 1 Remove the revolving connection from the attachment as described in Section 4 6 1 2 Remove the front snap ring from the revolving connection shaft CAUTION Remove all burrs and paint from exposed shaft surface prior to removal
53. nal leaks Rotation without Load 1 Install pressure gauges to the rotator motor fittings 2 Rotate the Clamp without a load and note pressure readings of both gauges e f the Clamp rotates faster in one direction than the other or rotates in one direction only the check valve assembly may need service Refer to Section section 4 5 e lf the lower gauge reading exceeds 500 psi 35 bar there is excessive back pressure in the supply circuit Check for restrictions such as numerous fittings 90 degree fittings or hose sizes less than No 8 Flowmeter Pressure Gauges Check Valve Hydraulic Motor Drive Box Single Drive Group Pressure Gauges Dual Drive Group RRO191 eps 674512 R7 ROUBLESHOOTING 3 4 3 Rotation with Load 1 Rotate a load requiring approximately 3 4 of the attachment s maximum torque capacity as shown in the Table opposite and note gauge readings e lf the higher gauge reading is substantially less than the truck pressure as measured at the carriage hose terminal the rotator motor geroter set may need repair Refer to Section 4 4 e Ifthe higher gauge reading is close to truck pressure as measured at the carriage hose terminal and no rotation occurs the rotator motor output shaft or drive box may need repair Continue troubleshooting Dual Drive Models Remove the left drive group from the attachment as described in Section 4 3 1 Cap the connector fittings on t
54. ng amps per manufacturer s f Align new tubes flush with inner edge of casting recommendations Do not use electrodes exposed to moisture without first re drying them at 200 F 75 C for 2 hours Apply weld holding a close arc Do not oscillate or use a wash bead pattern e Cool arm tip base metal as follows 38F 90F normal air cool 100F slow cool with insulating blanket cover 8 Remove slag after each weld and inspect for defects NOTE Arc craters undercut overlap and porosity are C not permitted Repair any weld defect as required 9 Grind all welds to smooth transitions between parts START STOP START f Weld Sequence B START STOP RCO306 eps 674512 R7 21 Q ERVICE 4 3 4 3 1 4 3 2 22 Drive Group Drive Group Removal and Installation 1 Remove the Clamp from the truck as described in section 4 1 2 Dual Drive Units Disconnect the crossover tubes from the check valve assembly 3 Remove the four capscrews fastening the drive group to the baseplate For reassembly tighten the capscrews to 75 ft los 100 Nm 4 For reassembly reverse the above procedures with the following exceptions e After the drive group has been reinstalled check the gearcase lubricant level Lubricant must be up to the bottom of the fill plug hole If necessary fill with Cascade Gear Lube Part No 656300 or SAE 90 wt gear lube AGMA mild 6 EP Gear Lube Drive Gro
55. nterference fit Pin 312 in diameter x 1 250 in long Arm Tip Repair The following procedure describes tip removal and replacement using Service Kit 683065 25F 6047539 38F 674928 45F 6OF 66F and 676810 77F 90F and larger Each kit includes four replacement arm tips to repair one arm WARNING Cascade Corporation recommends that a qualified welder experienced in this type of repair be used for best quality 1 Remove the contact pad as described in Section 4 2 2 2 Scribe a cut line using dimension A back from the inner surface of the existing pivot pin hole on both sides of the arm tip 3 Remove the worn tip portion of the arm casting at the cut line by grinding sawing or flame cutting Remove any contaminants from around the repair area Model 25F 38F 45F 60F 66F 77F 90F 100F 0 26 and larger Pad Pivot Pin Plugs Pad Link spring Contact Pad Link I Q oO ee D O n C WO Pad Opener springs Retainers Pivot OR Pin Drive Pin 9 2 Retainer ae RC1987 eps Remove tips of arm casting 38F PADS RCO762 eps Cut line Pd 674512 R7 Q ERVICE 4 2 4 Arm Tip Repair Continued Dimensions 4 Position the new tubes on the arm tips using dimensions Model B in cm Cin cm Din mm ee C pe a a rod of diameter D through 38F 74184 06 2489 12 0 50 Gi ea were anes 18 24 15 63 23 30 127 5 Preheat the arm tip base m
56. ot build up clamp pressure the cartridge may be faulty Refer to section 4 6 6 for replacement procedure 674512 R7 Swin Cylinder Short Arm 1 Swing Cylinder RCO790 eps a Long Arm 3 13 T 3 4 3 4 1 3 4 2 14 ROUBLESHOOTING Rotation Function There are four potential problem areas that can affect the rotation function Operator may be handling roll incorrectly Loads may be too heavy or rotated off center exceeding capacity of Clamp Refer to Operator s Guide for suggested handling procedures Low hydraulic pressure or flow from lift truck Worn or defective hydraulic rotator motor or check valve assembly Worn or defective drive assembly or rotator frame bearing assembly Supply Circuit Test WARNING Before removing hydraulic lines relieve pressure in the Attachment hydraulic system Turn the truck off and move the truck auxiliary control valves several times in both directions Check the pressure delivered by the truck Refer to the truck Service Manual The pressure must be within 100 psi 7 bar of specified truck pressure Pressure to the Clamp must not exceed the following 45F 160F 2300 psi 160 bar 38F 2600 psi 180 bar Check the flow volume at the carriage hose terminal see Section 5 1 1 for recommended flow volumes If the truck pressure and flow are correct proceed with the Rotation circuit pressure test 3 Check for exter
57. pinion bearing and seal Install the complete pinion assembly into the housing Remove excess Loctite CAUTION Verify that the Loctite does not squeeze into the seal or bearings 4 Install the worm s outer bearing race in the drive motor side of the housing Make sure the race taper is inward as shown 5 Install the drive motor as described in Section 4 4 1 6 Install the worm and bearings in the housing Fully engage the worm with the drive motor shaft Install the remaining outer bearing race Make sure the race taper is inward as shown 24 aN TK il Sue ae SSS SIN RCO179 eps 1 PINION AND BEARING WITH EXTERNAL SEAL Housing Seal Pinion Bearing Non sealed Pinion gear Seal Bearing Seating Seating Area Area RC2118 eps PINION WITH SEALED BEARING Housing Pinion Bearing Sealed RC2648 eps HEAVY DUTY PINION WITH SEALED BEARINGS Baseplate Pinion LS Bearing SN Housing ce Pinion Pinion Bearing Gear p First Second 6 RC2124 eps Bearing Bearin Seating a Area Area Additional Snap Ring Worm Gear Bearing Snap Ring RCO178 eps 674512 R7 Q ERVICE 4 3 3 Drive Group Reassembly Continued T Temporarily install the end cover without shims Tighten 10 11 12 13 the capscrews sequentially in 10 ft lb 15 Nm increments to 20 ft lbs 30 Nm Measure the gap between the end cover and housing in three p
58. placement The following procedure describes installing wear tiles on short arm tip castings using Service Kit 206588 The kit includes four replacement wear tiles WARNING Cascade Corporation recommends that a qualified welder experienced in this type of repair be used for best quality 1 Rotate the clamp to the horizontal roll handling position with the short arm upward Lower the clamp to the ground 2 Clean the arm tip casting surfaces to be welded Remove paint rust grease scale and other contaminants Weld Areas 3 Locate the wear tiles on the arm tip casting as shown Clamp in place with a C clamp 4 Preheat the weld area to 100 F 38 C before welding 5 Weld the wear tile backing plate to the arm tip casting using one of the following weld methods RC0006 eps WELD METHOD A Attach the ground wire to the short arm Weld using FCAW Flux Core Arc Weld AWS E7OT 1 1 16 in 1 5 mm diameter wire with 100 CO2 shielding gas at 35 50 CFH Use DC polarity set at 26 30 volts and 260 325 amps Apply the fillet holding a close arc Do not oscillate or use a wash bead pattern Let the welds slow cool WELD METHOD B Attach the ground wire to the short arm Weld using SMAW Shielded metal arc welding E 7018 low hydrogen 1 8 in 8 mm electrodes Use DC polarity or a AC welding machine set at 130 325 amps Do not use electrodes exposed to moisture without first re drying them at 200 F 75
59. pring Stop Valve Block LP Back up Ring Remove all fittings from the valve block Wiper Ring 5 Clean all parts with kerosene or solvent 6 For reassembly reverse the above procedures with the following exceptions e Install new O rings back up rings wiper rings l RC0691 eps EN O Rings yr Plunger Wiper Ring Plunger on Gland Nut Spring Back up Ring 410 2 Stop Position Adjustment 1 Rotate the Clamp in each direction and assure that the Clamp stops in the proper vertical or horizontal position 2 If the stops need to be adjusted loosen the stop bolt locknut and adjust the stop bolt as required Tighten the locknut M RC0692 eps 674512 R7 51 ERVICE Electronic Rotational Control ERC iloi 1 Supply 411 1 ERC Stop Valve Service gl KZ WARNING Before removing hydraulic Valve amp Wie Y lines relieve pressure in the hydraulic Block aCe system Turn the truck off and open the truck auxiliary control valves several times in both directions Limit Switches STOP Deceleration aa Ramps Stop oil side 1 Disconnect the ROTATE hydraulic hoses from the stop me Capscrews valve fittings and tag for reassembly 2 Remove the solenoid coils by unscrewing the mounting nut and sliding the coil off the valve cartridge For Z reassembly tighten the nut lightly to 5 f
60. r Early AK yu Pre Type 0 lt c Rotator Adjustable Drive Motor N N Q Z NOTE Truck components not shown D O Adjustable Counterbalance Relief Valve Valves RC4334 eps Shuttle Valve P ee gt sequence Valve Early Pre Type 0 P Counterbalance aS cl OP Valves Flow BMG Counterbalance Valves 10 674512 R7 _ T BOQUBLESHOOTING 3 2 7 Dual Drive with Brake Hydraulic Schematic Dual Drive Brake Valve Rotator Dual Drive Motor Hose Reel To Clamp Components Clamp Rotate Auxiliary Auxiliary Valve Valve Tank RC4072 eps 674512 R7 11 E T ROUBLESHOOTING 3 3 3 3 1 3 3 2 12 Clamp Function There are five potential problem areas that can affect the CLAMP function e Clamping roll improperly or handling rolls that exceed capacity of the attachment Refer to Operator s Guide for suggested procedures e Low hydraulic pressure or flow from lift truck e External leaks e Defective solenoid coil or valve if equipped e Worn defective revolving connection shaft seals or cartridge valves cylinder seals or check valves Supply Circuit Test WARNING Before removing hydraulic lines relieve pressure in the Attachment hydraulic system Turn the truck off and move the truck auxiliary control valves several times in both directions 1 Check the pressure delivered by the truck Refer to the
61. r Internal Y Hose By Reeving Truck Auxiliary Valve CLAMP ARM OPENING ROTATE CCW PRESSURE Hi RETURN Ld RCO680 eps NOTE For ARMS CLOSING ROTATE CW reverse the colors shown 4 674512 R7 _ T BOQUBLESHOOTING 3 2 2 Swing Frame Clamp Hosing Diagram Rotator Drive CCW N Revolving Connection Dual Drive Box RC4071 eps Long Arm S ee Cylinders Short Arm Cylinders oS AS if equipped 4 Port Hose Reel NOTE Short arm cylinders operate Swing only when Clamp is Cylinder rotated to the 45 degree position Hose Reel or Internal Hose Reeving Truck Auxiliary Valve ROTATE and SWING Y 77F Solenoid Valve RC0682 eps Truck Auxiliary Valve CLAMP 45F 60F ARM OPENING Solenoid Valve ROTATE CCW PRESSURE EE RETURN E NOTE For ARMS CLOSING ROTATE CW reverse the colors shown 674512 R7 _ 7 BQUBLESHOOTING 3 2 2 Swing Frame Clamp Hosing Diagram Continued ae Drive Revolving Connection Long Arm Cylinders Short Arm Cylinders if equipped 4 Port Hose Reel NOTE Short arm cylinders operate only when Clamp is rotated to the 45 degree position Hose Reel or Internal Hose Reeving Truck Auxiliary Valve ROTATE and SWING 45F 60F SWING RETRACT Solenoid Valve PRESSURE RETURN S
62. r Q as shown RR0842 eps NOTE Remove the seals by pushing from the back side as shown 15 Remove the brass shim from the flange RRO860 eps Modified Screwdriver RR0843 eps Flange Original Design RRO858 eps 28 RRO859 eps 67451 2 R7 Q ERVICE 4 4 3 Drive Motor Inspection Remove all Loctite residue from the threaded holes e Clean all parts with solvent and blow dry Do not use paper or cloth towels e Inspect all parts for small nicks burrs or scratches Remove imperfections with emery cloth Replace parts where imperfections could not be removed e Inspect the flange seal seats for scratches Check for cracks in the flange area that could cause leakage 4 4 4 Drive Motor Reassembly 1 Install the brass shim into the pressure seal side of the flange Install wiper seal and pressure seal into the flange The pressure seal must be seated evenly Wiper Seal Place the bearing race in the flange seated evenly with the pressure seal and flange Brass Shim Lubricate the flange seal with petroleum jelly and seat in lio of flange on the pressure seal side as shown Install thrust bearing onto the output shaft RR0O633 eps Install the flange onto the output shaft with the pressure Pressure Seal a seal side against the output shaft Bearing Race E Flange Seal Clamp housing into the vise with the flange side facing upward Install the output shaft flange assembly into the
63. res with the following exceptions e Refer to the electrical schematic in Section 3 5 for correct wire and diode Installation 4 12 2 Early Swing Frame Clamps Serial numbers 675414 675467 NOTE No longer available replaced by above J 2 3 4 Remove the cover from the valve assembly Disconnect the wires and diode from the coil terminals Remove the solenoid cartridge top nut and coil Remove the solenoid cartridges and check valve cartridges from the valve body Remove the seals from the cartridges For reassembly reverse the above procedures with the following exceptions e Install new O rings and back up rings as shown e Lubricate the cartridge seals with O ring lube or petroleum jelly prior to installation e Refer to the electrical schematic in Section 3 5 for correct wire and diode Installation O Rings Back up Rings RC0688 eps p J SOLENOID VALVE CARTRIDGE 674512 R7 RC0204 eps Coil Solenoid Valve Solenoid Coil Cartridges O Rings l Back up Rings CHECK VALVE CARTRIDGE 55 PECIFICATIONS s1 Specifications 5 1 1 Hydraulics T Truck Relief Setting 45F 160F Clamp amp Rotate Circuits 38F Rotate Circuit 2000 psi 140 bar Recommended 2300 psi 160 bar Maximum 38F Clamp Circuit 2300 psi 160 bar Recommended 2600 psi 180 bar Maximum i Fall ODN AO Deane Geen arr eee N IP
64. rvice NOTE Bushings require replacement if bushing to pin clearance exceeds 1 16 in 1 6 mm 42 1 2 Remove the cylinder from the Clamp as described in section 4 7 2 or 4 7 3 Remove the bushings from the cylinder using a bushing driver NOTE Bushing drivers can be machined using the dimensions shown below Install new bushings in the cylinder Replace with the same number of bushings removed CAUTION Bushings may be damaged if installed without a proper bushing driver Bushing Driver Dimensions A B Bearing I D Driver O D 38F 45F 1 11 in 28 2 mm 1 36 in 84 5 mm 60F 66F 1 23 in 31 2 mm 1 48 in 87 6 mm 70F 90F 1 23 1m 31 2 mm 1 48 in 37 6 mm and larger 7 in 1 5 in E 38 mm a B A RC0362 eps Bushings RC1984 eps 674512 R7 Q ERVICE 4s Cylinder Service 4 8 1 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 2 Screw the piston retainer out with a pin type spanner wrench or special socket 3 Remove the piston rod retainer assembly from the cylinder shell 4 Clamp the piston rod retainer assembly across the rod end IMPORTANT Never clamp directly on the rod sealing surface Q1 Remove the piston nut from the rod 6 Clamp the piston on the top and bottom in a soft jawed vise
65. t lbs 7 Nm ES 3 Remove the four capscrews and remove the stop valve I from the rotator drive assembly Keep track of the two O rings For reassembly tighten the capscrews to 35 ft lbs 50 Nm 4 Service the valve in a clean work area Remove the solenoid and cartridge valves Remove all fittings from the valve block Clean all parts with solvent BC DEGEL Solenoid res Coil top 2 Control Box 5 For reassembly reverse the above procedures with the following exceptions e Install new O rings and back up rings on cartridge 2 WAY valves and valve block as shown SOLENOID e For complete installation procedures refer to Electronic Rotational Control Installation Instructions 6048228 o Retainer Nut 4 DECEL Coil c A Back up Rings RC1014 eps ounterbalance eee MINIM Ae Cartridges SOLENOID Tighten to VALVE Ne 35 ft los 45 Nm KAW Two Way Solenoid Valve Tighten to 80 ft los 110 Nm RC1013 eps COUNTERBALANCE STOP Coil Qe Wiring Harness RC1015 Valve Four Way Solenoid i Block Valve Tighten to Back up Rings 18 ft los 25 Nm 52 674512 R7 S ERVICE 4 11 2 Stop Position Adjustment 1 2 3 Rotate the attachment in each direction to verify it stops in vertical and horizontal
66. truck service manual The pressure must be within 100 psi 7 bar of specified truck pressure Pressure to the Clamp must not exceed the following 45F 160F 2300 psi 160 bar 38F 2600 psi 180 bar 2 Check the flow volume at the carriage hose terminal see Section 5 1 1 for recommended flow volumes If the truck pressure and flow are correct proceed with the Clamp circuit pressure test Clamp Circuit Test WARNING Before removing hydraulic lines position both arms at midstroke to relieve cylinder pressure Turn the truck off and move the truck auxiliary control valves several times in both directions 1 Check for external leaks at the cylinders and revolving connection 2 Long Arm Cylinders Install a pressure gauge to each long arm cylinder s test port While clamped ona medium to full size roll close the long arm fully Watch the gauge pressure readings Short Arm Cylinders Install a pressure gauge to each short arm cylinder s gauge port Rotate the Clamp to the 45 degree position While clamped on a medium to full size roll close the long arm fully Watch the gauge pressure readings e lf the initial gauge pressures are not within 100 psi 7 bar of system pressure measured at the hose terminal the revolving connection may be faulty and requires service Refer to Section 4 6 e f one of the gauge pressures drops more than 150 psi 10 bar initially and additional drop exceeds 25 psi
67. up Disassembly and Service Remove the drive group from the baseplate as described in Section 4 3 1 2 Lay the drive group pinion down on two 4 x 4 in 10 x 10 mm wood blocks placed on both sides of the pinion 3 Remove the four capscrews fastening the cover plate to the housing 4 Remove the center capscrew plug from the cover plate and install a early 3 8 in NC or later M10 capscrew with a minimum thread length of 2 in 50 mm Remove the cover plate by turning the capscrew clockwise while lightly tapping around the sides of the cover plate 5 Drain the lubricant from the housing 6 Remove the three capscrews fastening the end cover to the housing 7 Remove the drive motor as described in Section 4 4 1 N RC0172 eps Drive Group 674512 R7 Q ERVICE 4 3 2 Drive Group Disassembly Bearing and Service Continued 8 Tap the worm and bearing assembly out through the end cover side of the housing Remove the opposite outer bearing race through the motor side of the housing RC0173 eps 9 Press the pinion gear seal pinion bearings and worm gear out of the housing as an assembly RC0174 eps Housing Pinion Bearing ra Worm Gear Key 10 Remove the snap ring from the pinion gear shaft Press the pinion gear bearing from the worm ring gear and cover plate pinion bearing Remove the pinion shaft key Pinion Gear IMPORTANT Heavy Duty Pinion uses two bearings with the f
68. ves several times in both directions 2 Place a drip pan under the cylinder and disconnect the hoses from the cylinder ports Plug the hose ends and tag for reassembly 3 Remove the anchor pin retainer and anchor pin from both ends of the cylinder Remove the cylinder and note location of shims For reassembly tighten the anchor capscrews to 10 ft los 13 Nm RC0309 eps 4 Service the cylinder as described in Section 4 8 4 7 4 Cylinder Check Valve Service 1 Close the arm attached to the cylinder being serviced to gain access to the cylinder check valve Rotate the attachment to the vertical roll handling position WARNING Before removing Cylinder hydraulic hoses relieve pressure in the Check Valve attachment hydraulic system Turn the Cartridge truck off and move the auxiliary control 45F 120F valves several times in both directions 2 Remove the check valve cartridge from the cylinder port Remove the O rings and Back up rings Clean the check valve cartridge with clean solvent Install new O rings and Back up rings as shown o A GO Lubricate the check valve cartridge with O ring lube or petroleum jelly prior to reassembly Tighten the check valve cartridge to 35 ft lbs 45 Nm 38F RC1980 eps 4 CHECK VALVE CARTRIDGE a O Rings RCO311 eps Back up Rings 674512 R7 41 Q ERVICE 4 7 5 Cylinder Bushing Se
69. w Zealand Tel 64 9 273 9136 Fax 64 9 273 9137 Cascade do Brasil Rua Joao 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 86 592 651 2500 Fax 86 592 651 2571 Sunstream Industries Pte Ltd 18 Tuas South Street 5 singapore 637796 Tel 65 6795 7555 Fax 65 6863 1368 10 2012 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 674512 R7
70. w hardware kit when installing a new bearing assembly cross pattern Zos RTS pn tightening LDK ha oee sequence pe KN log Alternating NOL O iS e q O T 1 ae RC2306 eps NOTE Remove center lower mounting spacer if equipped to gain access to bearing capscrews For reassembly tighten capscrews to 60F 66F 77F 15 ft lbs 20 Nm 90F 100F 120F 30 ft lbs 40 Nm 6 Attach two eyebolts to the baseplate Attach an overhead hoist and lift the baseplate away from the faceplate bearing assembly 674512 R7 Faceplate Bearing Assembly Capscrews WARNING Check the attachment weight located on the nameplate to make sure the overhead hoist and chains or straps are at least the rated capacity of the attachment 47 Q ERVICE 4 9 4 Rotation Bearing Assembly Removal and Installation Continued 7 Remove the capscrews fastening the bearing assembly 48 to the faceplate For reassembly apply threadlocker and tighten the capscrews using the following technique Bearing Capscrews A Apply Loctite 242 blue to clean and dry capscrews Clean and dry the threaded holes in the faceplate Threads must be clean and dry for new Loctite to Cure properly B Tighten using the alternating cross pattern shown to one half the final torque value shown below C Tighten using the alternating cross pattern to the final torque value then doubl

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