70E Roll Clamps - Cascade Corporation
Contents
1. Remove the cover and disconnect the wires as shown O Remove the four retaining capscrews and end cap J l DQ l 5 Remove the old coil and install the new coil Disconnect Both Terminals Remove Capscrews Ga For Reassembly Lube CAUTION Always replace the old coil To Torque to 45 50 in lbs with the same voltage new coil K Ca L 4 ne Reverse the above procedures to reassemble and in stall on truck Remove Capscrews L For Reassembly Lube Remove Old Coil and install New Coil 6 a R R R S l d V CAUTION Always Replace Old Coil f N acine 5016nO aive EA 371 Remove and Service WARNING Disconnect the ground cable from the battery on internal com bustion trucks or disconnect the truck battery on electric trucks WARNING Disconnect the ground cable from the battery on internal com bustion trucks or disconnect the truck battery on electric trucks 1 Remove the three mounting capscrews Remove the cover and disconnect the wires as shown Remove the four retaining capscrews and end cap C Remove the old coil and install the new coil Disconnect CAUTION Always replace the old coil both terminals with the same voltage new coil 9 DNN CAUTION Always Replace Dd Coil oo with Same Voltage New Coil Reverse the above procedures to reassemble and in stall on truck Remove Capscrews is A For Reassembly Lube E a S S ace 8 ae Remove C2. If the auxiliary valves on your truck are controlled by a single handle install the knob on the single control handle Remove the existing knob from the appropriate auxiliary valve control handle and install the special knob as shown If the control handle is not threaded weld on the special adapter and install the knob as shown It may be necessary to saw off a portion of the handle to achieve a comfortabie length Cabie Assembly from control Mounting Solenoid Plate Valve Tack Weld Cord Assembly NS un Terminal CS Ground Connect to Truck Ignition on off Switch Solenoid Mounting Capscrews Torque to 45 50 in lbs To Solenoid Valve Cable Assembly Connector Push Button Control Switch tgnition on off Switch GND Cord Assembly CABLE ASSEMBLY NOT SHOWN FOR CLARITY Special Control Push Button 3 8 16 UNC Facing Threads toward driver Jam Nut tighten to secure Knob 3 8 24 UNE Special Adapter discard if not required Threads Use Loctite 242 here only Auxiliary Truck Valve Contro Handle Form 5165 Rev O sein 4 Installation Instructions 454 Control Knob Placard Installation 4 6 4 6 1 Er mw The control knob placard is a disc with printing on both sides that may be installed on top of the control knob with either side showing If your truck auxiliary valves are operated with a single control handle th
3. Inspect the rod piston and retainer for nicks or burrs If deeply gouged then replace the part Otherwise remove minor nicks and burrs with an emery cloth NOTE Minor nicks are those that will not cause a bypass of oil when the cylinder is operating Inspect the inside of the cylinder shell and remove any minor nicks or burrs see note above with a butterfly Replace the cylinder shell if it is deeply gouged Inspect the outer shell for any deformities which could weaken the shell s performance when under pressure Replace if necessary Assembly Lubricate all new seals with STP before installing To install the new seal in the piston or retainer hook one side of the seal in the groove and push it over the piston or retainer NOTE Polishing the chamfer angle will let the seal slide onto the groove much easier Note the direction of the U Cup seals If installed backwards the seals will not work properly Refer to the specific instructions for the cylinder you are servicing See page 13 23 or 13 24 Always reassemble the rod assembly by sliding the retainer on first and then the piston Install and torque the retaining nut before sliding the rod assembly back into the shell Pin Type Spanner Wrench Claw Type Spanner Wrench Remove Seal from Piston Do Not Scratch the Groove Install New Seal as Shown Form 5165 Rev O sections BGTVICG 4 3 Plumbing 2 Stage Cylinder for Converter Unit Shown
4. e Service Manual 7OE Roll Clamp P N 667442 cascade corporation P O Box 20187 e Portland Oregon 97220 503 666 1511 Contents Page Number INTRODUCTION Section 0 lt lt anaa 13 1 PERIODIC MAINTENANCE Section 1 13 2 TROUBLESHOOTING Section 2 General Procedures 00000 13 3 Schematicsiins fg Taa t d s etek 13 5 Clamp Circuit 0 6 Z KRK cee eee 13 6 Swing Circuit e eee eee 13 9 Rotate Circuit 0 eee eee 13 13 SERVICE Section 3 Clamp Removal 0 00 e eee 13 16 Clamp AIM a bac ees wel eee N EEEN 13 17 SWING Ar eoru RN ea AEE oat ae es 13 19 Cylinder lt lt 26A TE T RE bearers wae es 13 21 Revolving Connection 2000 13 25 Waterman Solenoid Valve nua 13 27 Racine Solenoid Valve 0 eee eee 13 27 Rotator Drive Group 1 2 0 0 0 0 0 eee 13 28 MOOT a aee sb aie ad see ote EO E 13 31 Junction Block 2 0 0 0 2 13 33 Frame Assembly 000 c eee eeee 13 34 INSTALLATION Section 4 INEPODUCTION lt aR date odie we wiles die ded 13 37 Truck System Requirements 13 37 Hose Reel installation aun ueasususena 13 38 Junction Block Installation 13 38 Solenoid Valve installation 13 39 Auxiliary Valve Control Knob Installation 13 40 Hydraulic Port Identification 13 41 Plumbing the Truck eee ae 13 44 WIT ied cs fo ed Soak aa Rad Oe a8 13 45
5. nent open the arms 1 2 turn the truck off and relieve all pressure in the system by opening and closing all auxiliary valves Be sure you complete this procedure with the solenoid valve activated After completing any service procedures always test each function swing rotate and clamp through 5 complete cycles First test the clamp empty to bleed off any excess air trapped in the system Then test each function with a load to make sure the clamp operates correctly before returning it to the job Rotate Circuit Plumbing 25 1 Rotator Rotator Motor Motor ROTATE COUNTERCLOCKWISE ROTATE CLOCKWISE PRESSURE memme RETURN Junction Block T PRESSURE mmm RETURN Junction Block Solenoid Solenoid Valve e Re Right Hand Right Hand Hose Reel Hose Ree Rotate Swing Auxiliary Valve 252 Rotate Circuit Troubleshooting There are four potential problems that could affect the rotation system e Clamp swings when it is supposed to rotate e Clamp does not rotate or swing when the ROTATE button is depressed and the valve is opened e Clamp will not rotate a roll up to the rated capacity of the clamp e Clamp will rotate in one direction but not in the other To isolate the specific cause of your problem refer to the procedures outlined below 1 PROBLEM Clamp swings when it is supposed to rotate PROBABLE CAUSE To Sol
6. 3 4 4 Two Stage Clamp Cylinder Service Read the Disassembly procedures page 13 22 first Use a claw type spanner wrench to remove the retainer Pull the plunger assembly out of the cylinder shell 2 Remove the setscrew Restrain the plunger with a pin type spanner wrench and use another pin type spanner wrench to remove the retainer Pull the rod assembly out of the plunger See the Disassembly Inspection and Assembly techniques in the General Procedures on page 13 22 7 E Remove Setscrew E For Reassembly Lube Torque to 50 70 in lbs Form 5165 Rev 0 PRONLRESSS SN RSS BS G 1D Unscrew Retainer with a Claw type Spanner Wrench and Pull the Piunger out of the Shell Be Sure to Replace Seal with Lip in this Direction SN Se Be Sure to Replace this O ring K Restrain Plunger with a Pin Type Spanner Wrench Use another Pin Type Spanner Wrench to Remove Retainer For Reassembly Lube Torque to 125 175 ft lbs 13 23 Section 3 Service 3 4 5 Swing Cylinder and Single Stage Clamp Cylinder Service Remove the retainer Unscrew Retainer use a Claw type CLAMP CYLINDER Use a spanner wrench on Ciaw Type Spanner Wrench the clamp cylinder SWING CYLINDER Use a use a pin type Pin Type Spanner Wrench R Rod Assembly spanner wrench on ee S iy Lube the swing cylinder For Redssembl
7. Connect the rod end of the swing cylinder to the swing arm lube torque capscrews to 50 55 ft lbs Lift the swing arm into the position shown NOTE Center the swing arm on the frame and make sure the swing arm is stable prior to tapping in the pin O Place the clamp cylinders into position NOTE Add enough shims to make the arm fit snug against the frame then tap the pins into place Install the retainer and lube torque the capscrews to 35 40 ft lbs G Lower the swing arm to within 3 of the trame Connect the base end of the cylinder to the frame Lube torque the capscrews to 35 40 ft lbs Reconnect the swing cylinder hoses to the ports on the revolving connection 333 Swing Arm Assembly 13 20 Install Retainer and Capscrews Lube Torque Capscrews to 35 40 ft Ibs Lift Swing Arm into this Position 2 Connect Swing Cylinder to Arm Lube Torque Capscrews to 50 55 ft ibs Place Frame on Floor Place Ciamp Cylinder in Position and Tap in Pins Return the Same Shims to Their Previous Locations 6 Connect Swing Cylinder to Frame Lube Torque Capscrews to 35 40 ft Ibs Form 5165 Rev O sin 2 Service 3 44 To Service Cylinder s on the Clamp Extend the swing arm fully to service the swing cylinder or extend the clamp arm fully to service the clamp cylinders 2 Disconnect the rod end of the cylinder and
8. solenoid does not click when the ROTATE button is depressed the spool is jammed and the solenoid should be replaced IF there is no current through the ohmmeter the coil is defective and should be replaced 2 PROBLEM Clamp does not rotate or swing when the ROTATE button is depressed and the truck valve is opened PROBABLE CAUSE e Mechanical malfunction in the Rotator Drive Group or the Rotator Bearing mechanism SOLUTION Refer to page 13 28 for disassembly and inspection of the Rotator Drive Group and page 13 34 for the Rotator Bearing mechanism 13 14 Form 5165 Rev 0 sn 2 WOUDIeshooting amp 252 Rotate Circuit Troubleshooting Cont 3 PROBLEM Clamp will not rotate a roll up to the rated capacity of the clamp PROBABLE CAUSES Insufficient truck hydraulic pressure s Incorrect roll handling procedures s Excessive back pressure in truck hydraulic system TESTS Check Auxiliary System Pressure Here Check the pressure being delivered by the truck s hydraulic system at the rotate swing auxiliary valve ports The pressure should initially be the truck s system pressure a 100 p s i loss is OK If the pressure is not within this range refer to your truck s service manual for adjustment Pressure must not exceed 2000 p s i Make sure the operator is gripping the roll as shown in the illustration Gripping a roll particularly a long roll near the end a
9. 13 15 Section 3 Service 31 Clamp Removal A There are two ways to remove the 70E Roll Clamp from Back Truck Away the truck L a Few Inches A is to be used if you are servicing any of the following _ Drive Group Revolving Connection Basepiate _ Ring Gear amp Bearing Assembly Frame B is to be used for servicing all remaining components 3 1 1 A Open the clamp arm fully and the swing arm to within 3 of fully extended Remove the lower mounting hooks 5 Mark Disconnect and Cap these Hoses For Reassembly Lube Torque to 85 90 ft Ib Extension 68 72 ft Ib Hook 85 90 ft ib Class Ill 4 amp 0 Class IV 4 amp 0 Lower the mast until the clamp is on the floor Lower the carriage enough to clear the upper mount B ing hooks and back away a few inches G Disconnect and cap the hoses at ports B C E G and F IMPORTANT Mark all the hoses with their proper port identification for ease in reconnecting For reinstallation reverse the above procedures i Keep Chains to the Outside of Clamp Arms 3 1 2 B O Lower the Carriage and Position the clamp with the swing arm on the bottom Back Away a Few Inches 2 Secure a hoist chain to each side of the clamp making sure the chains will support the weight of the clamp te oO Position Clamp With Swing Arm at Bottom WARNING Make sure your overhead crane has a
10. Flushing the Hoses e 020s eee 13 46 Attachment Installation 13 46 Attachment Stop Blocks 13 48 Testing Prior to Operation 13 48 Ring Gear Assernbly Frame Revolving Connection Clamp Cylinder Solenoid Valve Clamp Arm Junction AGC Cascade Corporation reserves the right to alter or improve the specifications or design configuration of its products without notice Contact Plate wing Basepiate Swit Cylinder K ad sion O Introduction This manual provides the periodic maintenance troubleshooting service procedures and installation in structions for the Cascade 70E Paper Roll Clamp There are two basic units mili unit and converter unit The miii unit is equipped with single stage clamp cylinders and will handle rolls 30 to 60 in diameter The converter unit has two stage cylinders and will clamp any roll up to 60 in diameter The Cascade 70E Paper Roll Clamp is a three function attachment The functions are CLAMP A Mill unit can clamp rolls between 30 and 60 inches in diameter A Converter unit can clamp rolls of any diameter up to 60 inches SWING A clamped load can be positioned side to side or up and down depending on how the attach ment has been rotated without affecting clamping force ROTATE 360 continuously To perform all three functions the 70E is equipped with a unique hydraulic syste
11. bushing and fitting A B into the housing C Tighten the bushing B only Any attempt to tighten the hose fitting after installation in the bushing may result in a cracked housing CAUTION If rotator fiuid was spilled when the motor was removed perform the following Remove the plug at the top of the side cover Fill the gearcase to the plug hole level with Keystone WG 1 Cascade part no C 656300 Install the plug Form 5165 Rev 1 Coupling Remove Nuts 2 For Reassemb y Lube Torque to 15 20 ft bs LS Remove the Plug Fitting OOD Level Bushing UD Fill the Gearcase LG to the Plug Hole Housing d 13 31 sain 9 Service 3 9 Motor Disassembly and Remove Capscrews amp For Reassembly Lube Torque Reassembly Cascade only services the adapter and cover the drive shaft and the seal kit which includes the seal seat and seat assembly and the 2 large O rings Due to cost if any other parts need replacement it is cost effective to replace the complete motor assembly The instructions below are for replacing the seal kit drive shaft adapter and cover only IMPORTANT Service the motor in a clean work area Clean the outside of the motor and dry thoroughly Remove any sharp edges or burrs Mark the sections of the motor with a punch or scribe for matching during reassembly Remove the four capscrews from the motor cover With a fibre hammer tap the cover to loosen
12. correctly before returning it to the job 23 14 Clamp Circuit Plumbing 2 3 2 13 6 Junction Block Left Hand Hose Reel Revolving Solenoid B Connection Tee Fitting CLAMP CLOSE PRESSURE mmnm RETURN z Auxiliary Rotate Swing Valve Auxiliary Valve Clamp Circuit Troubleshooting There are four potential problem areas that could affect clamping force Insufficient hydraulic pressure e External leaks s Malfunctioning cartridge check valves Worn or defective cylinder seals To isolate the problem area compiete the following check list in the exact sequence indicated Junction f Block Left Hand ji 9 Hose Reel BI S RS S Valve Revolving Connection CLAMP OPEN PRESSURE pans RETURN Rotate Swing Auxiliary Auxiliary Valve Vaive Clamp Cylinder Cartridge Checks In Revolving Connection Truck 7 System Possible Leak Points Form 5165 Rev O va 2 WOUDIeshooting 2 Clamp Circuit Troubleshooting Cont 1 Pressure Test Open the arms 1 2 Install your pressure gauge on one of the clamp cylinder test ports Set up the pressure test described in paragraph 2 1 3 To perform this test move the contro handie to the CLAMP position The initial reading should be the truck s system pressure a 100 psi loss is OK If the gauge does not register the truck system pressure check the pressure being del
13. do not raise the roll Department at 800 547 5266 more than 3 inches off the floor In Oregon 666 1511 13 8 Form 5165 Rev 0 Carefully operate the clamp with a maximum load in the vertica position to determine if the problem has been solved WARNING Stay clear of the load sein 2 WOUDIeshooting 2 4 2 4 1 Rotate Swing Auxiliary Vaive 2 4 2 Swing Circuit WARNING Before servicing any hydraulic compo nent open the arms 1 2 turn the truck off and relieve all pressure in the system by opening and closing all auxiliary valves Be sure you complete this procedure with the solenoid valve activated After compieting any service procedures always test each function swing rotate and clamp through 5 complete cycles First test the clamp empty to bleed off any excess air trapped in the system Then test each function with a load to make sure the clamp operates correctly before returning it to the job Swing Circuit Plumbing Junction Block l Swing Left Hand Cylinder Hose Heel Junction Block Right Hand Hose Reel SWING RETRACT PRESSURE mm Auxiliary RETURN Valve Swing Circuit Troubleshooting If the swing function is not operating properly you should first recheck the plumbing diagram on page 13 5 to be sure the attachment is correctly plumbed to the truck You should also check for severe oil leakage in the following areas e Hose reels e J
14. on page 13 16 Remove the clamp arm first see page 13 17 Attach a hoist chain to the swing arm as shown Remove the pin from the head end of the swing cylinder E Lift the arm 6 inches using the hoist chain Mark the hoses with the port callouts and disconnect and cap the hoses at the revolving connection 7 Note the quantity and location of washers before removing the pin Remove the pin retainer Screw an eyebolt into the pin remove the pin Attach Hoist Chain WARNING Keep hands clear of the swing arm pivot area after removing the pins Remove Retainer Install Eyebolt and Remove Pin NOTE Keep track of how many washers were with See Caution and each pin They must be replaced exactly where they Note in Paragraph 7 came from WARNING Make sure your overhead crane has a rated lifting capacity of at least 1000 Ibs Disconnect and Cap Hoses Bushing Replacement Install Bushing with Split Located as Shown NOTE The bushings have a special grey coating on the inside surface Be careful not to scratch or mar this surface when installing the bushing or inserting a pivot pin plit Drive the old bushing out with a bushing driver of same diameter Do not gouge the bore surface of the arm 2 Install the new bushing with a bushing driver Drive it in flush Form 5165 Rev O 13 19 scion gt QETVICE 33 2 Swing Am Installation Place the frame on the floor as shown
15. the driver and forward or down Mark the output port A Mark the opposite port B b Shift the auxiliary handle away from the driver and forward or down Mark the output port C Mark the opposite port D 4 Remove the jumper hoses Solenoid Valve Mark the ports of the solenoid valve as shown 1 Mark the port on the front of the valve body A 2 Mark the port farthest from the coil F 3 Mark one port of the tee fitting installed in the port closest to the coil D and mark the other port of the tee fitting E One Handle Systems Rearward Qutput with Handle Rear One Handle Systems Forward 7 Output with Handle For Ward or Down Two Handle Systems Waterman Solenoid Valve Form 5165 Rev O seen 4 Installation Instructions eo Hose Reels 4 64 It is important to also determine the hose reel ports that correspond to the hoses of the reels You can do this by blowing compressed air 35 psi maximum through each hose reel port and feel which hose is in line Mark the hose reel ports as follows 1 Left hand Reel as viewed from the driver s seat mark the port that is in line with the inboard hose C and mark the opposite port E 2 Right hand Reel as viewed from the driver s seat mark the port that is in line with the inboard hose B and mark the opposite port F Junction
16. the truck valves Install the pressure gauge as indicated in the test checklist on the following pages for each circuit Form 5165 Rev O 13 3 sae 2 MOUDleshooting 21 3 General Pressure Test amp Bleed Procedures Cont Place the drain hose in an empty container Open the needle valve 12 1 turn maximum WARNING Before operating the truck make sure there are no people in the vicinity of the drain hose Open the truck valve and power the truck at idle Wait approximately 4 5 seconds and close the needle vaive tightly Close the truck auxiliary valve You are now ready to read the gauge 21 4 Get All The Facts Before You Begin Working On The Clamp It is extremely important to gather all the facts regarding the problem before you begin your service procedures The best way to gather the information is to talk with the operator Ask for a complete description of the malfunc tion The following guidelines will help you decide where to begin your troubleshooting procedures A Clamp Circuit e Clamp drops rolis after they have been gripped e Clamp will not carry roils up to the capacity of the clamp Clamp arm won t function properly e Clamp arm drifts towards swing arm when in the horizontal position If one of these problems exists see page 13 6 B Swing Circuit e Swing function operates very slowly e Swing is in one direction only e Clamp drifts when i
17. wheel onto the pinion shaft and align with the woodruff key G Press the bearing onto the pinion shaft Reinstall the snap ring G Assemble the spring washers spacers and ball thrust bearings See Caution below on the worm shaft and install in the housing CAUTION The ball thrust bearing must be assembled on the worm with the thickest portion of the outer race the side stamped with the manufacturer and part number facing away from the washers Small 1 454 Spacer Worm Thrust Bearing 16 WASHER CUSHION DRIVE Spring Washers Assemble Washers Spacers and Bearings on Worm and install in the Housing 15165 Rev 1 3 Install Pinion Install KR Woodruff Key Press Worm Wheel onto Pinion Shaft Press Bearing onto Pinion Shaft Install Snap Ring 13 29 section O SErVIcCe 3 8 3 Reassembly Cont Gap Should install the endcap If the gap is more or less than ee gene shown the spring washers were incorrectly stacked End Cap Remove the worm and restack the spring washers as shown in Step 8 Then alternately tighten the endcap capscrews 2 3 of a turn Tighten the capscrews to a torque of 7 10 ft lbs Alternately Tighten Capscrews 2 3 of a Turn 10 For Reassembly Lube Torque to 7 10 ft lbs Fill Gearcase to this level install the Motor Lube Torque Retaining Nuts to 15 20 ft lbs Reinstall the cover 12 R
18. 15 GPM s Truck carriage must conform to Industrial Truck Association ITA dimensional standards as shown below Dimension A in Min Max Class tll 18 68 18 74 Class IV__ 23 44 23 50 Mounting WARNING Rated capacity of the truck attachment combination is a responsibility of the original truck manufacturer and may be iess than shown on the attachment nameplate Consult the truck nameplate Form 5165 Rev 0 13 37 un 4 Installation Instructions 42 Hose Reel Installation Your truck must be equipped with some method to route four No 8 hoses between the truck mounted control valves and the attachment You may use two hose reels mast internal hose sheaves counter weighted hose sheaves etc For most installations Cascade recommends using two 14 5 inch diameter hose reels Cascade Model H8L P N C 646042 on the left hand side and Cascade Model H8R P N C 646043 on the right hand side If the attachment is to be installed on a high lift mast larger hose reels may be required Consult the Cascade Hose Reel Selection Guide form 4031 or contact Cascade Customer Service Install the hose reels according to the Instructions supplied with the reels 43 Junction Block Installation for use with hose reels install two junction blocks on the back side of the truck Carriage upper crossbar as shown below Use the special junction block included with the attachment on the right hand side of the carriage Cascade reco
19. Blocks Mark the junction block ports as shown Form 5165 Rev 0 Outboard Hose E Inboard Hose C of ete yet Outboard F Hose C B Inboard Hose Left hand Reel IMPORTANT Ports may be the reverse of those shown Left hand Junction Block Right hand Junction Biock 13 43 cen 4 Installation Instructions POSSONO 47 Plumbing the Truck Connect the truck hydraulic system hoses only as far as the junction block ports E C B and F as shown below connecting the same lettered ports together When installing the hoses s Be careful not to twist pinch or otherwise damage the hoses e Use No 8 hose 1 2 inch ID with minimum fitting orifices of 1 inch e Use as few fittings as possible Use 45 elbows instead of 90 elbows wherever possible Do not route the hoses through tilt cylinder cutouts or anywhere else they may be damaged by moving components s As much as possible route groups of hoses together Rotator Motor Junction Biock Revolving Connection Left Hand Hose Reel Solenoid Valve Junction Block Tee Right Hand Hose Reel Rotate Swing Auxiliary Valve NOTE Auxiliary valve ports and hose reel ports may be reversed fram those shown Clamp Auxiliary Valve 13 44 Form 5165 Rev 0 sen 4 Installation Instructions a E Wiring eae 1 To prevent inadvertent contact with hot wires or con Solenoid ie
20. Cascade service representative at 800 547 5266 toll free or in Oregon call 666 1511 Form 5165 Rev 0 5 Drifts Down Clamp Arm SS Oo AA CT d L Swing Cylinder Fully Extended Needle Valve Left hand Junction Block Revolving Connection Left Hand Junction Block Extend Swing Cylinder Close Needle Valve 13 11 secin 2 IOUDIeshooting 2 42 13 12 Swing Circuit Troubleshooting Cont 5 PROBLEM Swing function operates very slowly when swinging roll NOTE The swing function is intentional ly designed to operate slowly This pro blem should be considered only if there has been an appreciable reduction in speed over the normal operating speed PROBABLE CAUSE e Wrong size hoses were installed e Revolving valve is internally damaged SOLUTION e Use No 8 Hoses e Replace the revolving valve body 6 If the problems listed in this section do not corres pond to the problem you are experiencing or if the procedures outlined have not solved your problem DO NOT PROCEED Call a Cascade service representative at 800 547 5266 toll free or in Oregon call 666 1511 Cascade s Service Department is open from 10 00 a m to 8 00 p m Eastern time Swing Very Slowly When Swinging Roll Call Cascade s Service Department at 800 547 5266 In Oregon 666 1511 Form 5165 Rev 0 2 sein 2 IOUDIeshooting Rotate Circuit WARNING Before servicing any hydraulic compo
21. Cover Mounting Capscrews as follows 1 Secure the cable assembly with the clip as shown 2 Place the cover on the solenoid and torque the cover capscrews to 30 45 in Ibs 3 Reconnect the truck battery Clip Lockwasher Nut Form 5165 Rev 0 13 45 sexo 4 Installation Instructions 49 Flushing the Hoses Prior to connecting the truck system to the attachment the hoses should be flushed Fiushing will remove con taminants that might damage the vaives and cylinders 1 Connect hoses together using a nipple as shown 2 Start the truck and actuate both auxiliary valves for about 30 seconds in both directions This causes oil to carry any debris left in the hoses to the truck hydraulic tank and filter Stop the truck 3 Reconnect the hoses as shown on page 13 44 4 10 1 Wrap two chains around the clamp arm near its pivots as shown 2 Put a loose pallet next to the shipping pallet as shown in Step 1 3 Using a suitable hoist slowly raise the attachment Let the swing arm pivot on the support block and rest on the loose pallet Continue raising until the attachment baseplate is vertical Remove the lower mounting hooks See Step 2 4 Drive the truck in position and raise the carriage to engage the attachment upper mounting hooks Make sure the attachment is centered on the carriage and make sure the stop block on the upper left hand mount ing hook is engaged in a notch on the truck upper c
22. SS E BUTTON BUTTON TO ROTATE ROTATE Se Visible on trucks with A single handle controlling auxiliary valves Visible on trucks with B individual two handles controlling auxiliary valves Snap nap Ring S Dimple Up se Control Knob Down Placard Snap Ring Groove Recess Control Knob Forward A Rearward NOTE The terms rearward forward up and down as applied to auxiliary control handle movement are illustrated oe by the accompanying diagram i Ta anh sein 4 Installation Instructions 4 6 1 4 6 2 13 42 Truck Auxiliary Valves Cont Determine auxiliary valve output according to the follow ing procedures 1 Connect a jumper hose to each port of both auxiliary valves Put the ends of the hoses into a suitable container to collect oil 2 Start the truck and briefly shift the auxiliary control handle s while watching the flow from the jumper hoses 3 Mark or tag each port as follows stick a piece of masking tape next to each port for easy marking For Trucks with Two Auxiliary Handles a Shift the auxiliary handie closest to the driver the one with the special knob forward or down Mark the output port A Mark the opposite port B b Shift the second auxiliary handle forward or down Mark the output port C Mark the opposite port D s For Trucks with One Auxiliary Handle a Shift the auxiliary handie toward
23. a hoist chain to each eyebolt WARNING Be sure to attach a hoist chain to each eyebolt before removing the remaining ring gear capscrews The ring gear is very heavy and oily so take care to prevent pinching or dropping on fingers or feet Make sure your overhead crane has a rated capacity of at least 1000 Ibs O Remove the remaining capscrews and lift the ring gear and bearing assembly off the attachment to Each Eyebolt Remove Remaining Capscrews For Reassembly Lube Torque to 65 70 ft Ibs Form 5165 Rev O san O Service amp 311 3 Frame Service Install Bushing with Split Located as Shown 1 Bushing Replacement NOTE The bushings have a special grey coating Split L G on the inside surface Be careful not to scratch or mar this surface when installing the bushing or inserting a pivot pin Drive the old bushing out with a bushing driver of same diameter Do not gouge the bore surface of the frame 2 Install the new bushing with a bushing driver Drive it in flush Bushing Felt Seals Ring Gear Bearing Assembly Baseplate 2 Felt Seal Installation 1 Start one end of the seal strip in the groove Push the seal to the bottom of the groove and com press the seal towards the end where installation began If the seal won t fit in the groove stretch it to provide a thinner cross section With the seal pushed into the groove and com pressed cut it so the two ends meet s
24. and remove it inspect the seal seat Replace only if the sealing face is excessively worn or damaged Remove it by inverting the adapter and driving out the seat with a wooden block Press the new seat into the adapter To replace the drive shaft remove the snap ring and press off the gear in an arbor press To reassemble coat the drive gear bore with white lead Install one snap ring and press the gear on the shaft until the gear covers about 1 4 of the key slot Hold the key in place and press the gear the rest of the way onto the shaft until it contacts the snap ring Install the second snap ring GG G See Paragraph 6 C Before Removing the Drive Shaft Drive Shaft S Driven Shaft See Paragraph 5 Before Removing the Sea Seat Cover 13 32 Form 5165 Rev 1 ston O SETVICE p Junction Block Disassembly Q Label remove and cap the hoses at the junction block 2 Remove the junction block mounting capscrews and lift the junction block off the carriage Remove the shaft snap ring Q Remove all parts as shown Inspection e Thoroughly clean all parts e Inspect all parts especially the grooves and bore of the junction block for nicks and burrs If deeply gouged or worn then replace the part Otherwise remove minor nicks and burrs with an emery cloth Spacer or butterfly S NOTE Minor nicks are those that will not cause a bypass of oil when under pressure Rem
25. apscrews For Reassembly Lube Torque to 8 10 ft lbs Form 5165 Rev 0 Section 3 Service 3 8 3 8 1 3 8 2 13 28 Rotator Drive Group Removai and Installation 1 Set the attachment on the floor following procedure A on page 13 16 2 Remove the four gearcase retaining capscrews WARNING The baseplate is free to rotate when the gearcase is removed Therefore keep your hands and ciothing clear of the baseplate to avoid being pinched Disassembly 1 Drain the lubricant and lay the gearcase pinion down on 4 x 4 s placed on either side of the pinion Remove the six motor retaining nuts 3 Remove the two cover retaining capscrews Remove the center screw and replace with a 3 8 16 UNC x2 capscrew Turn the capscrew clockwise while lightly tapping the side of the cover with a plastic head hammer to loosen the cover Remove the endcap and bearing Remove the worm and spring washers Remove the snap ring from the pinion shaft O Use a gear puller to remove the worm wheel Remove the woodruff key from the pinion shaft Press the pinion out of the gearcase Press the seal and bearing out of the gearcase 12 Replace any item that is worn or galled Remove any burrs with an emery cloth or small hand grinder Press Pinion Out of Gearcase CAUTION Some units will have this style relief fitting in the end cap These units may have dam aged bal thrust b
26. arriage crossbar See Step 3 Step Vertical Remove Lower Mounting Hooks Pallet 13 46 Attachment Installation Base Plate SSL Connect these Hoses Together Left hand Hose Reel Right hand Hose Reel Connect Hoses To Ports A and F Together Step Rotator Motor Clamp Arm Loose Pallet sein 4 Installation Instructions Attachment Installation Cont not Revolving Connection 5 Measure the hose lengths required to plumb the at tachment Assemble the hoses and fittings or use Cascade Attachment Installation Kit C 665339 which contains the required hoses and fittings 6 Flush each hose with hydraulic oil to remove any debris that might contaminate the attachment Cap both ends of the hoses Left hand Lower the truck carriage and back the truck clear Hose Reel away from the attachment 8 Install one end of each hose assembled in Step 5 to the attchment revolving connection and rotator motor as shown below 9 Install the attachment onto the truck carriage as described in Step 4 Do not pinch the hoses 10 Install the lower mounting hooks and torque the Rotate capscrews to 85 90 ft Ib Swing Valve BK 11 Remove the lifting chains 12 Connect the attachment hoses to the truck junction blocks The Plumbing Diagram on page 13 44 illustrates the entire truck attachment hydraulic system correctly plumbed Hose Reel
27. aution in Paragraph 4 WARNING Keep hands clear of the clamp arm pivot area after removing pins Remove the pins and lift off the clamp arm 3 214 Bushing Replacement Install Bushing with Split Located as Shown NOTE The bushings have a special grey coating on the inside surface Be careful not to scratch or mar this surface when installing the bushing Split or inserting a pivot pin Big fa Drive the old bushing out with a bushing driver of same diameter Do not gouge the bore surface of the arm install the new bushing with a bushing driver Drive it in flush Form 5165 Rev O 13 17 Section 3 Service 3 22 Clamp Arm Installation Lift clamp arm into position Reinstall the same washers in the same order as they were removed Tap in the pins Install the eyebolts and capscrews and lube torque Lift Clamp PS the nut to 50 55 ft lbs Arm into 7 Position os D Connect the rod end of both clamp cylinders to the O Naa jj clamp arm lube torque the capscrews to 50 55 ft S Washers to their E Ibs Previous Locations e Instal Eyebolts Capscrews and Nuts Lube Torque Nuts to 50 55 ft ibs 4 Connect Cylinder to Clamp Arm Lube Torque Capscrews to 50 55 ft lbs 3 23 Clamp Arm Assembly 13 18 Form 5165 Rev 0 section DEVICE 3 3 3 3 1 Swing Arm Removal 1 Set the attachment on the floor following procedure B
28. burrs If deeply gouged then replace the part Otherwise remove minor nicks and burrs with an emery cloth or butterfly NOTE Minor nicks are those that will not cause a bypass of oil when the revolving connection is operating Assembly e Lubricate all new seals with STP and install as Lubricate New Seals with STP Before Remove Cartridge Valves For Reassembiy Lube Torque to O ft Ibs vos LT Wo ey Kee shown Reinstall the shaft on the fixed valve body before installing in the revolving valve body Take special care when sliding the shaft through the revolving valve body Do not damage the bore Reinstall the check valve cartridges Do not damage the cartridge seals z5 S e a Fom 51 65 Remove la Snap Ring Remove Cartridge Valves For Reassembly Lube l O Torque to 30 ft lbs Rev Lubricate New Seals With STP Before Installing i serion 2 SETVICE psa Waterman Solenoid Valve 3 6 1 Remove and Service WARNING Disconnect the ground cable from the battery on internal com bustion trucks or disconnect the truck battery on electric trucks WARNING Disconnect the ground cable from the battery on internal com bustion trucks or disconnect the truck e _ Remove Capscrews battery on electric trucks For Reassembly Lube Ss Torque to 30 45 in ibs Remove the two mounting capscrews Remove the two cover capscrews
29. e clamp operates correctly before returning it to the job 211 Truck System Requirements Pressure Your truck should supply enough pressure to adequately handle the heaviest load PRESSURE MUST NOT EXCEED 2000 psi Volume 15 20 g p m 212 Tools Required In addition to a normal selection of hand tools you will need e 1 No 6 Straight thread connector fitting with O ring 2 each No 8 and No 6 reducers e 1 metal plug No 8 37 flared male for hose e 2 metal caps No 8 37 flared female for ports e 2 pressure gauges that are capable of reading pressures up to 2500 p s i 2 needle shutoff valves rated at 2500 p s i e 1 voltmeter or test light s 1 ohmmeter 21 3 General Pressure Test amp Bleed Procedures For maximum accuracy you should set one of your HE pressure gauges up as indicated in this illustration The Pressure needle valve and drain line will allow you to bieed off trapped air in the system before you take your pressure readings Unless otherwise indicated you should always use this pressure gauge with the needle valve and drain line for troubleshooting To use the pressure gauge use the following procedures No 8 37 Flared to bleed the air from the system before reading your Female Fitting NOTE Make sure l the arrow points in gauge this direction Open the arms 1 2 Turn the truck off and relieve any pressure in the system by opening and closing
30. e hoses with the port callouts Remove and cap the hoses to all the fittings on the revolving connection C Remove the four plate capscrews G Remove the revolving connection out through the swing arm side Form 5165 Rev 0 2 Stage Cylinder for Converter Unit Shown TOP VIEW Disconnect Head End of Swing Cylinder Remove and Cap all Hoses at the Revolving Connection A So Remove Capscrews For Reassembly Lube Torque to 12 17 ft ibs 13 25 Pull Revolving Connection Out amp Swing Arm Side i sein Service 35 3 Revolving Connection Service 13 26 Disassembly Remove the snap ring PALITICOR Damaun any naint ar hiirre fram tha MPA M T IMPI FIC TOVE Gay WTI MT VUO TIM U I shaft end before pulling the fixed valve and shaft out of the revolving valve Pull the fixed valve and shaft from the revolving valve Remove the two capscrews retaining the shaft to the fixed valve Remove the O rings and Back up rings from the shaft O DO NOT remove any of the cartridges on the fixed valve G Remove the cartridge valves as shown from the revolving valve body Remove Capscrews For Reassembly Lube Torque to 20 25 ft Ibs Installing E Lubricate O a Seals with STP Before Installing K TT Revolving Valve Body inspection s Thoroughly clean all parts Inspect the grooves and bore of the revolving valve body for nicks and
31. e side marked A should be visible on tha nba the knob If Your triink aryiliary valuas ara gnaratad with VUI LEM QGUAINGI Y VAIGO GIS Veal YYI 1 individual contro handles the side marked B should be visible Hydraulic Port Identification Truck Auxiliary Valves The 70E hydraulic system is designed so that operation of the truck auxiliary valve control handle s conforms to in dustry standard practice as described by the following chart Motion of the operator s hand when actuating the truck auxiliary control handle while facing the load retract L Reawardorup roe pe eater Ue_ ici oamp ft Besar o On trucks with the auxiliary valves controlled by individual handles both SWING and ROTATE are operated by the auxiliary handle closest to the driver and CLAMP is controlled by the second auxiliary handle from the driver Function listed in sequence of location to opygrator Attachment movement On trucks with the auxiliary valves controlled by a single handle both SWING and ROTATE are operated when the auxiliary handle is shifted toward the driver and CLAMP is operated when the handle is shifted away from the driver Thus prior to connecting hoses to the truck it is vital that you first determine which ports of the auxiliary valves supply high pressure output when the handle s is shifted 51 BAR Daw A MM IVY VW PRE
32. earings due to iow rotator fluid Cascade has a drive box lube kit available which provides new ball thrust bearings and a new pressure relief fitting See Technical Bulletin 114 for complete ordering instructions Remove Worm and Spring Washers Remove End Cap and Bearing Remove Nuts E Drain For Reassembly Lube Lubricant Torque to 15 20 ft ibs Remove Screw and Replace with a 3 8 16 UNC x 2 Capscrew Loosen the Cover by Turning Capscrew Clockwise while Lightly Tapping the Side of the Cover Remove Woodruff Key Gearcase Boss 2 Remove Capscrews For Reassembly Lube Torque to 40 ft lbs See CAUTION in paragraph 2 K Remove Capscrews D For Reassembly Lube Torque to 45 50 ft Ibs Press Seal and Bearing out of Gearcase Use Gear Puller 1 to Remove Worm Whee Bearing Remove Snap Ring Form 5165 Rev 1 sean DETVICE Reassembly oO Press the bearing into the housing from inside with the help of the special tool C 664620 shown Make sure the bearing is fully seated and flush with the in side of the gearcase 2 Install the seal into the boss of the housing from out side of the housing Lip must be facing inward Seal should be flush with boss Support the bearing from inside with the special tool and press the pinion into the bearing from the outside O install the woodruff key into the pinion shaft 5 Press the worm
33. einstall the motor Fill the gearcase with 44 fluid ounces of Keystone WG 1 lube Cascade part no C 656300 NOTE C 656300 32 fluid ounces Install the gearcase on the rotator baseplate IE install Gearcase on Roll Clamp Lube Torque Capscrews to 40 ft Ibs 13 30 Form 5165 Rev 1 Section 3 Service 9 3 9 1 Motor Motor Removal and Installation The rotator motor can be removed for service with the attachment on the truck oo oo WARNING Before removing supply hoses relieve pressure that might be present in the hydraulic system With the truck off open the truck auxiliary control valves several times in both directions Remove cap and tag the supply hoses to the motor Remove the motor from the rotator drive assembly by removing the six retaining nuts Slide the motor out of engagement and remove the coupling and key from the motor shaft A small amount of rotator fluid might spill when the motor is removed Clean the motor and gear case mating surfaces with solvent Apply LOCTITE 515 sealer to these surfaces Install the motor and tighten the retaining nuts toa torque of 15 20 ft ibs Lubed CAUTION Because the threaded part on the motor is tapered overtightening the fitting in the port wiit split the housing Fittings should be snug but not overtightened Install reducers and fittings as follows Thread hose fitting A into bushing B until tight Fit the assembly of the
34. enoid Cable Valve Assembly Connector Push Button Control Switch Short circuit in electrical system to solenoid A Ignition e Solenoid not operating euler Sia Switch Note Make sure the solenoid coil is the same voltage rating as the truck s system Form 5165 Rev 0 Cord Assembly 13 13 sin 2 WOUDIeshooting 252 Rotate Circuit Troubleshooting ___ ooh E nU With Voltmeter or Connector Test Light Cable Assembly TEST Follow exact sequence Solenoid from contro knob Valve for voltage at solenoid Check for loose connections in all electrical wiring from the control button to the truck s ignition to the solenoid Terminal xX J S To Truck aN Ignition Disconnect the electrical leads at the solenoid Using a voltmeter or a test light make sure there is S electrical voltage at the electrical leads when the Ground ROTATE button is depressed IF there is no voltage to the solenoid begin troubleshooting the electrical circuit for short circuits be sure to include the ROTATE switch in the control handle in your tests IF there is voltage to the solenoid when the ROTATE button is depressed continue on with this checklist Solenoid for coil continuity Valve Using an ohmmeter check the solenoid coil by placing Test Coil With a lead on each solenoid terminal Ohmmeter IF there IS current through the ohmmeter but the
35. he baseplate and retorque all the ring gear bearing assembly capscrews to 65 70 ft Ib O Remove the plug on the side of the rotator drive gear case and fill to capacity with Cascade Rotator Drive Lubricant part no C 656300 or Keystone WG 1 13 1000 Hour Maintenance In addition to the 100 and 500 hour maintenance per form the following every 1000 truck operating hours O Check the pivot point bushings on the cylinders arms and rotator frame for worn deeply scratched or marred inside surfaces Replace if any of these symptoms exist See pages 13 17 13 19 13 24 and 13 35 14 2000 Hour Maintenance In addition to the 100 and 500 hour maintenance per form the following every 2000 truck operating hours D Replace all pivot point bushings See pages 13 17 13 19 13 24 and 13 35 13 2 Form 5165 Rev O tR sin 2 TTOUDP lesnooting General Procedures Please read this section before you begin troubleshooting WARNING Before servicing any hydraulic compo nent open the arms 1 2 turn the truck off and relieve all pressure in the system by opening and closing all auxiliary valves Be sure you complete this procedure with the solenoid valve activated After completing any service procedures always test each function swing rotate and clamp through 5 complete cycles First test the clamp empty to bleed off any excess air trapped in the system Then test each function with a load to make sure th
36. ivered by the truck pump as outlined in your truck service manual Adjust and repair as necessary Following the adjust ment recheck the pressure at the clamp cylinder test port If a gradual pressure loss continues after the 100 psi loss this indicates a problem in the clamp com ponents Proceed with the troubleshooting checklist If the pressure reading is not within 100 psi of the truck system pressure AND there is no gradual pressure loss your problem may not be hydraulic but may be related to the application of the clamp In this case call Cascade s Service Department at 800 547 5266 toll free or in Oregon 666 1511 2 External Leaks __ Refer to the diagrams on the preceding page and check for all areas that could have external leaks Repair as necessary and carefully operate the clamp with a foad to determine if the problem has been solved WARNING Stay clear of the load while testing and do not raise the roll more than 3 inches off the floor 3 Cartridge Check Valve Test Open the arms 1 2 Relieve any pressure in the system by opening and closing the truck valves then turn the truck off __ Remove both of the inside hoses pressure lines from the clamp cylinders Plug one hose with a No 8 metal plug __ Set up the pressure test described in paragraph 2 1 3 To perform the test move the control handle to the CLAMP position The initial reading should be the truck s system
37. late to the mounting surface IMPORTANT If you secure the mounting plate with capscrews make sure the heads of the capscrews are on the 1 625 in side facing the solenoid valve rast ER P25 ye Location 3 Secure the solenoid valve to the mounting plate using S the capscrews removed in Step 1 ne phot Be chert ae i ty Solenoid Lo TL Valve NOTE Do not install the cover at this time You will need the cover off to gain access to the solenoid valve electrical connections later Cover Solenoid Solenoid Valve Mounting Capscrews Form 5165 Rev 0 Mounting Plate Either drill thru or drill and tap mounting surface for two 5 16 in 13 39 sen 4 Installation Instructions 4 4 2 4 5 13 40 Waterman Solenoid Valve 1 Disconnect the ground cable from the battery internal combustion trucks or disconnect the truck battery electric trucks 2 Tack weld the mounting plate to the mounting surface using a mild steel welding rod 3 Place the solenoid on the mounting plate and torque the mounting capscrews to 45 50 in lbs Auxiliary Valve Control Knob Installation A special control knob which includes an electrical switch and wiring to control the solenoid valve is included with the attachment s if the auxiliary valves on your truck are controlled by individual handles the knob should be installed on the handle closest to the operator when he is in the driver s seat
38. m The system makes it possible to operate all three functions with only two truck auxiliary valves in conjunction with a truck mounted solenoid valve supplied with your attachment Form 5165 Rev O _Clamp Arm ie ee H Viamp arm is pivoted to swing arm CLAMP Only the clamp arm moves NOTE Mill units can handle 30 to 60 inch rolls only Swing arm is pivoted to the attachment faceplate When the swing arm is actuated the clamp arm moves with it Both arms move simultaneously 13 1 secon 1 Periodic Maintenance 11 100 Hour Maintenance Every time the lift truck is serviced or every 100 truck operating hours whichever comes first the following maintenance should be completed D Check the edge of the contact plates for wear or sharp nicks that could damage or tear paper rolis Replace the contact plates if necessary U Check the pressure see paragraph 2 1 1 on page 13 3 by performing the pressure test outlined in the Clamp Circuit Troubleshooting page 13 7 and the Swing Circuit Troubleshooting page 13 9 12 500 Hour Maintenance In addition to the 100 hour maintenance perform the following maintenance every 500 truck operating hours DU Lubricate the ring gear bearing assembly with wheel bearing grease Rotate the clamp one full turn during lubrication O Retorque the mounting hook capscrews using the torque specifications on pages 13 16 and 13 34 D Remove the plug on the back of t
39. mine if the problem has been solved WARNING Stay clear of the load while testing and do not raise the roll more than 3 inches off the floor 5 Cylinder Low Pressure Seal Test Open the arms 1 2 Remove both of the outside hoses return lines from the clamp cylinders Plug the hoses with No 6 metal plugs Install a needle valve attached to a length of hose into the open port on each clamp cylinder Close the needle valve tightly Rotate the clamp to the horizontal position with the clamp arm on top If the clamp arm drifts down then both cylinders have damaged seals If no drift occurs one of the cylinders MAY have defective seals Perform the following to determine if one of the clamp cylinders needs new seals Needle Valves Slightly open the needle valve on cylinder A If the clamp arm drifts down then cylinder B has defective seals If no drift occurs then cylinder B seals are OK Repeat this needie valve test on cylinder B If the clamp arm drifts down then cylinder A has 6 l defective seals If you have carefully and accurately completed this check list and you still have not solved the problem Hing OUT eb cursipen eylndel A SRA ate ON DO NOT PROCEED Please call one of our service representatives at 800 547 5266 toll free or in Oregon 666 1511 Our Service Department is open from 10 00 a m to 8 00 p m Eastern Time Cail Cascade s Service while testing and
40. mmends using a junction block without checks P N C 652055 on the left hand side Hose Reel Mast IMPORTANT Make sure junction block hose reel ports y are aligned with Locate the junction blocks so the hose reel ports of the hoses of hose reels blocks are aligned between the flanges of their respective hose reels Junction Carriage Block Junction Block P N C 652055 Hose Reel Ports X Ta is Special Junction 7 nA Hose Reel Block P N C 665098 Port included with the attachment Truck Carriage 3 8 16 UNC x 1 in Capscrews 4 ples Torque to 15 ft lb 2 Holes in Carriage 2 Places 5 16 in Drill 1 in deep Tap 3 8 16 UNC 1 5 inch Form 5165 Rev 0 sen 4 Installation Instructions Solenoid Valve Installation Select some convenient location on the truck to install the solenoid valve assembly Cascade recommends that on most lift truck installations somewhere on the front of the truck cowl is a good location Make sure the location you select does not interfere with the operation of any other lift truck components mast hoses tilt cylinders etc It makes no difference if the solenoid valve assembly is positioned as shown below or upside down or oriented in any other way 441 Racine Solenoid Valve 1 Remove the solenoid valve mounting plate and cover from the solenoid valve assembly by removing the three mounting capscrews 2 Locate and secure the mounting p
41. n bilge horizontal position e Clamp attempts to do two functions simultaneously If one of these problems exists see page 13 9 C Rotation Circuit gt Clamp swings when it is supposed to rotate Clamp won t rotate e Clamp will not rotate rolls up to the capacity of the clamp s Clamp will rotate in one direction but not the other If one of these problems exists see page 13 13 13 4 Open Needle Valve 1 Turn Place Drain Hose in Container Form 5165 Rev O scion amp Iroubleshooting 2 Schematics Rotator 2 214 Plumbing Junction Block iF Junction Block Left Hand Hose Reel Right Hand Hose Reel Rotate Swing Auxiliary Valve 2 2 2 Hydraulic NOTE Auxiliary valve ports and hose ree ports Valve may be reversed from those shown Swing Rotate g Form 5165 Rev 1 13 5 sein 2 Iroubleshooting 2 3 Clamp Circuit WARNING Before servicing any hydraulic compo nent open the arms 1 2 turn the truck off and relieve all pressure in the system by opening and closing all auxiliary valves Be sure you complete this procedure with the solenoid valve activated After completing any service procedures always test each function swing rotate and clamp through 5 complete cycles First test the clamp empty to bleed off any excess air trapped in the system Then test each function with a load to make sure the clamp operates
42. nd then attempting to rotate it requires a tremendous amount of torque often times beyond the capacity of the clamp Requires Excessive Torque TT a pressure gauge into each port on the hydraulic motor do not use the needle valve drain line components THIS NOT THIS Securely grip a roll that weighs close to the capacity of the clamp Rotate the roll and note the pressure readings on the gauges during rotation IF the lower pressure reading exceeds 200 p s i you have excessive back pressure in your supply circuit Check for restrictions such as numerous fittings hose sizes less than 8 clogged oil filter etc IF the lower pressure does NOT exceed 200 p s i and the truck pressure is within the specified range the hydraulic motor needs repair refer to page 13 31 4 PROBLEM Clamp will rotate in one direction but not in the other PROBABLE CAUSE s Right hand junction block pilot spool is jammed SOLUTION e Replace right hand junction block d 5 If the problems listed in this section do not Call Cascade s Service correspond to the problem you are experiencing or if the procedures outlined have not solved your Department at 800 547 5266 problem DO NOT PROCEED Call a Cascade service representative at 800 547 5266 toll free or in In Oregon 666 1 511 Oregon call 666 1511 Cascade s Service Department is open from 10 00 a m to 8 00 p m Eastern time Form 5165 Rev O
43. ng arm should extend as viewed from the driver s seat 2 Move the rotate swing handle rearward or up Do not press the button on the contro knob The attachment swing arm should retract 3 Press the button on the control knob Move the rotate swing handle forward or down The attachment should rotate counterclockwise Return the handle to neutral and release the button 4 Press the button on the control knob Move the rotate swing handle rearward or up The attachment should rotate clockwise Return the handle to neutral and release the button 5 Move the clamp handle forward or down The clamp arm should open 6 Move the clamp handle rearward or up The clamp arm should close 7 Check the entire hydraulic system for leaks 8 Operate the attachment through several cycles to purge air from the system Attachment Upper Mounting Hook Steel Stop Block Truck Carriage Upper Crossbar A Form 5165 Rev O cascade roms TM Do you have questions you need answered right now Dial Directline 800 547 5266 toll free Cascade Corporation 1978 2 82 VGP Litho in U S A P N 667442 Form 5165
44. ove Reassembly anap e Lubricate all new seals with STP and install as shown e Take care when reinstalling the shaft on the junc tion block Do not damage the bore KI Remove Capscrews i Lube Torque Lubricate New Seals With STP to 15 ft Ibs Before Installing Form 5165 Rev 0 13 33 scion O DETVICE 3 11 3 11 1 3 11 2 13 34 Frame Assembly Baseplate Removal Set the attachment on the floor following procedure A on page 13 16 O Remove the drive group see page 13 28 and the revolving connection see page 13 25 before continuing Remove the upper mounting hooks 4 Replace the capscrews under the upper mounting hooks with eyebolts Attach a hoist chain to each eyebolt Remove Mounting Hooks For Reassembly Lube Torque to 85 90 ft Ibs WARNING Be sure to attach a hoist chain to each eyebolt before removing the remaining baseplate capscrews Make sure your overhead crane has a rated capacity of at least 1000 Ibs Remove Remaining Baseplate Capscrews Install Eyebolts Attach a Hoist Chain to Each Eyebolt G Remove the remaining 18 baseplate capscrews Ring Gear Bearing Assembly Removal Set the attachment on the floor following procedure A on page 13 16 2 Remove the drive group see page 13 28 the revolv ing connection see page 13 25 and the baseplate before continuing Replace two capscrews on the ring gear with eyebolts and attach
45. place revolving valve body see page 13 25 Fully Extended Clamp Swings This Way 3 PROBLEM Clamp swings in one direction only swing cylinder retracts but will not k y Not extend Bur v PROBABLE CAUSE Internal malfunction in revolving valve body SOLUTION s Replace revolving valve body see page 13 25 13 10 Form 5165 Rev 0 amp 2 4 2 swim 2 Troubleshooting Cont 4 PROBLEM Swing Circuit Troubleshooting Clamp in bilge horizontal position Swing arm on bottom Swing cylinder completely extended Ciamp drifts down particularly when clamping a roll PROBABLE CAUSE e internal leak in truck auxiliary valve for the swing function TEST Install a needle valve in the swing line at the left hand junction block as viewed from driver s seat Open the needle valve Clamp a roll Rotate the clamp to the bilge position with the swing arm on the bottom and fully extend the swing cylinder WARNING Exercise extreme caution when clamping a roll and make sure there are no people in front of the clamp or near the sides of the clamp Quickly close the needle valve and turn the truck off IF the needle valve eliminates the drift make a note of this and call a Cascade service representative at 800 547 5266 toll free or in Oregon call 666 1511 IF the needle valve does NOT eliminate the drift make a note of this and call a
46. pressure a 100 psi loss is OK if there is a gradual pressure loss after the 100 psi loss once the truck valve is closed one of the follow ing problems is responsible a Check valve cartridge is defective b Cartridge seals are severely damaged c Revolving valve body is damaged internally __ Repeat this test on the capped hose to check the other cartridge and cartridge seals __ Replace cartridge cartridge seals or valve body if necessary Form 5165 Rev O Close Clamp Arms Test Pressure Port Gauge Watch for Gradua Pressure Loss After Truck Valve is Closed 13 7 scion 2 roubleshooting 232 Clamp Circuit Troubleshooting Cont 4 Cylinder High Pressure Seal Test IMPORTANT In order to accurately check the cylinder seals you must have completed the prior steps in this check list Open the arms 1 2 Install a pressure gauge in the test port on one of the cylinders Set up the pressure test described in paragraph 2 1 3 To perform the test move the control handie to the CLAMP POSITION The initial reading should be the truck s system pressure a 100 psi loss is OK Pressure Gauge If there is a gradual pressure loss after the 100 psi loss once the truck valve is closed replace the cylinder seals see page 13 21 Repeat the test on the other cylinder test port Carefully operate the clamp with a maximum load in the vertical position to deter
47. pull the cylinder towards you Hydraulically retract the cylinder rod WARNING Before removing any hoses first relieve any pressure in the hoses by turning the truck off and opening and closing the truck auxiliary valves O Remove and cap all hoses at the cylinder If Cylinder was Removed from the Clamp 3 4 2 NOTE Cylinders can be removed during clamp arm and swing arm removal OR to remove a clamp cylinder pull out the pin as shown WARNING DO NOT PULL THE PIN COMPLETELY OUT When removing the swing cylinder make sure the AM swing arm is restrained by a hoist Q Clamp the cylinder shell base end in a soft jawed vise Do not clamp the cylinder shell in a vise Form 5165 Rev O Cylinder General Procedures Disconnect Rod and Pull Cylinder Towards You O Cap Hoses at the Swing Cylinder Clamp Cylinder Shell Pivot End Clamp Rod Assembly End Clamp Cylinder in Vise 13 21 ve 9 OEFVICE 3 4 3 13 22 General Procedures Disassembly Use a spanner wrench to remove the cylinder re tainers The illustration shows the two types needed to work on 70E cylinders Clamp the rod assembly pivot end in a soft jawed vise Do not clamp the rod shaft in a vise To remove the piston or retainer seal place the piston or retainer in a soft jawed vise and pry the seal up with a very blunt screwdriver Cut the seal to remove it Do not scratch the seal groove Inspection
48. quarely Bond the ends with 3M brand weatherstrip adhesive No 8001 or equivalent After the adhesive dries lubricate the seal with SAE 30 weight oil to swell the seal into the groove Form 5165 Rev O 13 35 Felt Seal sion 9 BGTVICG 3 11 4 Reassembly 13 36 Use Hoist Chain k to Place Ring Gear on Frame 1 To install the swing and clamp arms on the frame see pages 13 18 and 13 20 Set the frame and arms upright Attach the hoist chain to the ring gear eyebolts and lift the ring gear into position Set Arms and Frame Upright O Lube torque the capscrews to 65 70 ft lbs in order shown NOTE Apply a liberal amount of NLGI consistency No 0 grease to the teeth of the ring gear It is QO important that the ring gear teeth be lubricated Lobe Torcusihe before assembly Caa erens inthe Sequence Shown Lube Torque to 65 70 ft ibs See Note in Paragraph 4 G Using the hoist chain lift the baseplate into position on the bearing race Use Hoist Chain to Place Baseplate on Bearing Race Lubricate and Lube torque the capscrews to 75 80 ft Ibs in the install Hub Seal order shown WARNING The capscrews bolting the baseplate to the bearing race must be grade 5 minimum Lubricate the hub seal and install O Reinstall the revolving connection see page 13 25 G Reinstall the drive group see page 13 28 Lubricate the ball bearing race through the
49. rated lifting capacity of at least 3000 Ibs Remove the lower mounting hooks G Mark Disconnect and Cap Hoses See Diagram For Reassembly Lube Torque to Above Class lil 4 amp 0 85 90 ft Ib o a Extension 68 72 ft lb Class IV 4 amp 0 Gook 85 90 ft lb R Remove Lower Mounting Hooks GR Lower the truck carriage and back away from the clamp a few inches G Disconnect and cap the hoses at ports B C E G and F IMPORTANT Mark all the hoses with their proper port identification for ease in reconnecting Lower the clamp unti the frame rests on the floor Place a 2x4 under the lower mounting hook area For reinstallation reverse the above procedures 13 16 Form 5165 Rev 0 Place Clamp on Floor With a 2 x 4 Under the Lower Mounting Hook Area seton gt OEFVICE 2 Clamp Arm Removal Secure a Hoist Chain around o Set the attachment on the floor following procedure B on page 13 16 2 Disconnect the rod end of both clamp cylinders Secure a hoist chain around the clamp arm Disconnect End of Clamp Cylinder WARNING Make sure your overhead crane has a rated lifting capacity of at least 1000 Ibs O Remove the capscrew nut and eyebolt Note the quantity and location of the washers before removing the pins Make sure the same number of washers are replaced when reinstalling the pins 4 Remove Capscrew Nut and Eyebolt See C
50. s Cable Assembly nections disconnect the ground cable trom the battery Valve from contro internal combustion trucks or disconnect the truck Connector knob battery electric trucks 2 Route the cable assembly extending from the control knob under the floor board cowl etc to the solenoid valve assembly Make sure there is sufficient clearance around moving components Secure the cable to the control handle near its base with the tie supplied 3 Remove and discard the connector cover from the solenoid valve assembly 4 Connect the cable assembly and the cord assembly supplied with the attachment to the solenoid valve and the truck ignition on off switch as shown Connect to Truck Ignition Terminal Cable Male NOTE The wires on off Switch Assembly may be routed to Connector the Solenoid Valve Push Button as shown or they Control may be routed to Switch the opposite side Ignition of the valve on off Switch GND Cord Assembly Alternate Cover Clip Mounting Hole NA Install the Racine Cover as follows 1 Install the solenoid valve cover using the two mounting capscrews as shown 2 Secure the cable assembly to the cover Notice that the cover has two holes for the clip installation depending on from which side the wires lead to the solenoid valve 3 Reconnect the truck battery g Capscrew Cover Mounting Capscrews Torque to 8 10 ft lb 4 8 2 Install the Waterman Cover
51. unction blocks e Around swing cylinder rod s Revolving connection e Hose fittings 1 PROBLEM Clamp attempts to swing and close at the same time PROBABLE CAUSES e Internal leak in the truck auxiliary valve for the clamp function NOTE Please note that the leak is in the clamp auxiliary valve not the swing auxiliary valve s Malfunctioning fixed valve Form 5165 Rev 0 Left Hand Hose Reel Biock Right Hand Hose Reel SWING EXTEND Auxiliary PRESSURE mmn Rotate Swing Auxiliary Valve Junction Block Swing Arm Swing Cylinder 13 9 sein 2 MWOUDIeshooting 2 42 Swing Circuit Troubleshooting Cont TEST Install a needle valve in each clamp line at the auxiliary valve outlets Close both valves tightly Install and Close Two Needle Valves I ili Operate the clamp Re iF the needle valves eliminate the problem then your truck clamp auxiliary valve needs repair IF the needle valves do NOT eliminate the problem replace the fixed valve body see page 13 25 Falls Rapidly When I Clamp Arm Valve Opened LC 2 PROBLEM lt Clamp in bilge horizontal position Swing arm on bottom Swing cylinder completely extended e Clamp falls rapidly when swing control lever actuated to retract the swing arm PROBABLE CAUSE Internal malfunction in revolving connection Sis 2 I SOLUTION Swing Cylinder s Re
52. xN Truck Pump Use No 6 hose here to prevent accidental crossing at Revolving Connection Ports E and C Rotate Clockwise Rotator an A B Motor i ae F Rotate Counterclockwise Left hand Junction Block Close amp Swing Extend Revolving Right hand Connection G Swing Junction Retract Block Form 5165 Rev 0 13 47 secion 4 Installation Instructions 4 11 4 12 13 48 Attachment Stop Blocks Cascade recommends that a steel stop block be per manently welded on each side of the truck carriage upper crossbar adjacent to each attachment upper mounting hook as shown To perform the installation 1 Select square steel stock with a width about equal to the flat of the carriage upper crossbar dimension A 2 Cut two blocks from the stock each about as long as the width of the attachment upper mounting hook dimension B 3 Position the blocks adjacent to the upper mounting hooks The blocks should not extend behind the flat of the carriage upper crossbar dimension A 4 Weld the blocks in place Make sure you protect adjacent hoses and hydraulic components from weld splatter Testing Prior to Operation Check the level of the truck hydraulic tank and top off if necessary Then start the truck and test the attachment as follows to make sure it operates correctly 1 Move the rotate swing handle forward or down Do not press the button on the control knob The attach ment swi
53. y g cy Torque to 250 300 ft Ibs Be Sure to Replace this O ring Pull the rod assembly out of the shell 1 pth ce Reassembly en met Lube Torque to See the Disassembly j Y ga 450 500 ft Ibs Inspection and yp 7 La N T x L 4 LS Assembly techniques in the General Procedures on page 13 22 d we ata at Be Sure to Replace Seal with Lip in this Direction SWING CYLINDER 3 4 6 Bushing Replacement NOTE The bushings have a special grey coating on the inside surface Be careful not to scratch or mar this surface when installing the bushing or inserting a pivot pin o When replacing bushings in cylinders drive each old bushing out from the opposite side Do not drive both bushings with spacer out from the same side Drive the old bushing out with a bushing driver of same diameter Do not gouge the bore surface of the Split Split instali Bushings with Split Located as Shown cylinder 2 Drive the new bushing in flush turn the cylinder over CLAMP CYLINDER insert the spacer and drive the remaining new Single Stage and Two Stage bushing in flush olf Install Bushings with Split Located as Shown 13 24 Form 5165 Rev O 3 5 1 sion gt SETV CE Revolving Connection Plumbing 352 Removal and installation Q Set the attachment on the floor following procedure A on page 13 16 Disconnect the head end of the swing cylinder Mark th
54. zerk fit k be Teraueie ting on the ring gear bearing assembly Capserews in the D To reinstall the attachment on the truck see the Sequence Shown Installation Instructions Section 4 or reverse the procedures on page 13 16 75 80 ft Ibs See Note in Paragraph 6 Form 5165 Rev O sean 4 Installation Instructions 6 4 1 Introduction important Because of the 70E s unique operating system the procedures in this instruction manual must be followed carefully for proper attachment installation Failure to follow these instructions EXACTLY could result in the attachment not working properly or not working at all Since there is a significant difference between the 70E hydraulic system and a standard roll clamp hydraulic system take care in plumbing the 70E to a lift truck which previously had a standard roli clamp attached Truck System Requirements e Minimum hose and fitting size No 8 inch ID with minimum fitting orifices of inch e Minimum number and type of truck auxiliary valves 2 closed center valves the valves may be operated either by individual control handles or by a single control handle IMPORTANT if your truck is equipped with open center valves contact Cascade Customer Service Dial Directline 800 547 5266 toll free prior to installing the attachment e Maximum truck pressure to the attachment 2000 psi s Recommended minimum truck oil volume output to the attachment
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