"service manual"
Contents
1. Remove End Cap and Bearing CAUTION Some units will have this style relief fitting in the end cap These units may have damaged ball thrust bearings due to low 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 Drain For Reassembly Lube Lubricant Torque to 15 20 ft Ibs Remove Nuts KP Remove Capscrews For Reassembly Lube Torque to 45 50 ft lbs 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 Press Seal and Bearing out of Gearcase Use Gear Puller Bearing Remove Snap Ring Form5185 Rev 0 sein Service Rotator Drive Group Reassembly A 1 Press the bearing into the housing from the inside 2 60 using the special tool Cascade part number SD 3 25 C 664620 Make sure the bearing is fully seated and oy flush with the inside of the gearcase Support the bearing from the inside with the special tool and press the pinion into the bearing from the outside install the Woodruff key into the pinion shaft Press the worm gear onto the pinion shaft making sure you align it with the Woodruff key Press the bearing onto the pinion shaft Install the snap r2. rotate To conform to industry standard practice the system must be con nected so the clamp function operates when the solenoid valve is actuated button depressed If your unit does not operate in this manner you may in advertently drop the load when you want to sideshift left or rotate counterclockwise Make sure your attachment clamps and opens with the solenoid actuated before returning the unit to service 9 16 sn 4 Troubleshooting 44 Rotate Circuit Troubleshooting revolving clamps only To isolate the problem area in the rotation system com plete the foliowing check list 441 Problem Clamp will not rotate or will not rotate loads up to its rated capacity Probable causes e Insufficient truck hydraulic pressure incorrect load handling e Excessive back pressure in the truck hydraulic system Tests Q Check the pressure delivered by the truck hydraulic system A pressure drop of no more than 100 psi at the auxiliary valve port is OK If the pressure is not as specified refer to the truck service manual for adjust ment or service PRESSURE MUST NOT EXCEED 2000 PSI O Make sure the operator is gripping the load as shown in the illustration Gripping a load especially a long one near its end then attempting to rotate it requires a tremendous amount of torque often times beyond the capacity of the clamp O Install a pressure gauge into each port of the hydraulic motor
3. Class IV 23 44 C6B C7B C S C7S C6R C7R 18 74 Make sure the truck carriage is clean and the notches are undamaged Form5185 Rev O 2 2 x 2 Installation Instructions x Prior to Installation 1 Install the hydraulic hoses to the truck junction blocks using the correct Cascade Attachment Installa tion Kit The part numbers are as follows Basic Clamp Model C2B C 658372 Basic Clamp Models C3B C4B C6B and C7B C 658373 Sideshifting Clamp Model C2S C 663531 Sideshifting Clamp Models C3S C4S C6S and C7S and Turnafork Model C4T C 663532 Revolving Clamp Models C2R C3R C4R and C6R C 663585 Revolving Clamp Model C7R C 663598 OR use hoses and fittings as shown in Figure 1 2 3 4 5 or 6 Be careful not to pinch twist or otherwise damage the hoses IMPORTANT In order to conform to industry standard practice the hoses should be connected to the truck auxiliary valves as indicated by the following chart Function in order of location from Attachment operator Movement Motion of the operator s hand Right Rearward or up Sideshift Left Forward or Down Clockwise Rearward or Up Rotate Counter Forward or Down clockwise Clamp close Rearward or Up Clamp Release op en CAUTION 2 Flush the hoses as follows to prevent damage to the attachment hydraulic components a Connect the hoses f
4. Remove the Hoses X AN ee es the Check Valve 2 28 san D Service 5 62 Check Valve Service IMPORTANT Service the check valve in a clean work area 1 Remove the hose fittings from the valve body and remove the balls guides and springs Clean the parts Remove the allen head plugs and remove the plungers and spacers Clean the parts Inspect all parts Worn guides and plungers weak or broken springs and nicked balls should be replaced Inspect the pilot bores They should be smooth and free of scoring With the ball and seat only in place attach a hose from the truck junction block to each ball port and test for leakage WARNING Examine the pilot bores with a mirror to avoid the possibility of getting oil in the face 000 8 O Pressurize the line and examine each pilot bore for leakage if there is no leakage reassemble the check valve If leakage is present remove the hose and reseat the balls by tapping them into their seats with a brass punch Retest If the balls cannot be reseated the valve must be replaced Reassembly of the check valve is a reversal of disassembly Plug inspect the Pilot PJ Remove Plunger Bore Inspect the Components l Oe Ball _ Guide 1 Remove Valve g Spring Components Basic Clamp Check Valve Spring amp ee Remove Guide Valve oe Components Bores g merg O O Inspect the Components Spacer Plung
5. With a fibre hammer tap the cover to loosen 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 O DO See Paragraph 5 EJ Before Removing the Seal Seat OU C Remove Capscrews For Reassembly Lube Torque Opposite Capscrews to 55 ft lbs Ss See Paragraph 6 9 Before Removing the Drive Shaft Form 5185 Rev 0 sim D Service Frame Assembly Revolving Clamps Only eat 510 1 Baseplate Removal Perom i 1 Remove the attachment as described in Paragraph 5 1 2 Remove the revolving connection Paragraph 5 7 2 Remove the rotator drive group Paragraph 5 8 1 Remove the upper mounting hooks O Remove the two baseplate retaining capscrews closest to each upper mounting hook bolt pattern Replace the two capscrews with eyebolts Attach a hoist chain to each eyebolt Lift the hoist chains to take out the slack Lube Torque to
6. a Y Remove 7 I P Mounting Hooks S AAN e af 4S WARNING Make sure your hoist has a rated capacity of at least 1000 pounds O Remove the remaining baseplate retaining eRe A Remove Remaining capscrews Lift off the baseplate i Baseplate Capscrews Remove the hub seal from the rotator hub A fy Remove Rotator Hub Seal 5 102 Ring Gear Bearing Assembly Removal 1 Remove Baseplate 1 Remove the baseplate assembly as described in Paragraph 5 10 1 2 Replace two ring gear retaining capscrews with eyebolts Attach a hoist chain to each eyeboit Lift the hoist chains to take out the slack A Remove the remaining capscrews and lift the ring gear bearing assembly from the attachment WARNING Make sure your hoist has a rated capacity of at least 1000 pounds Instal Eyebolts and Attach a Hoist Chain to Each Eyebolt Remove Remaining Capscrews For Reassembly Lube Torque to 65 70 ft Ib amp C7 120 125 ft lb 2 40 Form5185 Rev 0 coin D Service 5 10 3 Frame Assembly Service The ring gear and bearing are matched components and must be replaced as an assembly Whenever the frame assembly is disassembled the felt seals must be replaced with new ones as foliows 1 Remove the old felt seals and clean the grooves 2 To install a new seal start one end of the seal strip in the groove Push the seal to t
7. ARMS CLOSING RETURN mmm Auxiliary ARMS OPENING PRESSURE Sttttttr RETURN FERETE Form 5185 Rev O a 4 Troubleshooting l o Hosing Diagram Sideshifting Clamps Cont Restrictor Fitting SIDESHIFTING SIDESHIFT LEFT SHOWN PRESSURE RETURN ma 4 24 Circuit Schematic Sideshifting Clamps Cylinders Restrictor Fitting Restrictor K itting Sideshifting Check Vaive GO Junction NOTE Junction Block blocks may or may not have check valves Truck Sidesnift Valve ic P Truck Relief Valve Truck Hydraulic Pump Form 5185 Rev 0 2 12 sim 4 Troubleshooting 4 25 Hosing Diagram Revolving Clamps Note Auxiliary Valve Ports and Hose Reel Ports may be Reversed From Those Shown Restnictor Fitting Junction Block Cylinder gt Revolving Connecti ARMS CLOSING t Junction z E Block PRESSURE Suz ll Rotate j RETURN 2 H Auxiliary d Clamp Hose Auxiliary Reel Valve Note Auxiliary Valve Ports Restrictor and Hose Reel Ports may be Fitting Reversed From Those Shown Rotator Motor Junction f Block Revolving Connection ARMS OPENING PRESSURE 238m RETURN mm Junction Block Auxiliary Valve Clamp Auxiliary Valve 2 13 Form5185 Rev 0 sein amp Troubleshooting 425 Hosing Diagram Revolving Clamps Cont Note Auxiliary Vaive Ports and Hose Ree Po
8. If it registers a drop of more than 100 psi in one minute check for external leaks in the system Refer to the accompanying diagram Repair the leaks and recheck cylinder pressure If there are no external leaks test the check valve as follows O NON REVOLVING CLAMPS ONLY Remove the gauge tee from the one cylinder rod end port but keep it con nected to the hose Remove the hose to the rod end port of the other cylinder Cap both cylinder ports and plug the hose that does not have the gauge connected O REVOLVING CLAMPS ONLY Remove both gauge tees from the cylinder rod end ports but keep them con nected to the hoses Cap both open cylinder ports O Connect a needle shutoff valve and drain line to the gauge tee s Put the drain line s in a suitable container O Open the needie valve s no more than 1 2 to 1 turn O Start the truck and let it idle Put the truck clamp lever to the clamp position and hold for 4 or 5 seconds to allow oil to flow to the container O While holding the clamp valve open close the shutoff valve s Keep holding the truck valve open until the gauge s reach within 100 psi of truck relief pressure O Return the truck clamp valve to neutral and watch the gauge s If the gauge s does not drop more than 100 psi in one minute one or both cylinders require service Refer to Section 5 Paragraph 5 3 If the gauge s does drop more than 100 psi in one minute the check valve is faulty and require
9. Pull the rod assembly out of the shell an iat naa All Others 10 12 ft Ib Remove the nut securing the piston to the rod Remove the self adjusting brass bushing from the re tainer to gain access to the rod seal Reassembly is a reverse of disassembly Remove the Bushing 5 from the Retainer 6000 Retainer QJ Remove the Nut Ky Remove the Rod Assembly For Reassembly Lube Torque to C2 and C3 Cotton Clamp Remove the Threaded Washer amp 4 70 80 ft lb C3 160 170 ft Ib For Reassembly C4 130 150 ft Ib Lube Torque ta C6 300 325 ft Ib 150 200 ft ib C7 325 350 ft lb Cylinder assembly with V Sealts 5 4 2 Cylinders with U cup Seals Remove the retainer Pull the rod assembly out of the shell Remove the nut securing the piston to the rod Reassembly is a reverse of disassembly Remove the Rod Assembly _ Remove the Retainer For Reassembly Lube Torque to C4 200 250 ft Ib C6 150 200 ft ib YZ RN NN NNN NN NN OO00e K Remove the Nut For Reassembly Lube Torque to C4 140 180 ft lb i i i ee anos ae Prpa TEN with U Cup Seals Form 5185 Rev O 2 26 sin Service 5 5 5 5 1 Restrictor Fittings Sideshifting Clamps including Turnafork Only An adjustable restrictor fitting is installed in the port of a cylinder to control the flow of hydraulic oil and therefore arm speed
10. Restrictor Fitting Service WARNING Before disassembling a restrictor fitting relieve pressure that might be in the hydraulic system With the truck off open the truck auxiliary control valves several times in both directions Remove the jam nut from the setscrew Remove the cap from the restrictor fitting body Unthread and remove the setscrew Replace the O ring For assembly reverse the above procedures Lubricate the O ring 00000 5 5 2 Restrictor Fitting Adjustment 2 27 Restrictor fittings should be adjusted so that when one arm bottoms during opening or closing the other arm is no more than 2 inches from bottoming Before adjusting make sure the truck hydraulic system provides the specified volume output as follows Volume Basic Clamps Sideshifting Clamps and Turnafork 5 20 gpm Revolving Clamps Reduired volume to obtain rated rotation speed specification C2R C3R 10 gpm Ca4R 15 gpm C6R 20 gpm C7R 20 gpm NOTE If you have questions concerning these ratings call Cascade s Service Department toll free 800 547 5266 To adjust 1 Loosen the jam nut on each restrictor fitting 2 Screw both setscrews in until they bottom then back off two full turns 3 Operate the attachment to determine which arm is moving slower 4 Back off the setscrew on the slower arm until arm speed is equalized 5 5 5 Back off both setscrews equally until desired arm speed is achieved without losing equ
11. i IMPORTANT Service the revolving connection in a clean work area eS Remove the snap ring s from the revolving connec tion shaft Remove the shaft from the body CAUTION Remove any paint or burrs from the shaft end and snap ring groove s before pulling the shaft out of the valve body to prevent damage to the valve Clean the parts and inspect the shaft bore for scoring If the bore is scored the valve body must be replaced Note the position of the O rings and backup rings then remove them from the valve shaft Be careful not to scratch the grooves Check the shaft grooves for rough edges or scratches Remove minor imperfections with fine emery cloth If the scratches cannot be removed replace the shaft NOTE A minor imperfection is one that wilt not cause a bypass of oil when the revolving connection is operating O Service cartridge type check valves as described in Paragraph 5 7 1 To service ball and plunger type check valves remove the plugs or hose fittings securing the ball checks and the piungers Remove the balls springs guides and plungers Thoroughly clean the parts Inspect the valve seats for scoring or elongation The valve seats can be reseated by tapping a ball into its seat with a brass punch If the seat cannot be reseated the valve must be replaced O Inspect the balls for nicks and scratches Inspect the pilot bores They shouid be smooth and free of scoring If you cannot smooth min
12. i cascade Service Manual Clamps for Bolt on Arms and Turnafork _ Serial Numbers 634448 through 66641 Basic Clamps Sideshifting Clamps Revolving Clamps Turnafork Model C4T Cascade is a registered trademark of Cascade Corporation Turnafork is a trademark of Cascade Corporation Contents Number INTRODUCTION Section1 2 1 INSTALLATION INSTRUCTIONS Section 2 2 2 Truck System Requirements 2 2 Prior to Installation 000 2 3 Installation 0 00 02 eee ee eee 2 5 Attachment Stop Blocks 2 6 Prior to Operation 02 2 6 PERIODIC MAINTENANCE Section3 2 7 TROUBLESHOOTING Section 4 2 8 SERVICE Section 5 2 19 Clamp Removal and Installation 2 19 AIMS eai hoes ged coh ak porn ie ekee ela be ake 2 20 Arm Removal and Installation 2 20 Arm Carrier Load Arm Disassembly and Reassembly 2 000 eee 2 21 Turnafork Arm Disassembly and Reassembly 2 22 Turnafork Arm Service 55 2 23 Turnafork Arm Indexing 4 2 23 Sliding Arm Bushing Replacement Two piece Style 0 00 2 23 Sliding Arm Bushing Replacement One piece Style 0 5 2 24 Cylinders General Procedures 2 24 Cylinder Removal and Installation 2 24 Cylinder Disas
13. Bushing 5 3 5 3 1 Replacement One piece Style Remove the bushing retainer snap ring and washer from the end of the arm carrier bar Slide off the old bushing Slide the new bushing on and install the washer and retaining snap ring Lubricate the bushings with a graphite base grease before assembling arm carriers onto the attachment 00 Cylinders General Procedures Cylinder Removal and Installation Q REVOLVING CLAMPS ONLY Rotate the attach ment so the arms are positioned side by side Extend the arms past the width of the frame Remove the cylinder rod anchor nuts IMPORTANT Refer to the procedures pertaining to cylinder anchor nuts as described in Paragraph 5 2 1 Step 2 Retract the cylinder rods until they come out of engagement with the arm lugs CAUTION Rods will drop as soon as they disengage the frame Protect the rod surface Remove the bumper plate A WARNING Before removing any 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 and tag the hoses to the cylinders Cap the hoses and the cylinder ports Remove the cylinder shell anchor nuts Paragraph 5 2 1 Step 2 Lift the cylinders away from the clamp frame Installation is a reverse of removal IMPORTANT Refer to the procedures pertaining to anchor nuts Paragraph 5 2 1 Step 6 Operate the at
14. MUST NOT EXCEED 2000 PSI Volume Basic Clamps Sideshifting Clamps and Turnafork 5 20 gpm Revolving Clamps Required volume to obtain rated rotation speed specification C2R C3R 10 gpm C4R 15 gpm C6R 20 gpm C7R 20 gpm NOTE if you have questions concerning these ratings call Cascade s Service Department toll free 800 547 5266 Tools Required in addition to a normal selection of hand tools you will need Two pressure gauges capable of measuring pressure to 2500 psi Two No 6 swivel nut run tees 37 JIC suitable for mounting gauges e Two No 8 swivel nut run tees 37 JIC suitable for mounting gauges e Two No 6 JIC plugs for hose ends e Two No 8 JIC plugs for hose ends e Two No 6 metal caps for ports Two No 8 metal caps for ports e Two needle shutoff valves rated for 2500 psi service minimum Recommended supplier for needle shutoff valves Marsh Instrument Co Skokie IH e Two steel sleeves as shown by the accompanying illustration Install the gauges in the tees In some tests you will in stall the needle valve and a drain line in conjunction with the gauge arrangement Form 5185 Rev O Pressure Gauge Swivel Nut Run Tee Pressure Gauge Needle Shutoff Swivel Nut Valve Run Tee Drain Hose IMPORTANT Make Sure The Arrow Points in This Direction Male Connector 1 7 8 h ER Steel Sleeve 2 1 2 2 8 sein TOubleshooting
15. Remove Hases and Fittings Valve Body Remove and Inspect Cartridges Cartridge Valve Back Up Replace Ring 6 as Required O Install Cartridge Valves after Lubricating Seals 2 30 swim D Service 5 7 2 Revolving Connection Removal and Installation 2 31 To service the check valves on ball and piunger type revolving connections or to service the revolving con nection shaft the revolving connection must be removed from the attachment Remove the attachment from the truck as described in Paragraph 5 1 2 Remove the cylinders as described in Paragraph 5 3 1 Remove cap and tag the cylinder supply hoses from the revolving connection valve body Remove cap and tag the truck hoses to the revolving connection shaft extending out the back of the attachment Remove the shaft keeper bar Pull the revolving con nection out of the attachment installation of the revolv ing connection is a reversal of removal CAUTION ALL UNITS EXCEPT C7R The shaft locating hole marked X must be engaged by the horizontal keeper bar Instali the attachment onto the truck as described in Section 2 Remove the Hoses Remove the Hoses See CAUTION Step 7 6 Remove the Revolving Connection Remove Shaft Keeper Revolving Connection Shaft Keeper Bar Form 5185 Rev 0 tion Service 57 Revolving Connection Service
16. following procedure C Check the arm bushings If they are worn marred or deeply scratched replaced the bushings 2000 Hour Maintenance After each 2000 hours of lift truck operation in addition to the 100 hour 500 hour and 1000 hour maintenance procedures perform the following procedure O Replace all sliding arm bushings IMPORTANT After completing any service procedure always test each function through 5 complete cycles First test the clamp empty to bleed 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 Form 5185 Rev O wun roubleshooting 4 1 4 1 1 4 1 2 General Procedures WARNING Before servicing any hydraulic component relieve pressure in the system Open the arms 1 or 2 inches turn the truck off and open the truck auxiliary valves several times in both directions After completing any service pro cedure always test the function through several cycles First test the attachment empty to bleed air trapped in the system to the truck system Then test the attachment with a load to be sure it operates cor rectly before returning it to the job Stay clear of the load while testing Do not raise the load more than 3 inches off the floor while testing Truck System Requirements Pressure Your lift truck should supply sufficient hydraulic pressure to handle the heaviest load PRESSURE
17. 3 Get All The Facts Before You Begin Working On The Clamp It is important that you gather all the facts regarding the problem before you begin service procedures The best way is to talk with the operator Ask for a complete description of the malfunction The following guidelines will help you decide where to begin your troubleshooting procedures A Clamp Circuit e Clamp drops load after it has been picked up Clamp will not carry load up to its rated capacity Clamp arms will not function properly e Clamp drops the load when sideshifting or rotating If you encounter one of these problems refer to Paragraph 4 3 B Rotating Circuit revolving clamps only e Clamp will not rotate e Clamp will not rotate loads up to its rated capacity Clamp rotates in one direction only If you encounter one of these problems refer to Paragraph 4 4 2 9 ARMS CLOSING sim amp IOUDIeshooting 42 Plumbing 421 Hosing Diagram Basic Clamps including Turnafork PRESSURE RETURN me Se ARMS OPENING Restrictor A H Cylinder Cylinder 4 2 2 Circuit Schematic Basic Clamps including Turnafork Form 5185 Rev 0 Restrictor xg Fitting UI Note Junction Block Oo fd Junction May or May Not have IK K Block Check Valves tes 2 10 sin 4 Troubleshooting 4 23 Hosing Diagram Sideshifting Clamps Sideshifting Check Vaive i f Junction Block S
18. 90 Straight Thd Elbow 90 Straight Thd Elbow iT Rotate Connector Counter Rotate Clockwise Clockwise Open Close ee ee s 90 i Connect Eib aa Ive Connect To Truck 45 Swivel to Truck Junction Elbow Junction Block Block Figure 5 Plumbing Diagram Models C3R C4R and C6R Form 5185 Rev 0 Prior to Installation Cont VIEWED FROM THE DRIVER S SEAT Straight Thd Connector 90 Elbow Straight Thd Connector 90 Elbow Side Left bed i Close p ae tll Connect is t i To Truck Connect oH i Junction To Truck 7 edn Block Junction pa ij ts Block aay a i i Ea E EE Check Valve 90 Elbow Figure 4 Plumbing Diagram Models C3S C4S C6S and C7S Front of Lift Truck Rotate Counter Clockwise Rotate Note The Junction Blocks On I Your Truck May Be Reversed clockwise From Those Shown No 8 90 45 Hose Swivel AS Straight Straight Elbow Thread Thread Elbow Elbow yi oT sth ot pee Close et Sa ee te Connect To Truck Junction Block Hose o 45 Swivel Elbow Rotate Rotate Counter Clockwise Clockwise N ee r Connect 90 To Truck Swivel Junction Elbow Block Viewed From the Driver s Seat Figure 6 Plumbing Diagram Model C7R wa 2 Installation Instructions 2 Installation 1 Using a suitable hoist and chain position the c
19. E C 656300 32 fluid ounces Install the gearcase onto the attachment baseplate Fill Gearcase Nuts to with Lubricant UK install Gearcase on Roli Clamp Gap Should Install be 200 030 End Cap fy Alternately Tighten Capscrews 1 2 of a Turn For Reassembly Lube Torque to 7 10 ft ibs Install the Motar Lube Torque Retaining 15 20 ft lbs Lube Torque Capscrews to 40 ft lbs Form 5185 Rev O sein D Service ss Motor 5 91 Motor Removal and Installation Revolving Clamps Only The rotator motor can be removed for service with the attachment on the truck WARNING Before removing supply A 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 o 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 will spli
20. TANT A statement preceded by IMPORTANT is information that possesses special significance NOTE A statement preceded by NOTE is information that is handy to know and may make your job easier Form 5185 Rev 0 non 2 Installation Instructions WARNING Rated capacity of the truck attachment combination is a responsibility of the original truck manufacturer and may be less than that shown on the attachment nameplate Consult the truck nameplate 21 Truck System Requirements e Truck relief valve setting 2000 psi maximum Truck hydraulic system should provide the following rates of flow Volume Basic Clamps Sideshifting Clamps and Turnafork 5 20 gom Revolving Clamps Required volume to obtain rated rotation speed specification C2R C3R 10 gpm C4AR 15 gpm C6R 20 gpm C7R 20 gpm NOTE If you have questions concerning these ratings call Cascade s Service Department toll free 800 547 5266 Recommended hose and fitting size C2B Basic Clamps and C2S Sideshifting Clamps No 6 hoses with minimum fitting orifices of 297 9 32 inch All others No 8 hoses with minimum fitting orifices amp of 13 32 inch Truck carriage must conform to the Industrial Truck Association ITA dimensional standards as shown in the following chart Dimension A in Mounting Class Il C2B C3B C4B C28 C3S C4S C2R C3R CAR CAT Class II 18 68 C4B C6B C4S C S C4R C6R
21. alization 6 While holding the setscrew with a screwdriver tighten the jam nuts Restrictor Fitting Body Replace the O Ring Remove the Setscrew Gy Remove the Cap V GY Assembly is the Reverse of IT Disassembly wo Remove the Jam Nut Form 5185 Rev 0 ry section D Service 5 6 5 6 1 Form 5185 Check Valve Basic Clamps Sideshifting Clamps and Turnaforks Only The check valve assembly on basic clamps has a single pilot operated check valve The check valve assembly on sideshifting clamps and Turnaforks have three pilot operated check valves Check Valve Removal and installation Remove the attachment from the truck as described in Paragraph 5 1 Remove cap and tag the cylinder supply hoses to the check valve Remove cap and tag the truck hoses to the check valve Remove the check valve by removing the capscrew securing the vaive to the attachment frame Installation of the check valve is a reversal of removal Instali the attachment onto the truck as described in Section 2 Sideshifting Clamps 0000006 PE Hose Arrangement Msc be 3 All Units except C2B we A x es I A Remove i g ER ee the Hoses ee i a SNS Paa ee i i eee a i BEKI a Y Remove the a Sa 3 Check Valve CRS gN i Remove x ren a Oe Pe the Hoses i n i zi 7 s Rer ve Remove H the Check the Moses Valve C2B Hose Arrangement Basic Clamps Rev 0
22. and Reassembly 2 5 5 2 4 Turnafork Arm Service 0 5 5 2 5 Turnafork Arm Indexing 0 3 5 2 6 Sliding Arm Bushing Replacement Two Piece Style 2 2 2 002 2000 8 1 0 5 2 7 Sliding Arm Bushing Replacement One Piece Style 6 0 0 0 cee eee 1 0 5 3 1 Cylinder Removal and Installation 0 5 5 4 1 Cylinders with V Seals 0 0 8 5 4 2 Cylinders with U Cup Seals 0 8 5 5 1 Restrictor Fitting Service 0 5 5 5 2 Restrictor Fitting Adjustment 0 5 5 6 1 Check Valve Removal and Installation 1 8 5 6 2 Check Valve Service 2 0 0 7 5 7 1 Revolving Connection Cartridge Type Check Vaive Service 00 0 7 7 2 Revolving Connection Removal and Installation 0 ee eee 1 0 5 7 3 Revolving Connection Service 0 9 5 8 1 Rotator Drive Group Removal and Installation 0 5 5 8 2 Rotator Drive Group Disassembly and Service 1 5 5 8 3 Rotator Drive Group Reassembly 1 5 5 9 1 Motor Removal and installation Revolving Clamps Only 0 8 5 9 2 Motor Disassembly Service and Reassembly 1 0 5 10 1 Baseplate Removal 1 0 5 10 2 Ring Gear Bearing Assembly Removal 1 0 5 10 3 Frame Assembly Service AIG 1 0 5 10 4 Frame Reassembly 5 2 0 Form5185 Rev O wv cascade o TM Do you have questions
23. ation Instructions 24 Attachment Stop Blocks Cascade recommends that a steel block be permanently welded on each side of the truck carriage upper crossbar adjacent to each attachment upper mounting hook To perform the installation Select square steel stock with a width about equal to the flat of the carriage upper crossbar dimension A Cut two blocks from the stock each about as long as the width of the attachment upper mounting hook dimension B Position the blocks adjacent to the upper mounting hooks The blocks should not extend behind the flat of the carriage upper crossbar dimension A Weld the blocks in place Make sure you protect adjacent hoses and hydraulic components from weld splatter 25 Prior to Operation Check the cylinder anchor nuts to make sure they are secure If your clamp has old style anchor nuts make sure the spring retainer is in place If you have new style anchor nuts make sure they are properly staked 2 Before picking up a load operate the attachment through a fuli cycle to force any air from the system to the truck hydraulic tank Check for leaks 3 Pick up a maximum load and operate the clamp If the clamp does not function correctly recheck the plumb Attachment Upper Mounting Hook Steel Stop Block Truck Carriage Upper Crossbar Oo 8 Make Sure Spring Retainer is in Place ing If the clamp drops the load contact Cascade s Check For Servi
24. ce Department telephone 800 547 5266 toll free At Least One or in Oregon call 666 1511 Stake Here WARNING Make sure there are po OLD STYLE NEW STYLE people in the vicinity of the attach CYLINDER ment when picking up a load CYLINDER ANCHOR NUT ANCHOR NUT Form 5185 Rev 0 2 6 sino Periodic Maintenance 3 1 3 2 3 3 3 4 2 7 100 Hour Maintenance Every time the lift truck is serviced or every 100 hours of truck operation whichever comes first complete the following maintenance procedures OJ Check the cylinder anchor nuts for looseness 500 Hour Maintenance After each 500 hours of lift truck operation in addition to the 100 hour maintenance procedure perform the follow ing procedures D Retorque the mounting capscrews Use the torque specifications shown in Section 2 Rotating Clamps Only O Lubricate the ring gear bearing assembly with wheel bearing grease Rotate the clamp one full turn during lubrication DO Remove the plug on the back of the baseplate and retorque all the ring gear bearing assembly capscrews to 65 70 ft lb 120 125 ft lb on C7R Replace the plug O Remove the plug on the rotator drive gearcase and fill to capacity with Cascade Rotator Drive Lubricant Cascade part number C 656300 or Keystone WG 1 Replace the plug 1000 Hour Maintenance After each 1000 hours of lift truck operation in addition to the 100 hour and 500 hour maintenance procedures perform the
25. ck Immediately close the arms together again to bring them back in phase Sliding Arm Bushing Replacement Two piece Style NOTE An attachment with two piece bushings may be converted to the new style one piece configuration by the installation of the appropriate One Piece Bushing Conversion Kit Contact Cascade Customer Service for information Remove and discard the old long and short bushings To ease removal spread the short bushing by inser ting a screwdriver blade into the bushing slot Similarly insert two screwdrivers into two opposing slots in the long bushing to disengage the bushing re taining lip It may be necessary to drive off the long bushing with a block and a hammer 2 Install the long bushing Spread the slots of the bushing with screwdrivers as during removal If the bushing will not go over the arm carrier bar heat it in boiling water for 3 or 4 minutes to soften it Make sure the bushing retaining lip engages the groove in the arm carrier bar install the short bushing Spread the bushing to ease installation Make sure the bushing fits into the outer most groove in the arm carrier bar Lubricate the bushings with a graphite base grease before assembling arm carriers onto the attachment Arm Carrier a Bar Remove the Bushings Lubricate Bushings Long Bushing Short Bushing Short Bushing Form5185 Rev O secion D Service 5 2 7 Sliding Arm
26. de tubes are badly damaged the frame must be replaced Before installing arm carriers make sure the guide tubes are clean and free of metal projections For reassembly reverse the above procedures except for the following special instructions for cylinder anchor nuts Nut NOTE When tightening cylinder anchor nuts pressuriz ing the cylinders outward will increase friction between OLD STYLE CYLINDER ANCHOR NUT the cylinder rod and the lug and may make tightening easier a OLD STYLE ANCHOR NUTS Install the washer onto the cylinder rod then fit the cylinder rod into the arm car rier Install the nut Tighten the nut against the washer Back the nut off until it aligns with the slot in the cylinder rod Install the spring retainer The clearance between the lug and the washer should be about 5 32 inch CAUTION Do not attempt to remove the looseness or damage to the assembly could result b NEW STYLE ANCHOR NUTS Install the washer onto the cylinder rod with the counterbore side facing outward toward the nut then fit the cylinder rod into the arm carrier Restrain the washer Nut Stake Washer into Cylinder with a wrench and torque the nut to C3 55 65 ft tb Cointeroored Rod Groove C4 130 150 ft lb C6 and C7 205 235 ft lb Lock the Washer Lug nut by staking the cone shaped washer with a case amp hardened chisel Be sure the washer is driven into the NEW STYLE CYLINDER ANCHOR NUT slot
27. do not use the needle valve 0 Securely grip a load that weighs close to the capacity of the clamp O Rotate the load and note the pressure readings on the gauges during rotation If the lower pressure reading EXCEEDS 200 psi you have excessive back pressure in your supply circuit Check for restrictions such as numerous fittings and elbows hose sizes less than No 8 clogged oil filter etc If the lower pressure does NOT EXCEED 200 psi and the truck pressure is within specifications the hydraulic motor needs repair Refer to Section 5 Paragraph 5 9 2 for service procedures 2 17 Check Truck System Pressure NOT THIS Requires Excessive Torque Check For Pressure Differential Form 5185 Rev O sin 4 WOUDIeshooting 6 4 42 Problem Clamp rotates in one direction only Probable cause The pilot spool in the junction block that supplies the rotator motor is jammed Solution Replace the junction block Call Cascade s Service Department if you have carefully and accurately completed this check list and you still have not solved the problem call us Our Service Department is open from 10 00 AM to 8 00 PM Eastern time Call 800 547 5266 toll free In Oregon 666 1511 Form 5185 Rev O 2 18 im Service s1 Clamp Removal and Installation Q Open the clamp arms completely On revolving clamps make sure the attachment is rotated so the arms are positioned side b
28. e the 6 Remove the Shaft Inspect Snap Ring Grooves inspect the Seats Inspect the Inspect Pilot j the Balls Piunger a oN C2R C3R CAR and C6R Ball and Plunger type Revolving Connection 8 Spring Remove the Plugs Remove the Remove and Replace O Rings Check the Shaft Valve Grooves Body Cartridge type Revolving Connection 6 Service the Check Valves See Paragraph 5 7 1 P9 Remove the Shaft Back Up Ring Replace the O Rings Remove and and Back Up Rings Plug meme Plunger Components a L Inspect if pe FA the Seats Remove the Inspect Snap Ring o gt Balls Inspect re Quy Grooves 4 inspect O 5 Pilot Bores Ac the Bore sf Shige C7R Revolving Guide R L Connection Remove O Components Spring 2 32 swim D Service ss Rotator Drive Group Revolving Clamps Only Your attachment may be equipped with either a cush ioned rotator drive group or an uncushioned unit Cushioning is achieved by the installation of cone shaped spring washers on both sides of the worm powered by the rotator motor The worm gear is in mesh with the rotator ring gear Therefore shock loads applied to the at tachment arms are transferred to the worm through the worm gear and are absorbed by the spring washers All revolving clamps have a single drive group except the C7R which has a dual drive unit Special procedures for C7R models are noted in the following 5 8 4 Rotator Drive Grou
29. er Assembly Qo S z Ea purger S S S Remove the Sn Plug Sideshifting Clamp Check Valve Form 5185 Rev O sio D Service Revolving Connections Revolving Clamps Only The revolving connection has two cartridge valves located in the valve body Revolving Connection Cartridge type Check Valve Service The following procedures can be performed with the attachment on the truck 3 Remove the cylinders as described in Paragraph 5 3 1 Remove the four supply hoses and fittings from the front of the revolving connection valve body front of the revolving connection Thoroughly clean the parts inspect the cartridge valve assemblies for cut or defective external O rings NOTE Internal cartridge valve components are not serviceable Replace O rings and backup rings as required CAUTION Backup rings must be wound as shown to avoid seal damage during cartridge installation O rings must be installed on the pressure side of the groove lf teakage is visible between the shaft and valve body the shaft seals must be replaced To replace shaft seals the revolving connection must be re moved from the attachment Refer to the procedures in Paragraphs 5 7 2 and 5 7 3 Remove the two hex head cartridge valves on the O Installation of the cartridge valves is a reversal of removal Before installing each cartridge lubricate the O rings Form 5185 Rev 0 Back Up Ring Back Up Ring 2
30. ervice 2 41 Frame Reassembly 2 42 STANDARD LABOR TIMES Section 6 2 43 Form 5185 Rev O zw 1 Introduction amp This manual provides the installation instructions periodic maintenance requirements troubleshooting procedures and service guides for the following Cascade lift truck attachments Basic Clamp for Bolt on Arms Models C2B C3B C4B C6B and C7B e Sideshifting Clamp for Bolt on Arms Models C28 C3S C45 C6S and C7S e Revolving Clamps for Bolt on Arms Models C2R C3R C4R C6R and C7R e Turnafork Model C4T 11 Truck System Requirements Pressure Your lift truck should supply sufficient hydraulic pressure to handle the heaviest load PRESSURE MUST NOT EXCEED 2000 PSI Volume Basic Clamps Sideshifting Clamps and Turnafork 5 20 gpm Revolving Clamps Reauired volume to obtain rated rotation speed specification C2R C3R 10 gpm C4R 15 gpm C6R 20 gpm C7R 20 gpm NOTE If you have questions concerning these ratings call Cascade s Service Department toll free 800 547 5266 12 Special Instructions Definitions AWARNING A statement preceded by A WARNING is information that should be acted upon to prevent bodily injury A WARNING is always inside a ruled box gt CAUTION A statement preceded by CAUTION is information that should be acted upon to prevent machine damage IMPOR
31. gt Bushing GA 2 Ay A Remove Z Belicrank Remove ye L A Bushing Springs ya Capscrew Stop Remove Detent 9 Pin Spring and Bushing Wear Plate Fork O Ring Remove amp Bearing Remove Front Cover Remove Capscrews For installation Torque to 120 130 ft Ibs 2 22 s D Service 5 2 4 5 2 5 5 2 6 2 23 Turnafork Arm Service e Inspect all components and bushings for wear Replace bushings if the ID is scored or a concentra tion of wear is visible Replace any components with visible wear where they contact other components Replace the O ring on the arm bushing each time it is removed e Inspect the detent pin spring bushing and seat each time the arm bearing is removed Replace any part if a concentration of wear is visible Turnafork Arm Indexing Fully closing the arms depresses the actuators This releases the locking mechanism and causes the arms to change position If the arms get out of phase correct the problem as follows IMPORTANT If the arms ever get out of phase there may be nothing mechanically wrong with the attachment This condition usually occurs when both actuators are not fully depressed To reposition an arm manually With the arms fully closed actuators fully depressed reposition one arm by hand To reposition an arm hydraulically Close the arms hydraulically actuators fully depressed Then open the arm slowly until you hear one cli
32. he bottom of the groove all the way around the groove If the seal is too short stretch it evenly around the groove to lengthen it O Cut the two ends of the seal so they meet squarely Bond the ends of the seal with 3M brand weatherstrip adhesive No 8001 or equivalent After the adhesive dries lubricate the seal with SAE30 motor oil to swell the seal into the groove Frame Bumper Plate Dust Seals P C2R and C3R Revolving Frame Assembly Guar Ring Gear Bearing Assembly Hub Seal A Dust Seal Baseplate Bumper Plate Ring Gear Bearing Assembly Felt Seals Revolving Frame Assembly C4R C6R and C7ZR Seal C7R only Varies with Clamp 2 41 Form 5185 Rev 0 sin Service 0 4 Frame Reassembly 1 Attach the hoist chain to the ring gear eyebolts and lift the ring gear bearing assembly into position CAUTION All ring gear bearing assembiies have a heat treat overlap zone This zone is designated by a stamped letter on the outer ring of the assembly When installing the ring gear bearing assembly the heat treat overlap zone must be located in one of the four locations shown Lube torque the capscrews to 65 70 ft Ib C7 120 125 ft ib in the order shown NOTE Some units have fewer than the 24 capscrews shown here On these units lube torque using a similar pattern IMPORTANT Apply a liberal quantity of NLGI con sistency No 0 grease to the tee
33. in the end of the cylinder rod CAUTION Always use the hex style washer with the new style anchor nut DO NOT use the old style castellated nut with the hex style washer Form 5185 Rev 0 2 20 sein D Service 5 22 Arm Carrier Load Arm Disassembly and Reassembly Load arms that are integral with arm carriers cannot be disassembled Disassemble toad arms from bolt on or T bar arm carriers according to the following procedures For disassembly and reassembly procedures for Turna fork arms refer to Paragraph 5 2 3 Oo Secure the load arm with a suitabie overhead hoist and chain 2 Remove the capscrews retaining the bolt on arm carrier or T bars and cylinder anchor lug to the load arm For reassembly reverse the above procedure Bolt on Arm Carrier Load Arm Remove the Capscrews Lube Torque to Remove the Capscrews ES For Reassembl Lube Torque ta Torque Value 5 8 in 120 ft lb 3 4 in 205 ft lb 1 in 440 ft lb Capscrew Size T Bar Arm Carrier 2 24 Form 5185 Rev O an Service 5 2 3 See Caution Turnafork Arm Disassembly and Reassembly The arms can be disassembied with the attachment mounted on the truck and with the arm carriers installed on the attachment frame To disassemble an arm 1 Open the arms so they extend beyond the attach ment frame Remove the front cover to expose the indexing mechanism CAUTION To index
34. ing Assemble the spring washers spacers if equipped 2 06 1 D Special Tool Gearcase O00 0O oO and ball thrust bearings See Caution below on the TTT worm shaft and install in the housing CAUTION The ball thrust bearing must be i a assembled on the worm with the thickest portion of Install the outer race the side stamped with the Pinion manufacturer and part number facing away from the washers Bearing Special Tool Spring Smiat Large Small Washers Spacer Spacer Spacer Spring Washers Bearing 10 WASHER 16 WASHER CUSHION DRIVE CUSHION DRIVE Assemble Washers Install Spacers and Bearings Woodruff Key on Worm and Install in the Housing Note Some Units Do Not Have Spring Washers Press Worm Gear anto Pinion Shaft 5 Press Bearing onto Pinion Shaft Seve Z wt AK traan Le Install Snap Ring Ahr M am z Form 5185 Rev O 2 36 scion D Service 5 8 3 Rotator Drive Group Reassembly Cont 2 37 8 98080 O Install the end cap If the gap on cushion drive units is greater than that shown the spring washers are in correctly stacked Remove the worm and restack the washers Alternately tighten the endcap capscrews 1 2 of a turn Lube torque to 7 10 ft lbs Install the cover Install the motor Fill the gearcase with 44 fluid ounces of Cascade Rotator Fluid Cascade part number C 656300 NOT
35. l drop as soon as they disengage the frame Protect the rod surface C Retract the cylinders far enough to slip the steel sleeves over the cylinder rods E Extend the cylinders and reconnect the rods to the arms with the sleeves in place It is not necessary to lock the nut or install the keeper O Remove the supply hose to the rod end port restrictor fitting of one of the cylinders Install a gauge into the open end of restrictor fitting then reconnect the cylinder supply hose to the gauge tee In the case of a revolving clamp install gauges in the rod end restrictor fittings of both cylinders J Slowly retract the cylinders arms moving together until the sleeve contacts the cylinder end Make sure Slip On The Sleeves the gauge assembly does not interfere with the closing arms The arms are now blocked partially open or cylinders partially extended G Pull the clamp contro handie to the clamp position and hold for a few seconds C Return the handle to neutral The gauge s should register within 100 psi of specified truck pressure If it does not check the pressure delivered by the truck Refer to the truck service manual Adjust and repair as necessary TRUCK PRESSURE MUST NOT EXCEED 2000 PSI Recheck cylinder pressure Install Gauges in Rod End Restrictor f Fitting 9 15 Form 5185 Rev O un Troubleshooting General Pressure Test Cont O If the truck system is OK watch the gauge s
36. lamp as shown and remove the lower mounting hooks Position the truck close enough so the hoses on the ena junction biock s can be connected to the attachment Truck connect the hoses to the attachment as shown in the Carriage appropriate plumbing diagram O Raise the truck carriage and engage the attachment upper mounting hooks Center the attachment on the carriage making sure the positioning block is engaged in a notch on the carriage 5 Tilt the mast back and install the lower mounting hook Lube torque the capscrews as shown on the following chart Position Truck Close to Clamp Position Clamp Attachment Mounting Torque Sinema a Vi all models Class Value lubed Lower Mounting Making S Hooks c2R c3R ok 7476ft b it is Centered Raise the Carriage C2B C3B C4B C6B C2S C38 C4S C6S to Engage the Clamp 103 113 ft Ib il W 85 90 ft Ib 85 90 ft Ib 180 200 ft Ib 265 2985 ft Ib C6B C6S C7R C7B C7S Tilt Back and install Lower Mounting Hooks SEE CHART STEP 5 FOR TORQUE VALUES QO Install the arms Lube torque the capscrews as shown SEE CHART STEP 6 on the following chart FOR TORQUE VALUES Arm capscrew torque values lubed Attachment all models fey Install Arms Attachment Frame 100 120 ft Ib 180 220 ft Ib 420 465 ft Ib 2 5 Form 5185 Rev O 2 Install
37. or ir regularities with an emery cioth replace the valve With the ball and seat only in place attach a hose from the truck junction block to each ball port to test for leakage A D Pressurize the line and examine each pilot bore for leakage if there is no leakage reassemble the check valves If leakage is present remove the hose and reseat the balls by tapping them into their seats with a brass punch Retest If the balis cannot be reseated the valve must be replaced Install new O rings and backup rings on the revolving connection shaft Be careful not to distort the seals Reassembly of the revolving connection is a reversal of disassembly Lubricate the shaft O rings to ease reassembly Rotate the shaft into the body to prevent rolling the O ring seats Be careful not to damage the valve bore NOTE Bail and plunger type revolving connection valve bodies and shafts are not available as replace ment parts They must be replaced by cartridge type revolving connections which are interchangeable with ball and plunger types Form5185 Rev O Oo WARNING Examine the pilot bores with a mirror to avoid the possibility of getting oil in the face and Back Up Rings oo i a Back Up O Ring Inspect Ring the Bore Remove the Snap Ring 4112 Remove and Replace O Rings and Back Up Rings ea Remove 7 the Plugs 2 o Be Plunger inspect Remove the Snap Ring oo Bore Remov
38. p Removal and Installation 1 Remove the attachment from the truck as described in Paragraph 5 1 2 C7R Models only Remove the four capscrews securing the two halves of the cover over the dual drive coupling and remove both cover halves Then remove the chain around the coupling sprockets E Remove Capscrews Remove the rotator gear drive case retaining For Reassembly Lube capscrews and remove the gearcase s from the at Torque to 40 ft Ibs A See WARNING in Paragraph 3 tachment baseplate WARNING With the gear case s removed the baseplate is free to rotate Keep clear of the baseplate to avoid being pinched QO C7R Models only Remove the coupling sprockets from the worm shaft of each drive group 6 Service the rotator drive group as described in Paragraphs 5 8 2 and 5 8 3 O Reinstallation of the rotator drive group is a reverse of removal except the C7R Perform the following Steps 7 through 16 to synchronize the C7R dual drive group Install the citcular seal located in the coupling cover over one sprocket hub The lip of the seal should face the sprocket teeth Leave the felt dust seal in place in the coupling cover O install the coupling sprockets on the worm shaft of each drive group Make sure the keys are in place Don t tighten the setscrews in the sprocket hubs yet O Install both drive groups onto the baseplate 2 33 Form 5185 Rev O sn D Service amp 5 8 1 Rotator Drive Gro
39. prockets Center Sprockets Pin Check for Clearance on Truck Synchronize Sprockets See Step 10 Ca Capscrew and li Ori oe Lockwasher te install Drive Groups For Reassembly Lube Torque To 40 ft Ib 2 34 sn D Service 5 8 2 Rotator Drive Group Disassembly and Service 2 35 o oo OOOO O000 Drain the lubricant from the gearcase Lay the gear case pinion down on 4 X 4 s placed on either side of the pinion Remove the rotator motor as described in Paragraph 5 9 1 Motor service procedures are described in Paragraph 5 9 2 Remove the capscrews retaining the gearcase cover Remove the capscrew from the center of the cover and replace it with a 3 8 inch 16 UNC capscrew 2 inches long Turn the capscrew clockwise while lightly tapping the side of the cover with a plastic head hammer to loosen it Remove the end cap and bearing Remove the worm and spring washers if equipped Remove the snap ring from the pinion shaft Using a gear puller remove the worm gear from the pinion shaft Remove the Woodruff key from the pinion shaft Press the pinion out of the gearcase Press the pinion bearing out of the gearcase Clean and inspect the components Replace any item that is worn or galied Remove any burrs with an emery cloth or small hand grinder Press Pinion Out of Gearcase Remove Worm and Spring Washers Note Some Units Do Not Have Spring Washers Gearcase
40. rm Removal and installation Arm removal is easiest to perform with the attachment mounted on the truck 1 Fully extend the arms On rotating clamps make sure the at tachment is rotated so the arms are positioned side by side 2 Remove the nuts retaining the cylinder rods to the arm lugs On old style retaining nuts first remove the spring washer IMPORTANT A new style retaining nut has a cone shaped locking washer swaged to the threads of the nut Locking is achieved when the washer is dimpled into the groove in the end of the cylinder rod To unlock the nut insert a punch or chisel into the hole in the center of the cone shaped washer and pry up the dimple If you re careful the nut may be reused several times NOTE Pressurizing the cylinders outward will increase fric tion between the cylinder rod and the lug and may make loosening the nuts easier Secure the arms with a suitable overhead hoist and chain WARNING Make sure your overhead hoist has a rated lifting capacity of at least 1000 pounds O Retract the cylinder rods until they come out of Make Sure engagement with the arm lugs Washer Lug euno ain is in Place i CAUTION Rods will drop as soon as they disengage the eS frame Protect the rod surface Pull the arms out of the clamp frame IMPORTANT Each time the arms are removed inspect the arm quide tubes for scoring Minor scoring can be removed with a hone If the gui
41. rom each junction block together b Start the truck and actuate the truck control valve s in both directions for about 30 seconds to carry any debris left in the hoses to the truck hydraulic tank and filter Forward or Down VIEWED FROM THE DRIVER S SEAT 90 Straight Thd Elbow Connector No 6 Hose cS on LV ssa soles teri H FEA H z namne Le TEAR ne Close Open EP Bo S ana ft E E s Connect rT To Truck ne al Junction Fae eee m i Block Check Valve Figure 1 Plumbing Diagram Model C2B VIEWED FROM THE DRIVER S SEAT 90 Elbow Straight Thd No 8 Connector Hose gt V Connect To Truck Junction To Junction Attachment Block Hose Fittings To Junction Block Form5185 Rev O sen 2 Installation Instructions 2 2 VIEWED FROM THE DRIVER S SEAT Straight Thd Connector Straight Thd Connector 90 Elbow No 6 o Hose 90 Elbow No 6 Hose Side Shift Left 7 Open Shift Close Right owe Connect NS cre pc To Truck an Junction Connect To Truck Block Junction Block j Cheet valve Straight Thd Connector Figure 3 Plumbing Diagram Model C2S NOTE The Junction Blocks On Your Truck May Be Reversed From Those Shown x 90 Swivel o Elbow d 9 ivel Straight 0 Swive Viewed From the Driver s Seat Thd Elbow Connector
42. rts may be Reversed From Those Shown Restnictor Fitting pes Rotator Motor Junctioni Block ROTATE COUNTERCLOCKWISE SHOWN PRESSURE oou RETURN mm Circuit Schematic Revolving Clamps 4 2 6 Short Arm Cylinder Long Arm Cylinder a Na Restrictor A Fitting Restrictor Fitting na Onl Rotator i oj Revolving Connection NOTE Junction Junction Lol Lo lO fel Block Jundtion blocks may or oc Bi ck n may not have L 9 check valves Hose Mtz Hose Reel Beene Truck ae Reel i i Rotate E 1 Valve aNG Q Truck amp wi Xm feet ATT ane wW Valve ry w E Truck Hydraulic Pump Form 5185 Rev O 2 14 sim IOUDIeshooting 43 Clamp Circuit Troubleshooting There are four potential problem areas that could affect clamping force e Insufficient hydraulic pressure from the lift truck External leaks e Malfunctioning check valve e Worn or defective cylinder seals To isolate the problem area complete the following check list in the exact sequence indicated Remove The Bumper Plate General Pressure Test O Rotate the clamp so the arms are side by side revolving clamps only O Open the clamp arms and remove the bumper plate from the front of the attachment O Disconnect the cylinder rod ends from the arms IMPORTANT Refer to the procedures described in Section 5 Paragraph 5 2 1 Step 2 CAUTION Rods wil
43. s service on revolving clamps if only one gauge registers a 100 psi drop in one minute the check valve connected to that hose only is at fault Refer to Section 5 Paragraph 5 6 or 5 7 O After making the necessary corrections remove the cylinder rod sleeves reconnect all hoses and replace the bumper plate Make sure the cylinder anchors are secure Refer to Section 5 Paragraph 5 2 1 Step 6 for special instructions regarding cylinder anchor nuts O Cycle the attachment 4 or 5 times without and with a load before returning the attachment to service Call Cascade s Service Department If you have carefully and accurately completed this check list and you still have not solved the problem call us Our Service Department is open from 10 00 AM to 8 00 PM Eastern time Call 800 547 5266 toll free In Oregon 666 1511 Farm 518A Rev A Junctions POTENTIAL EXTERNAL LEAK POINTS NON REVOLVING CLAMPS ONLY Cap The Open Restrictor Fitting Cap The Hose FEN Needle Lai Shutoff Valve Cap The Open Restrictor Fitting REVOLVING CLAMPS ONLY Pressure Gauge Needle Shutoff Valve Cap The Open Restrictor Fitting IMPORTANT Use of Solenoid and One Truck Control Valve Sideshifting and Revolving Ciamps Only Some trucks use a single auxiliary valve in conjunction with a solenoid valve to control two functions clamp and sideshift or clamp and
44. s with V seals inspect the self adjusting brass bushing that fits inside the retainer If the ID is scored the bushing should be replaced uncer Reassembly Lubricate all new seals before installing Use a mixture of petroleum jelly and hydraulic oil Carefully note the direction of seals If they are in Stalled backwards the seals will not seal properly Refer to the illustration of the cylinder you are servicing e When installing U cup seals onto a piston hook one side of the seal in the groove and push it over the piston NOTE Polishing the chamfer angie will allow the seal to slide into the groove much easier e Always reassemble the rod assembly by sliding the re tainer on first then the piston assembly Install and torque the piston retaining nut before sliding the rod assembly back into the shell e When reassembling a cylinder always observe all torque values as shown on the appropriate illustration Pin Type Spanner Wrench Do Not Clamp Rod on Threaded or Sealing Surfaces Clamp Only at Extreme End of Major Diameter Clamp Shell Only at Extreme Base End Form 5185 Rev O sain Service Cylinder Service Read the General Procedures Paragraph 5 3 before proceeding 5 41 Cylinders with V seals Remove the setscrew from the threaded washer Remove the Setscrew For Reassembly Remove the threaded washer Lube Torque to C2 and C3 Cotton Cl
45. sembly 2 25 Cylinder Inspection 2 25 Cylinder Reassembly 2 25 Cylinder Service 0 eee eee eee 2 26 Cylinders with V seals 00 2 26 Cylinders with U cup Seals 2 26 Restrictor Fittings Sideshifting Clamps including Turnafork Only 2 27 Restrictor Fitting Service 2 27 Restrictor Fitting Adjustment 2 27 Check Valve Basic Clamps Sideshifting Clamps and Turnaforks Only 2 28 Check Valve Removal and Installation 2 28 Check Valve Service 2 29 Revolving Connections Revolving Clamps Only 00 0 eee 2 30 Revolving Connection Cartridge type Check Valve Service 020 2c eee 2 30 Revolving Connection Removal and Installation 0 0 eee eee 2 31 Revolving Connection Service 2 32 Rotator Drive Group Revolving Clamps Only 2 33 Rotator Drive Group Removal and Installation 0 0 0 005 2 33 Rotator Drive Group Disassembly and SOIVICE cab sagas Senne soled ae altes 2 35 Rotator Drive Group Reassembly 2 36 MOTOT a s5 eink SAE sea a eee neue 2 38 Motor Removal and Installation Revolving Clamps Only 0 2055 2 38 Motor Disassembly and Reassembly 2 39 Frame Assembly Revolving Clamps Only 2 40 Baseplate Removal 2 40 Ring Gear Bearing Assembly Removal 2 40 Frame Assembly S
46. t the For Reassembly Lube Remove Nuts housing Fittings should be snug but not overtightened Tordue to 15220 ft lbs Install reducers and fittings as follows Thread hose fitting A into bushing B until tight Fit the assembly of the 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 fluid was spilled when the motor was removed perform the following Remove the plug at the top of the side cover Fiil the gearcase to the plug hole level with Keystone WG 1 lube Cascade part no C 656300 Install the p ug oo Fitting Bushing Housing Form 5185 Rev O 2 38 sim Service 5 9 2 Motor Disassembly and 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 60 O 2 39 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
47. tachment through several full cycles to force air in the system to the truck hydraulic tank Check for leaks 009 9 Form 5185 Rev O Arm lt Carrier Bar Remove the O Lubricate Old Bushing Bushings Remove the Snap Ring and Washer Frame Capscrews D swim D Service 5 3 2 5 3 3 5 3 4 2 25 cynnar Disassembly Use a pin type spanner wrench to remove cylinder retainers When servicing a cylinder clamp it in a soft jawed vise Clamp the cylinder and the rod on the major diameter at the extreme end only Never clamp the cylinder rod sealing surface V seals will slide off the piston easily To gain access to the rod seals remove the self adjusting brass bushing from the retainer after the retainer has been removed To remove a U cup seal from a piston put the piston in a soft jawed vise Pry the seal up with a blunt tool such as a screwdriver then cut the seal to remove it Be careful not to scratch the seal groove Cylinder Inspection e Inspect the rod piston and retainer for nicks or burrs lf deeply gouged replace the part Minor nicks and burrs can be removed with an emery cloth NOTE A minor nick is one 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 and burrs see Note above with a butter fly hone Replace the cylinder shell if it is deeply gouged On cylinder
48. th of the ring gear before continued assembly Using the hoist chain lift the baseplate into position on the bearing race z Lubricate q O Lube torque the capscrews in the order shown some Grease Fitting units may have a different quantity of capscrews Use torque values as follows C2 C3 and C4 65 70 ft Ib 1 Lube Torque the C6 55 60 ft Ib Epere in the C7 200 205 ft lb Sequence Shown a Lube Torque to f WARNING The capscrews that secure the baseplate to the bearing Use Hoist Chain to Place Ring Gear on Frame CAUTION The Letter Stamped on the Ring Gear Must be Located at one of These Arrows 65 70 ft Ib C7 120 125 ft Ib race must be grade 5 minimum 5 Lubricate and install the hub seal 6 Reinstall the revolving connection See Paragraph 5 7 2 Q Reinstall the rotator drive group See Paragraph 5 8 1 8 Lubricate the bearing race through the grease fitting on the ring gear bearing assembly baseplate on C3R clamps O instal the attachment on the truck as described in Section 2 Use Hoist Chain to Place Basepiate on Bearing Race Lubricate and Install Hub Seal Lube Torque the Capscrews in the Sequence Shown See step for Torque Values Form 5185 Rev 0 2 42 sO Standard Labor Times 6 1 6 2 2 43 Standard Labor Time is the average time required to per form each operation described in Sec
49. the arm with the cover removed fabricate and install a bar that spans the front cover capscrew holes that will secure the indexing mechanism Remove the two springs in the center of the bellcrank Remove the belicrank Push the vertical crank bar aside and remove the selector plate Make a Bar to Secure the Uncovered Mechanism Remove Selector O0 O OO Oo 0000 Remove the snap ring that secures the actuator Remove the actuator To remove the fork remove the twelve socket head capscrews retaining the circular arm bearing For installa tion tighten to a torque of 120 130 ft Ibs Press the bearing out of the arm manually Remove the detent pin spring and bushing For reassembly reverse the above procedures except for the following special instructions The two capscrew stops should be adjusted so the arm stops at a true horizonta and vertical position when it is indexed In the vertical clamp position the capscrew shouid stop the arm so it just engages the detent pin in the arm base Tighten the nut toa torque of 85 90 ft Ibs Lubricate the arm bearing when reassembling Make sure the arm turns freely on the bearing Lubricate the bellcrank fittings with SAE 90 grease Form5185 Rev O 5 Plate 7 Remove Actuator Remove N ey Snap Te Ring Sos G tty Crank aa Bar A L eG O 4 me Pivot Pin Ki i aa F
50. tion 5 Service Each Standard Labor Time is identified by the Service Section paragraph number and title that corresponds to that operation The Standard Labor Times are based on the assumption a qualified serviceman is working on a reasonably clean at tachment with adequate tools We realize the actual time required to perform an operation may occasionally be greater than that listed especially if a first time serviceman lacks the needed tools or if a bolt is frozen But considering all factors that can affect the job Cascade can only honor warranty labor claims based on these carefully evaluated averages We strongly urge servicemen to read the applicable Service Sections of the manual before repairs are in itiated If problem diagnosis is difficult call the Cascade Service Department at 1 800 547 5266 toll free or in Oregon call 666 1511 To arrive at the total Standard Labor Time for a job list each operation and add the times As an example to replace bushings your list should look something like this 5 1 Clamp Removal and Installation 0 8 5 2 1 Arm Remova and Installation 1 0 5 2 6 Arm Bushing Replacement _1 0 Total Standard Labor Time 2 8 Standard Labor Times Paragraph Number Times 5 1 Clamp Removal and Installation 0 8 5 2 1 Arm Removal and Installation 1 0 5 2 2 Arm Carrier Load Arm Disassembly and Reassembly 0 2 0 2000 0 5 5 2 3 Turnafork Arm Disassembly
51. up Removal and Installation Cont To synchronize the worm shafts rotate each sprocket counter clockwise by hand until you feel resistance Using the uppermost allen head capscrew on the shaft end cap as a reference mark one tooth of the sprocket Then turn the sprocket clockwise counting the teeth as they pass the allen head capscrew Stop turning when you feel resistance Now rotate the sprocket back counterclockwise half the number of teeth counted The sprockets are now positioned haliway between where you felt resistance Install the chain around the sprockets If one sprocket does not align with the chain rotate it no more than 1 2 tooth width until it does Center the sprockets within 1 8 inch between the drive unit end hous ings Tighten the setscrews on both sprocket hubs Coat the chain with Richfield No 2MP grease or equivalent Position the seal on the sprocket so that it aligns with the grooves in the cover Install the cover over the sprockets making sure the seals are in place CAUTION The steel pin on one cover half must align with the hole in the other half before you tighten the screws After the attachment is installed on the truck power the rotator to check for clearance be tween the coupling and the baseplate Install the attachment onto the truck as described in Section 2 Form 5185 Rev O Po Cover LE Position Seal f Insta S
52. y side 2 Remove the lower mounting hooks For reassembly lube torque the lower mounting hook capscrews as shown on the following chart Mounting Class Lower Carriage and Back Truck Away Slightly Disconnect Hoses Put Weight on Torque Value lubed Attachment all models C2B C3B C4P C6B C28 Remove Lower Mounting Hooks Lower Attachment onto Pallet Position wooden blocks or a shipping pallet under the SEE CHART attachment Lower the mast carriage until the attach ore ae OR ment is resting on the blocks VALUES O On attachments so equipped set a 1000 pound weight on the forks to hold the attachment upright NOTE Attachments with load arms other than forks amp don t require additional stabilizing weight 6 Making sure the weight on the arms is secure con tinue lowering the mast carriage enough to clear the upper mounting hooks Back the truck away a few inches to gain access to the hoses to the attach ment WARNING Before removing any hoses relieve pressure that might be present in the hydraulic system With the truck off open the truck auxiliary control valve s several times in both directions O Disconnect and cap the hoses to the attachment Tag the hoses for ease in reconnecting For reinstallation reverse the above procedures or consult the Installation Instructions Section 2 2 19 Form 5185 Rev 0 sain Service e 52 Arms 5 21 A
53. you need answered right now Dial Directline 800 547 5266 toll free Cascade Corporation 1980 2 80 VGP NATIONAL ASSOCIATION OF SERVICE MANAGERS Litho in U S A Part Number C 667447 Form 5185
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