Clamps - Cascade Corporation
Contents
1. Attachment Stop Blocks Using a suitable hoist and chain position the clamp as shown and remove the lower mounting hooks Position the truck close enough so the hoses on the junction blocks can be connected to the attachment Connect the hoses to the attachment as shown in the appropriate plumbing diagram Raise the truck carriage and engage the attachment upper mounting hooks Make sure the centering block on the attachment aligns with the center notch on the carriage IMPORTANT Some models have a positioning block welded to the inside of the upper mounting hook Center the attachment on the carriage making sure the posi tioning block is engaged in a notch on the carriage Tilt the mast back and install the lower mounting hook Lube torque the capscrews to 103 113 ft Ib 35C Class 64 69 ft Ib 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 1 2 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 Mak2. seht Jt o To Tru 2 Block Junction Block jot VIEWED FROM THE DRIVER S SEAT Figure 2 Plumbing Diagram Carton Clamps with a Hi Ball Valve o Conventional 90 Swivel Hose Port B Check Elbow Close Valve Siue igh raight Thread j 90 Straight Thread Connector Thread Elbow Connector Port iv Close Open Open i Shift To Truck Lift Right Junction Block j Connect To Truck Note The Junction Blocks on your Truck may be Reversed from those Shown Shut off Valves Figure 3 Plumbing Diagram Appliance Clamp with a Conventional Valve VIEWED FROM THE DRIVER S SEAT Hi Ball Valve into Port CL 90 Straight OP Thread Elbow 90 Swivel 90 Swivel Elbow i Elbow Straight 43 Thread Ba iH Straight Connector p Thread A E Connector lt 90 Straight AP traight HEN N a d N Open Close Elbow 4 Side aae 2 MESA Shift Shift Connect uf X Left E Right To Truck i 1 gt j Junction r i Connect Block To Truck Junction Block Sf SHE Note The Junction Blocks on 2 S hi your Truck may be Reversed from those Shown Shut off Valves Figure 4 Plumbing Diagram Appliance Clamp with a Hi Ball Valve Form 5191 0 2 Installation Instructions 2 3 2 4 2 5 Installation 9
3. D Service 5 5 5 5 1 6 31 Check Valves Standard Carton Clamps and Appliance Clamps have a sliding spool fluid control valve that serves as a check valve and a flow divider Hi Ball attachments are equipped with a special Hi Ball valve Appliance Clamps are additionally equipped with two sideshifting shutoff valves to control the flow of oil to the clamp cylinders at the end of the sideshifting stroke Check Valve and Appliance Clamp Shutoff Valve Removal and Installation 9 Remove the attachment from the truck as described in Paragraph 5 1 Remove cap and tag the hoses or tubes to the check valve and Appliance Clamp shutoff valves Remove cap and tag the truck hoses to the attachment shutoff valves by removing the capscrew s securing the valve to the attachment frame Installation is a reversal of removal Install the attachment onto the truck as described in Section 2 IMPORTANT APPLIANCE CLAMP SHUTOFF VALVES ONLY When installing shutoff valves make sure the adjustable stop leaves 0 20 inch of travel on the valve plunger when the arms are completely closed Remove the check valve and Appliance Clamp 9 Fluid Control Valve Remove Remove Hoses P d VIEWED FROM THE FRONT OF THE ATTACHMENT Carton Clamp with Fluid Control Valve Remove Tubes Remove Hoses 2 Remove Remove Shut off FRONT OF THE Valves
4. cascade rca TM e Service Manual Carton Clamps and Appliance Clamp e Manual Number 667451 cascade corporation Cascade is a Registered Trademark of Cascade Corporation 20187 Portland Oregon 97220 503 666 1511 Contents Page e Number INTRODUCTION Section 1 6 1 INSTALLATION INSTRUCTIONS Section 2 6 2 Truck System Requirements 6 2 Prior to 6 3 Installation 25 0 cogn RR 6 5 Attachment Stop 6 5 Prior to 6 5 PERIODIC MAINTENANCE Section 3 6 6 TROUBLESHOOTING Section 4 6 7 General 6 7 0 6 9 Checking Truck Output 6 17 Clamp Drops Load Only When Sideshifting 6 17 General Pressure Test Carton Clamps with a Conventional Valve Only 6 18 General Pressure Test Appliance Clamps with a Conventional Valve 6 20 Troubleshooting Tests Clamps with a Hi Ball Valve ry eant Doa ee 6 22 SERVICE Section 5 6 24 Clamp Removal and Installation 6 24 AIMS ue 6 24 Arm Removal and Installation 6 24 Arm Disassembly Service and Reassembly Carton Clamps 6 26 Arm Disassembly and
5. 5 5 1 Valve Removal and Installation Carton Clamp and Appliance Clamp Check 0 5 Appliance Clamp Shutoff Valve 0 4 Hi Ball Valve 1 5 5 5 2 Check Valve 0 8 5 5 4 Shutoff Valve Service Appliance Clamps 0 5 Form 5191 Rev 0 NATIONAL ASSOCIATION OF SERVICE MANAGERS cascade Do you have questions you need answered right now e Dial Directline 800 547 5266 toll free Cascade Corporation Litho in U S A 3 79 Form 5191
6. 9 Periodic Maintenance 3 1 3 2 3 3 3 4 Form 5191 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 Check the cylinder anchor nuts for security Carton Clamps Only Check the hard facing on the bottom of each arm stabilizer If there is visible wear or if your attachment has an old style wear shoe along the lower edge of the arm build up the surface with weld as shown 500 Hour Maintenance After each 500 hours of lift truck operation in addition to the 100 hour maintenance procedures perform the follow ing procedure Retorque the mounting capscrews Use the torque specifications shown in Section 2 1000 Hour Maintenance After each 1000 hours of lift truck operation in addition to the 100 hour and 500 hour maintenance procedures perform the following procedure O 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 Replace all sliding arm bushings Rev 0 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 f
7. ARMS OPENING PRESSURE umm RETURN 6 9 Form 5191 0 Form 5191 Rev 0 4 Troubleshooting 421 Hosing Diagram Carton Clamps with Conventional Valve Cont SIDESHIFT LEFT PRESSURE zum RETURN 422 Circuit Schematic Carton Clamps with Conventional Valve NOTE Junction Blocks May or May Nat He ay Not Have Check Valves Junction a Block Hose Hose Reel Sideshift Truck Truck Relief Valve Truck Hydraulic Pump 6 10 sin 4 Iroubleshooting 423 Hosing Diagram Appliance Clamp with Conventional Valve ARMS CLOSING PRESSURE ARMS OPENING PRESSURE zum 6 11 Form5191 0 san 4 Iroubleshooting 423 Hosing Diagram Appliance Clamp with Conventional Valve Cont 127 Sideshifting a Shutoff Valves SIDESHIFT LEFT 6 Block PRESSURE Sms RETURN e 424 Circuit Schematic Appliance Clamps with Conventional Valve NOTE Junction Blocks May or heck Valves 2 d Junction Block Truck Hydraulic Truck Relief Valve Pump Form 5191 0 6 12 4 4 Troubleshooting 425 Hosing Diagram Carton Clamps with Hi Ball Valve ARMS CLOSING PRESSURE Zum RETURN 1 ARMS OPENING PRESSURE Umm Form 5191 Rev O 4 Troubleshooting 425 Hosing Diagram Carton Clamps with Hi Ball Valve Cont SIDESHIFT
8. DRIVER S SEAT ift In order to conform to industry standard practice the hoses should be connected to the truck auxiliary valves as indicated by the following chart Connect To Truck I Junction Function in order of location from operator Attachment Movement Motion of the operator s hand Sideshift Right Rearward or Up Sideshift Left Forward or Down Clamp close Rearward or Up e Release open Forward or Down Figure 1 Plumbing Diagram Carton Clamps with a Conventional Valve Sideshift Clamp CAUTION 2 Flush the hoses as follows to prevent damage to the attachment check valve assembly and the cylinders Refer to the appropriate plumbing diagram aen a Connect the hoses from each junction block Block Hose Fittings together b Start the truck and actuate the truck control valves in both directions for about 30 seconds to carry any debris left in the hoses to the truck hydraulic tank and filter To Junction Block 63 Form5191 0 2 Installation Instructions NOTE The Junction Blacks on Your Truck may be Reversed from those Shown Hi Ball Valve 90 Swivel Elbow Into Port B2 Straight Straight 90 Swivel Thread Connector Connector b Side Side Close Open Shift _ Shift a d Right Left Connect
9. 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 Clamp arm s won t operate properly If you encounter this problem refer to Paragraph 4 3 Clamp drops the load only when sideshifting If you en counter this problem refer to Paragraph 4 4 Clamp drops the load after it has been gripped Clamp will not carry loads up to the rated capacity of the clamp If you encounter one of these problems refer to the following appropriate Paragraph Carton Clamps with a conventional check valve Paragraph 4 5 Appliance Clamps with a conventional check valve Paragraph 4 6 Any attachment with a Hi Ball valve Paragraph 4 7 Rev O Pressure Gauge 24 inch Extension Hose Needie Shutoff Swivel Nut Valve Run Tee Drain Hose 1 1 p IMPORTANT Make Sure The Arrow Points in This Direction 1 inch 24 inches gt STEEL SLEEVE For Appliance Clamps With Conventional Valve Only 6 8 san 4 Iroubleshooting 42 Plumbing 421 Hosing Diagram Carton Clamps with Conventional Valve ARMS CLOSING PRESSURE zm RETURN
10. LEFT PRESSURE Ium RETURN with Hi Ball Valve Form 5191 0 426 Circuit Schematic Carton Clamps Hi Ball Valve Cartridge Valves Are not Serviceable 7 1 1 1 1 1 H p 1 Junction Bios NOTE Junction Blocks May or May Not Have Check Valves y Truck Hydraulic Truck Relief Valve Pump OPTIONAL ressure Relief Valve C 660412 6 14 si 4 Troubleshooting 427 Hosing Diagram Appliance Clamp with Hi Ball Valve Sideshifting Shutoff Vaive ARMS CLOSING PRESSURE RETURN zum ARMS OPENING PRESSURE Zum 6 15 Junction Form 5191 0 sain 4 Iroubleshooting 427 Hosing Diagram Appliance Clamp with Hi Ball Valve Cont Sideshifting Shutoff Valve Sideshifting Shutoff Valve SIDESHIFT LEFT PRESSURE zum RETURN 428 Circuit Schematic Appliance Clamp with Hi Ball Valve 2 Hi Ball Valve Cartridge Valves Are not Serviceable Sideshifting Shutoff Valves Junction Block NOTE Junction Blocks May or May Not Have Check Valves Pressure Relief Valve Test Port micum e Valve Truck H drauli m i d Truck Relief Valve Puno ydrau Pressure Rener Valve C 660412 Form 5191 0 6 16 sain 4 Troubleshooting Checking Truck Output If the clamp arm s won t operate properly make sure the truck sy
11. before proceeding 5 41 Cylinders with V seals Remove the setscrew from the threaded washer Remove the threaded washer Pull the rod assembly out of the shell 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 Remove the pistons and retainer and replace all seals 00000 Be Sure to leplace This Seal CS Remove the Nut For Reassembly Lube Torque to 300 350 ft Ib 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 Remove the piston and retainer and replace all seals 5 4 2 0000 Be Sure to Replace This Seal iil lt Remove the Nut Form 5191 Rev O Remove the Bushing from the Retainer TN MM Remove Pistons and Remove the Setscrew 69 Retainer and Replace All Seals o PS Remove the Rod Assembly For Reassembly Lube Torque to 20C 50 60 ft Ib 35C 70 75 ft Ib For Reassembly Lube Torque to Retainer SM gt gt N Remove the Threaded Washer 3 Remove the Rod Assembly For Reassembly Lube Torque to 120 150 ft lb For Reassembly Lube Torque to 20C 150 175 ft Ib 35C 175 225 ft Ib Remove the Retainer Remove Pistons and Retainer and Replace All Seals 6 30
12. 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 lf 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 Removal and Installation 0 8 5 2 4 Arm Bushing Replacement _1 0 Total Standard Labor Time 2 6 Standard Labor Times Paragraph Number Times 5 1 Clamp Removal and Installation 0 8 5 2 1 Removal and Installation 0 8 5 2 2 Disassembly Service Reassembly Carton Clamps 1 5 5 2 3 Arm Disassembly and Reassembly Appliance 0 5 5 2 4 Sliding Arm Bushing Replacement Two Piece 1 0 5 2 5 Sliding Arm Bushing Replacement One Piece 1 0 5 3 1 Cylinder Removal and Installation 0 5 5 4 1 Cylinders with 0 8 5 4 2 Cylinders with U Cup 0 8
13. 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 attachment through several full cycles to force air in the system to the truck hydraulic tank Check for leaks Form 5191 Rev 0 Backrest 20C CARTON CLAMP SHOWN 6 28 D Service 5 3 2 5 3 3 5 3 4 6 29 Cylinder 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 Inspect the rod piston and retainer for nicks or burrs If 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 operat
14. 3 Clamps Controlled with One Auxiliary Valve and a Solenoid Valve If your unit is plumbed to sideshift when the solenoid valve is energized replumb the circuit so the clamp function operates when the solenoid valve is energized 6 17 Form 5191 Rev 0 san 4 Iroubleshooting 4 5 Form 5191 General Pressure Test Carton Clamps with a Conventional Valve Only 0 Open the arms completely to gain access to the check valve ports Locate and identify Port C on the check valve and disconnect the cylinder hose from the elbow Install the gauge and tee into the elbow as shown then reconnect the cylinder hose to the open end of the tee Close the arms completely Make sure the gauge assembly does not interfere with the closing arms Pull the contro handle to the clamp position and hold for a few seconds Return the handle to neutral The gauge 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 f the truck system is OK watch the gauge If it registers a drop of more than 100 psi in one minute check for hydraulic leaks in the system Refer to the accompanying diagram Repair the leaks and recheck the pressure f the truck system is OK and the gauge does not drop more than 100 psi in one minu
15. ATTACHMENT Appliance Clamp with Fluid Control Valve pu SP VIEWED FROM THE 52 Form 5191 0 sein D Service Form 5191 Rev 0 Remove Hoses 3 Remove Hi Ball Valve 227 VIEWED FROM GR THE FRONT OF CS mA THE ATTACHMENT 2 02 1972 Qarton Clamp with Hi Ball Valve Remove the Shut off Valves Shut off Valve VIEWED FROM THE FRONT OF THE ATTACHMENT Appliance Clamp with Hi Ball Valve 6 32 san D Service 552 Check Valve Service IMPORTANT Service the fluid control valve in a clean work area 6 33 0 0060 0 Using the special wrench Cascade part number C 2645 provided with the valve seat repair kit remove the allen head plugs from both ends of the valve If the special wrench is not available use a No 5 JIC fitting cap Carefully remove the internal parts and lay them out in the correct order on the work bench CAUTION The balls can become lodged in the in ternal ports during disassembly Make sure the balls are removed before proceeding Remove the hex head plugs from both ends of the valve Carefully remove the internal parts and lay them out in the correct order on the work bench Clean all internal parts with kerosene or cleaning solvent Replace the springs O rings and ball seats using Cascade s valve seat repair kit Insert the piston pin and spacer the end with the small hole goes in fi
16. Pressurizing the cylinders outward will increase friction between the cylinder rod and the lug and may make loosening the nuts easier Form 5191 0 Lower Carriage and Back Truck Away Slightly Disconnect Hoses Lower Carriage until Remove Lower Attachment Rests on Pallet For Reassembly Mounting Hooks Lube Torque to 103 113 ft Ib 35C Class 11 64 69 ft Ib Carton Clamp Arm Shown 6 24 D Service 5 2 1 6 25 3 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 4 Retract the cylinder rods until they come out of engagement with the arm lugs 5 Pull the arms out of the clamp frame IMPORTANT Each time the arms are removed in spect the arm guide tubes for scoring Minor scoring can be removed with a hone If the guide tubes are badly damaged the frame must be replaced Before in stalling arm carriers make sure the guide tubes are clean and free of metal projections 6 For reassembly reverse the above procedures except for the following special instructions for cylinder anchor nuts NOTE When tightening cylinder anchor nuts pressurizing the cylinders outward will increase friction between 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 t
17. Reassembly Appliance Clamp 6 26 Sliding Arm Bushing Replacement Two piece Style 6 27 Sliding Arm Bushing Replacement e One piece 6 27 Cylinders General Procedures 6 28 Cylinder Removal and Installation 6 28 Cylinder Disassembly 6 29 Cylinder 6 29 Cylinder Reassembly 6 29 Cylinder 6 30 Cylinders with V seals 6 30 Cylinders with U cup Seals 6 30 Check Valves 6 31 Check Valve and Appliance Clamp Shutoff Valve Removal and installation 6 31 Check Valve Service 6 33 Hi Ball Valve 6 34 Shutoff Valve Service Appliance Clamps ly is oco Iob eI 6 34 STANDARD LABOR TIMES Section 6 6 35 Form 5191 0 1 Introduction 1 1 1 2 6 1 This manual provides the installation instructions periodic maintenance requirements troubleshooting procedures and service guides for Cascade Carton Clamp models 20C 35C and 60C and the Cascade Appliance Clamp model 20C Truck System Requirements Pressure Clamps with conventional check valve assembly Your lift truck should supply sufficient hydraulic pressure to handle the heaviest load PRESSURE MUST NOT EXCEED 2000 PSI Clamps wi
18. e Appliance Clamps Only 5 5 4 IMPORTANT Service the shutoff valve in a clean work area 9 Remove the hex head plug and remove the plunger and ball assembly from the valve body Remove the internal components 2 Remove the snap ring and disassemble the plunger guide ball seat ball and spring 8 Clean and inspect the ball and ball seat Replace the valve body if the seat cannot be reconditioned The ball can be reseated by tapping it into its seat with a brass punch Replace the ball if it is nicked or scratched Reassembly is reverse of disassembly Form 5191 0 SON Guide Ball Ball Seat Spring 2 Plunger O Ring DO NOT Remove This Fitting Hi Ball Valve Part No Stamping Appliance Clamp Shut Off Valve Back Up Ring Clean and Inspect Ball d and Bali Seat 77 90 8 the A Remove Snap Ring Remove the Plug 6 34 si Standard Labor Times 6 1 6 2 6 35 Standard Labor Time is the average time required to per form each operation described in Section 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
19. e sure you protect adjacent hoses and hydraulic components from weld splatter 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 Before picking up a load operate the attachment through several cycles to force any air from the system to the truck hydraulic tank Check for leaks Pick up a maximum load and operate the clamp If the clamp does not function correctly recheck the plumb ing If the clamp drops the load contact Cascade s Service Department telephone 800 547 5266 toll free in Oregon 666 1511 WARNING Make sure there are no people in the vicinity of the attach ment when picking up a load Connect Hoses to Clamp Position to Clamp Lube Torque 103 113 ft Ib 35C Class 11 Position Clamp 1 and remove Lower Mounting Hooks Tilt Back and 5 install Lower Mounting Hooks to 64 69 ft Ib 1 Make Sure Spring Retainer is in OLD STYLE CYLINDER ANCHOR NUT Attachment Upper Mounting Hook Steel Stop Block Place Check For 9 At Least One Stake Here NEW STYLE CYLINDER ANCHOR NU Form 5191 Truck Close f Making sure it is Centered Raise the Carriage to Engage the Clamp Truck Carriage pper Crossbar T Rev 1 4
20. erformed with the arms on the attachment and with the attachment on the truck NOTE The contact plate does not have replaceable pads If a pad is completely worn the contact plate must be replaced Remove the contact plate from the stabilizer 2 Remove the stabilizer by removing the two pivot pins that secure it to the arm base Inspect the stabilizer pivot bushings If the non metallic coating is worn through or if the bushjng ID is worn replace the bushing CAUTION Use a bushing driver to replace the bushings Do not damage the bushing ID Remove the arm carrier either T bar or integral Reassembly is a reverse of disassembly NOTE The camber of the contact plates can be ad justed by removing the top spacer between the con tact plate and the stabilizer If even more camber is required combine the top spacer with the bottom spacer 523 Arm Disassembly and Reassembly Appliance Clamp The rubber pads on Appliance Clamps are not replaceable If the pad is worn or if the arm is damaged the complete arm assembly must be replaced The left hand and right hand arms are not interchangeable The arm carrier can be removed and reinstalled in the same manner as Carton Clamps Form 5191 Rev 0 4 Remove the Contact Plate For Reassembly Lube Torque to 20C 35C 120 125 ft Ib 60C 280 290 ft Ib Remove the Arm Carrier T bar shown 2 Remove the Stabilizer A
21. f one cylinder Install a gauge into the open port then re connect the cylinder supply hose to the gauge tee Slowly retract the cylinders arms moving together until the sleeves contact the cylinder end Make sure the gauge assembly does not interfere with the closing arms The cylinders are now blocked partially open Pull the clamp control handle to the clamp position and hold for a few seconds Return the handle to neutral The gauge 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 f the truck system is OK watch the gauge If it registers a drop of more than 100 psi in one minute check for hydraulic leaks in the system Refer to the accompanying diagram Repair the leaks and recheck cylinder pressure e f there are not external leaks test the check valve as follows page 6 21 Rev 0 Slip the Sleeves Reconnect Cylinder Hose To Tee Sideshifting hutoff Cylinder Soh J Junction Truck Auxiliary Valve POTENTIAL LEAK POINTS 6 20 4 Iroubleshooting 4 6 6 21 General Pressure Test Appliance Clamps with a Conventional Valve Only Cont Remove the gauge tee from the cylinder rod end port but keep it connected to the hose Rem
22. gages the groove in the arm carrier bar e 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 before assembling arm carriers onto the attachment Lubricate Bushings Long Bushing Short Bushing 5 25 Sliding Arm Bushing Replacement One piece Style Remove the bushing retainer snap ring and washer M rm P from the end of the arm carrier bar P Slide off the old bushing Bar Slide the new bushing on and instal the washer and retaining snap ring Lubricate the bushings before assembling arm Q carriers onto the attachment p Remove the Lubricate Old Bushing Bushings 1 Remove the Snap Ring and Washer o oo 6 27 Form 5191 Rev 0 4 5 Service Cylinders General Procedures 5 31 Cylinder Removal and Installation o o 900 06 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 Remove the backrest 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
23. he arm carrier Install the sleeve then thread on the nut Tighten the nut until the sleeve bottoms 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 NOTE Service replacements for old style anchor nuts are of the new style configuration 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 with a wrench and torque the nut to 20C and 35C 55 65 ft Ib 60C 130 150 ft Ib Lock the nut by staking the cone shaped washer with a case hardened chisel Be sure the washer is driven into the slot 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 Arm Removal and Installation Make Sure Washer Lug Spring Counterbored Washer Retainer is in Place Sleeve Nut OLD STYLE CYLINDER ANCHOR NUT Nut Stake Washer into Cylinder Rod Groove Lug NEW STYLE CYLINDER ANCHOR NUT Form 5191 Rev 0 4 5 Service 522 Arm Disassembly Service e and Reassembly Carton Clamps The following procedures can be p
24. he gauge VIEWED FROM THE REAR Refer to Section 5 Paragraph 5 6 Pressure if the gauge does not drop more than 100 psi in one Gauge minute one or both cylinders require service Refer to Section 5 Paragraph 5 3 If the gauge does drop more than 100 psi in one ee To Truck n unction minute the check valve is faulty and requires service Block ete O After making the necessary corrections reconnect the hoses Cycle the clamp 4 or 5 times without and with a load before returning it 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 e Call 800 547 5266 toll free In Oregon 666 1511 Form 5191 0 4 Iroubleshooting 4 6 Form 5191 General Pressure Test Appliance Clamps with a Conventional Valve Only Open the arms completely Disconnect the cylinder rod ends from the arms IMPORTANT Refer to the procedures described in Section 5 Paragraph 5 2 1 Step 2 Retract the cylinders far enough to slip the steel sleeves over the cylinder rods 1 Extend the cylinders and reconnect the rods to the arms with the sleeves in place It is not necessary to the nuts or install the keepers Remove the supply hose to the rod end port o
25. he gauge assembly does not interfere operate the attachment several times and watch the arms to be sure the valve is operating properly IMPORTANT Feather the control valve instead of operating at full speed so you can more easily observe the movement of the arms The following should happen when the arms are closing from the fully open position Both arms should begin closing simultaneously The right arm should complete its travel first The left arm should hesitate before completing its final 4 6 inches of travel e As soon as the right arm reaches the end of its travel and immediately before the left arm continues to move the system pressure should increase to approx imately 1650 psi warm oil If it does not lift truck pressure must be adjusted to 1700 psi minimum DO NOT EXCEED 2000 PSI The pressure should then drop as the left arm completes its final 4 6 inches of travel If the system does not pass these tests the Hi Ball valve is faulty and should be replaced If the system does pass these tests and the clamp will not handle the load remove the gauge from Port CL and perform the following General Pressure Test Rev 0 Port CL To Pressure Gauge VIEWED FROM THE REAR To Truck Junction Port CL 24 Inch Block Extension NETT 4 ie Install Tee Fitting T Pressure Gauge To Truck Junction Block 6 22 4 Iroubleshoo
26. ing 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 cylinders with V seals inspect the self adjusting brass bushing that fits inside the retainer If the ID is scored the bushing should be replaced Cylinder Reassembly Lubricate all new seals before installing Use a mixture of petroleum jelly and hydraulic oil on seals 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 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 angle will allow the seal to slide into the groove much easier 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 When reassembling a cylinder always observe all torque values as shown on the appropriate illustration Do Not Clamp Rod On Threaded or Sealing Surfaces Clamp Only at Extreme End of Major Diameter Clamp Shell Only At Extreme Base End Remove Seal from Piston Do Not Scratch the Groove Form 5191 Rev 0 s D Service Cylinder Service Read the General Procedures Paragraph 5 3
27. ly Volume Clamps with a conventional check valve assembly 20C Carton Clamp and Appliance Clamp 2 6 gpm 35C and 60C Carton Clamps 8 18 gpm Clamps with a Hi Ball valve assembly Minimum 3 gpm Maximum 7 gom IMPORTANT HI BALL ATTACHMENTS ONLY If clamp ing pressure must be reduced below 1700 psi an aux iliary relief valve Cascade part number C 660412 must be plumbed into the circuit See the appropriate Hydraulic Schematic Paragraph 4 2 6 and 4 2 8 The relief setting must be no less than 1000 psi and the truck pump volume output must not exceed 6 gpm Form 5191 Rev 0 Section 4 Troubieshoc ting 4 1 2 4 1 3 Form 5191 Tools Required In addition to a normal selection of hand tools you will need one each of the following for attachments with a conventional valve and two each for attachments with a Hi Ball valve Pressure gauge capable of measuring pressures to 2500 psi No 8 swivel nut run tee 37 JIC suitable for mounting gauges e Needle shutoff valve rated for 2500 psi service minimum Recommended supplier for needle shutoff valve Marsh instrument Co Skokie lil e Hose with female ends for use as a drain line No 8 JIC cap for cylinder port e No 8 JIC plug for hose end e No 8 Orring to JIC straight adapter fitting Hose 24 inches long APPLIANCE CLAMP WITH CONVENTIONAL CHECK VALVE ONLY Two steel sleeves as shown by the ac companying illustration
28. ove 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 Connect a needle shutoff valve and drain line to the gauge tee Put the drain line into a suitable container CJ Open the needle valve no more than 1 2 to 1 full turn 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 C While holding the clamp lever open close the shutoff valve Keep holding the truck valve open until the gauge reaches within 100 psi of truck relief pressure Return the truck clamp valve to neutral and watch the gauge f the gauge does not drop more than 100 psi in one minute one or both cylinders require service Refer to Section 5 Paragraph 5 3 f the gauge does drop more than 100 psi in one minute the check valve is faulty and requires service Refer to Section 5 Paragraph 5 6 After making the necessary corrections remove the cylinder rod sleeves and reconnect all hoses Make sure the cylinder anchors are secure Refer to Section 5 Paragraph 5 2 1 Step 6 for special instructions regarding cylinder anchor nuts 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 stil have not solved the
29. 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 5191 Rev 0 sin Iroubleshooting 4 7 4 7 1 Form 5191 Troubleshooting Tests Clamps with a Hi Ball Valve Only Operational Tests If you are having trouble with a clamp equipped with a Hi Ball valve check the following before performing the General Pressure Test Paragraph 4 7 2 e Make sure the truck hoses are the same size as those used on the attachment They must be No 8 with minimum fitting orifices of 13 32 inch A flow divider can be used to reduce the volume delivered to the attachment Make sure the attachment is plumbed to the truck cor rectly Refer to the Hosing Diagram or Circuit Schematic Paragraph 4 2 for your system Make sure the truck pump supplies the specified volume to the attachment at the carriage junction block 3 gpm minimum 7 gpm maximum If a pressure regulator is used volume to the attachment must not exceed 6 gpm NOTE If your truck output exceeds the specified max imum a flow divider may be installed to provide the correct output Make sure there are no hydraulic leaks in the system If these conditions are met check for proper operation of the Hi Ball valve according to the following procedures 1 Open the attachment arms and install a pressure gauge and tee into valve Port CL as shown 2 Making sure t
30. rm Base Inspect the Bushings Pivot Pin Setscrew Spacer NOTE Clamps manufactured prior to June 1975 had re placeable Wear Shoes on bottom of the Contact Plates These Shoes have been replaced by a Hard Facing which is Welded to all Replacement Stabilizers Refer to the Periodic Maintenance Section Paragraph 3 1 for procedures for Field installation of the Facing Arm Carrier For Reassembly Lube Torque to 175 180 ft Ib 6 26 D Service 524 Sliding Arm Bushing Replacement Two piece Style e NOTE An attachment with two piece bushings may be converted to the new style one piece configuration by the Remove the Bushings Arm installation of the appropriate One Piece Bushing Conversion Kit Contact Cascade Customer Service for information 9 Remove and discard the old long and short bushings To ease removal spread the short bushing by insert ing a screwdriver blade into the bushing slot Similar ly insert two screwdrivers into two opposing slots in the long bushing to disengage the bushing retaining lip It may be necessary to drive off the long bushing with a block and a hammer 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 en
31. rst into the valve body Coat both seat O rings with Vaseline or equivalent Insert each O ring into its check cavity area then insert the seat and press it in place Insert the remaining components in the order shown CAUTION Before inserting the spring make sure the ball is properly seated Use the wrench cap to Remove torque the allen head Plugs plug to 10 ft Ib Special Wrench or No 5 JIC Fitting Cap Remove the Components 1 Remove the Plugs OLD STYLE CONFIGURATION if the internals of your valve look like these parts a seal kit part number C 652895 is available to update your valve Piston Pin Parts Valve Body Spring Spacer Metering Cartridge Clean AM Remove the Components Fluid Control Valve Assembly Form 5191 Rev 0 san D Service 553 Hi Ball Valve Service The Hi Ball valve is not a serviceable item and must be replaced as a complete assembly Refer to Troubleshooting Section 4 for troubleshooting procedures Order replacement valves using the assembly number stamped on the valve body When installing a replace ment valve flush all supply hoses as described in the In stallation Instructions Paragraph 2 2 Step 2 before in stalling the attachment onto the lift truck IMPORTANT Disassembly or repair of the Hi Ball valve without factory authorization will result in loss of warranty Shutoff Valve Servic
32. stem output conforms to the Truck System Re quirements Paragraph 4 1 1 before performing pressure tests on the attachment Correct volume output gpm is especially important on clamps with a Hi Ball valve You should check for the specified output with an accurate flow meter at the truck carriage junction block If output is not as specified your truck system may have to be adjusted or modified accordingly If your truck will not achieve the specified output and you have a clamp with a Hi Ball valve your at tachment may have to be modified to use a conventional valve Contact Cascade s Service Department if you have any questions 44 Clamp Drops the Load Only When Sideshifting If you encounter this problem with your clamp check the following before performing pressure tests on the attachment 4 41 Appliance Clamp Make sure the sideshifting shutoff valves are secure and adjusted properly The valve mounting should be adjusted so the plunger is fully depressed by the trailing arm right arm when sideshifting left and vice versa just before that arm reaches the end of its stroke 442 Carton Clamps If you are handling relatively narrow loads the trailing arm right arm when sideshifting left and vice versa may be reaching the end of its stroke before the leading arm If possible arrange your handling process to allow sideshifting the other direction If this is not practical contact Cascade s Service Department 44
33. tach ment is resting on the blocks Continue 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 attachment 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 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 Arms Arm Removal and Installation Contact pads contact plates and equalizers on Carton Clamps can be removed without removing the arm car riers from the attachment However the rubber pads on Appliance Clamp arms are not replaceable Remove arm carriers according to the following procedures 1 2 Open the arms past the clamp frame 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
34. te and you are having trouble picking up or carrying a load the problem is not hydraulic Refer to the Arm Service section Paragraph 5 2 2 or 5 2 3 or call Cascade s Service Department If there are no leaks and the gauge does drop more than 100 psi in one minute complete the following ad ditional test to locate the source of the problem page 6 19 Rev 0 To Pressure Gauge VIEWED FROM THE REAR Pressure Gauge 24 Inch Extension Hose To Truck j To Truck id Junction Block Junction Block Truck Auxiliary Valve POTENTIAL LEAK POINTS 6 18 sin 4 Iroubleshooting 4 5 6 19 General Pressure Test Carton Clamps with a e Conventional Valve Only Cont Open the arms fully Pressure Gauge L Disconnect the hose to the gauge tee and plug the hose O Install the needle valve and drain line to the open end of the tee Put the drain line in a suitable container the i 0 Open the needle valve no more than 1 2 to 1 turn To Suitable Start the truck and let it idle Put the truck clamp lever Container to the clamp position and hold for 4 5 seconds to allow oil to flow to the container O While holding the clamp valve open close the needle shutoff valve Keep holding the truck valve open until the gauge reaches within 100 psi of truck relief pressure Return the truck clamp valve to neutral and watch t
35. th Hi Ball valve assembly Your lift truck must supply no less than 1700 psi PRESSURE MUST NOT EXCEED 2000 PSI Volume 20C Carton Clamp and Appliance Clamp with conven tional check valve 2 6 gpm 35C and 60C Carton Clamps with conventional check valve 8 18 gpm All Clamps with Hi Ball valve 3 7 gpm Special Instructions Definitions A statement preceded by AWARNING is information that should be acted upon to prevent bodily injury A WARNING is always inside a ruled box CAUTION A statement preceded by CAUTION is information that should be acted upon to prevent machine damage IMPORTANT A statement 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 5191 Rev 0 sn 2 Installation Instructions 2 1 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 Truck System Requirements Truck relief valve setting Clamps with conventional check valve assembly 2000 psi maximum Clamps with Hi Ball valve assembly 1700 psi minimum 2000 psi maximum Truck hydraulic system should provide the following rates of flow 20C Carton Clamp and Appliance Clamp with con ventional check valve 2 6 gpm 35C and 60C Carton Clamps wi
36. th conventional check valve 8 18 gpm All Clamps with Hi Ball valve 3 7 gom Recommended hose and fitting size No 8 1 2 inch ID with minimum fitting orifices 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 Class II 14 94 20C 35C Class 111 60C 18 68 Make sure the truck carriage is clean and the notches are undamaged Form 5191 0 6 2 swim 2 Installation Instructions 22 Prior to Installation NOTE The Junction Blocks from those Shown 1 Install the hydraulic hoses to the truck junction blocks using the correct Cascade Attachment Installa 222 tion Kit The part numbers are as follows Port B Carton Clamps with a conventional valve C 663587 Close Carton Clamps with a Hi Ball valve C 663586 Appliance Clamp with a conventional valve C 663639 90 Swivel Elbo 90 Swivel Appliance Clamp with a Hi Ball valve C 663640 Straight Straight OR Thread _ Thread Connector 2A Connector use hoses and fittings as shown in Figure 1 2 3 or 4 Be careful not to pinch twist or otherwise damage the hoses Sf Poh IMPORTANT V Sideshitt Sidesh 2 Left Connect __ 90 Straight 9 To Truck 777 Thread Junction L Block Elbow 7 Block EVE VIEWED FROM THE
37. ting 4 7 2 General Pressure Test Open the arms completely to gain access to the check valve ports D Install pressure gauges with tees in Ports R1 R2 of the Hi Ball valve as shown O Close the arms completely Make sure the gauge assemblies do not interfere with the closing arms 24 Inch Pull the control handle to the position and Extension hold for a few seconds after the left arm has com pleted its travel to pressurize the clamp circuit Return the valve handle to neutral and watch the gauges f the gauges drop no more than 100 psi one minute and the attachment still fails to operate correctly the problem may be due to incorrect application of the at tachment or an auxiliary relief valve may be set too low to handle your loads f either or both gauges do drop more than 100 psi in amp Pressure one minute continue testing as follows to isolate the xd problem the arms and disconnect the hoses from the gauge tees that lead to the cylinder rod end ports ICON O Attach needle valves and drain lines to the gauge tees a Open both needle valves no more than 1 2 to 1 full turn and put the drain lines a suitable container CJ Move the control handle to the position to cause a flow of oil at the drain hoses Continue holding the control handle and close both needle valves tightly Hold the control handle to clamp
38. unction with a load to make sure the clamp operates correctly before returning it to the job Arm Stabilizer 12 minimum height WELDING SPECIFICATIONS ROD Stoody 2134 134 or equivalent This Wear Shoe has been re placed by a Hard Facing on the Arm Stabilizer 4 Iroubleshooting 4 1 4 1 1 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 unit through several cycles First test the attach ment empty to bleed air trapped in the system to the truck system Then test the attachment with a load to be sure it operates correctly before returning it to the job Stay clear of the load while testing Do not raise the load more than 3 inches off the floor while testing Truck System Requirements Pressure addition to conforming to the following re quirements your lift truck must supply sufficient hydraulic pressure to handle the heaviest load Clamps with a conventional check valve assembly Pressure to the attachment MUST NOT EXCEED 2000 PSI Clamps with a Hi Ball valve assembly Pressure to the attachment should be no less than 1700 psi and MUST EXCEED 2000 PSI If your truck out put does not conform to these tolerances the attachment will not operate correct
39. until the circuit is fully pressurized Return the handle to neutral and watch the gauges Junction f either or both gauges drop more than 100 psi in one minute the Hi Ball valve is faulty and must be replaced f neither gauge drops more than 100 psi in one minute one or both cylinders require service See Section 5 Paragraph 5 3 After making the necessary corrections remove the gauges and reconnect the hoses Cycle the attach ment 4 or 5 times without and with a load before returning it to service To Cylinder Rod Ends VIEWED FROM THE REAR 24 Inch Extension Pressure Gauges To Pressure 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 Needle Shutoff Call 800 547 5266 toll free Valves In Oregon 666 1511 re Container e 6 23 5191 Rev O 24 5 Service 5 1 amp 5 2 5 2 1 Clamp Removal and Installation o Open the clamp arms completely Remove the lower mounting hooks For reassembly lube torque the lower mounting hook capscrews to 103 113 ft Ib 35C Class 64 69 ft Ib Position wooden blocks or a shipping pallet under the attachment Lower the mast carriage until the at
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