Cascade E Series Manuale utente
Manual Number 215204 R-1
Cascade is a Registered Trademark of Cascade Corporation
cascadeT
E-Series
Non-Sideshifting and
Sideshifting Clamps,
Carton Clamps
ERVICE MANUAL
S
Page
INTRODUCTION, Section 1
Introduction, 1.1 1
Special Definitions, 1.2 1
INSTALLATION, Section 2
Truck System Requirements, 2.1 2
Recommended Hydraulic Supply Options, 2.2 3
Clamp Installation Procedure, 2.3 4
PERIOD MAINTENANCE, Section 3
100-Hour Maintenance, 3.1 9
500-Hour Maintenance, 3.2 9
1000-Hour Maintenance, 3.3 9
TROUBLESHOOTING, Section 4
General Procedures, 4.1 10
Truck System Requirements, 4.1-1 10
Tools Required (metric), 4.1-2 10
Troubleshooting Chart, 4.1-3 11
Troubleshooting Carton Clamp Loads, 4.1-4 12
Plumbing, 4.2 14
Non-Sideshifting – Hosing Diagram, 4.2-1 14
Non-Sideshifting – Hydraulic Circuit, 4.2-2 15
Sideshifting – Hosing Diagram/Clamp, 4.2-3 16
Sideshifting – Hosing Diagram/Sideshift, 4.2-4 17
Sideshifting – Hydraulic Circuit, 4.2-5 18
Sideshifting/Regen. – Hydraulic Circuit, 4.2-6 19
Clamp Function, 4.3 20
Supply Circuit Test, 4.3-1 20
Clamp Circuit Test, 4.3-2 20
Sideshift Function, 4.4 21
Supply Circuit Test, 4.4-1 21
Sideshift Circuit Test, 4.4-2 22
Electrical Circuit, 4.5 23
ONTENTS
C
i
SERVICE, Section 5
Clamp Removal, 5.1 25
Arms, 5.2 26
Arm Assemblies – Removal and Installation, 5.2-1 26
Drum Arm Pad Surface Replacement, 5.2-2 27
Carton & Rigid Arm Pad Replacement, 5.2-3 28
Carton Clamp Pad, Stabilizer Repair, 5.2-4 29
Carton Clamp Camber Adjustment, 5.2-5 30
Clamps without Arms, 5.2-6 31
Arm Bearings – Removal and Installation, 5.2-7 32
Valve/Manifold, 5.3 33
Valve Removal and Installation, 5.3-1 33
Manifold Removal and Installation, 5.3-2 33
Valve Service, 5.3-3 34
Relief Valve Cartridge Adjustment, 5.3-4 36
Cylinders, 5.4 37
Cylinder Service, 5.4-1 37
Cylinder Disassembly, 5.4-2 37
Cylinder Inspection, 5.4-3 38
Cylinder Reassembly, 5.4-4 39
Cylinder Replacement, 5.4-5 41
Base Unit, 5.5 42
Baseplate Replacement, 5.5-1 42
Solenoid Valve, 5.6 43
Coil Service, 5.6-1 43
Valve Service, 6.6-2 43
SPECIFICATIONS, Section 6
Specifications, 6.1 44
Hydraulics, 6.1-1 44
Auxiliary Valve Functions, 6.1-2 44
Truck Carriage, 6.1-3 44
Torque Values, 6.1-4 45
Page
215204 Rev. 1 1
I
NTRODUCTION
1.1 Introduction
This Manual provides the Installation, Periodic Mainte-
nance, Troubleshooting, Service and Specifications for
Cascade E-Series Clamps.
E-Series Clamps are designed for three-shift-a-day
continuous-duty operations with minimal maintenance.
They offer exceptional visibility for the lift truck driver and
provide optimized clamp force and load handling.
In any communication about the Clamp, refer to the
product I.D. number stamped on the nameplate as shown.
If the nameplate is missing, the numbers can be found
stamped on the back of the baseplate.
IMPORTANT: All hoses, tubes and fittings on E-Series
Clamps are JIC.
NOTE: Specifications are shown
in both U.S. and (Metric) units.
1.2 Special Definitions
The statements shown appear throughout this Manual
where special emphasis is required. Read all WARNINGS
and CAUTIONS before proceeding with any work.
Statements labeled IMPORTANT and NOTE are provided
as additional information of special significance or to
make the job easier.
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 the job easier.
WARNING - A statement preceded by
WARNING is information that should be
acted upon to prevent bodily injury. A
WARNING is always inside a ruled box.
45E-BC-005
cascade
LIFT TRUCK ATTACHMENT ATTACHMENT CAPACITY
SERIAL
NUMBER
CATALOG
NUMBER
ADDITIONAL
EQUIPMENT
ADDITIONAL
EQUIPMENT
ADDITIONAL
EQUIPMENT
FOR TECHNICAL ASSISTANCE, PARTS AND SERVICE
CONTACT:
1-800-227–2233
PORTLAND, OREGON USA
WEIGHT
LBS.
POUNDS
AT INCH LOAD
CENTER
CAPACITY OF TRUCK AND ATTACHMENT COMBINATION
MAY BE LESS THAN ATTACHMENT CAPACITY SHOWN
ABOVE. CONSULT TRUCK NAMEPLATE.
RECOMMENDED SYSTEM PRESSURE – 2000 PSI
MAXIMUM SYSTEM PRESSURE – 2300 PSI
cascade corporation
T
T
c
S/N 45E-BC-005
CL0412.ill
Nameplate
2 215204 Rev. 1
I
NSTALLATION
2.1 Truck System
Requirements
E-Series Clamps will provide maximum operating capabil-
ity when the following requirements are met.
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.
GA0082.ill
Clamp
Sideshift
Right
Tilt
Forward
Hoist Up
Auxiliary Valve Functions
Check for compliance with ITA (ISO) standards:
Tilt
Back
Hoist Down
Release
Sideshift
Left
GA0080.ill
Carriage
Clean carriage bars and inspect for
damaged notches
GA0028.ill
Carriage Mount Dimension (A) ITA (ISO)
Minimum Maximum
Class II 14.96 in. (380.0 mm) 15.00 in. (381.0 mm)
Class III 18.68 in. (474.5 mm) 18.74 in. (476.0 mm)
Truck Relief Setting
2300 psi (160 bar) Recommended
2600 psi (180 bar) Maximum
Truck Flow Volume ➀
Min. ➁Recommended Max. ➂
20E, 30E, 33E, 5 GPM 7.5 GPM 10 GPM
40E, 45E (19 L/min.) (28 L/min.) (38 L/min.)
➀Cascade E-Series Clamps are compatible with SAE 10W
petroleum base hydraulic fluid meeting Mil. Spec. MIL-0-5606 or
MIL-0-2104B. Use of synthetic or aqueous base hydraulic fluid is
not recommended. If fire resistant hydraulic fluid is required,
special seals must be used. Contact Cascade.
➁Flow less than recommended will result in reduced system
performance.
➂Flow greater than maximum can result in excessive heating,
reduced system performance and reduced hydraulic system life.
A
215204 Rev. 1 3
I
NSTALLATION
2.2 Recommended
Hydraulic Supply
Options
E-Series Clamps provide the best performance with one of
the hydraulic supply arrangements shown below. Refer to
Cascade
Hose and Cable Reel Selection Guide
, Part No.
212119, to select the correct hose reel for the mast and
truck. The hose and fitting requirements are:
• All hoses and fittings for CLAMP and SIDESHIFT
functions should be at least No. 6 with a minimum
internal diameter of 9/32 in. (7 mm).
Non-Sideshifting
A or B
RH or LH THINLINE™2-port hose reel group.
OR
C Mast single internal hose reeving group.
Sideshifting
A and B
RH and LH THINLINE™ 2-port hose reel groups.
OR
C Mast double internal hose reeving group.
Sideshifting with Solenoid
A 6-N-1 cable/hose reel group.
OR
A and C
Cable reel and single internal hose reeving group.
B
A
GA0033.ill
C
4 215204 Rev. 1
I
NSTALLATION
2.3 Installation Procedure
Follow the steps shown to install the Clamp on the truck.
Read and understand all WARNING and CAUTION
statements. If you don't understand a procedure, ask your
supervisor, or call the nearest Cascade Service Depart-
ment for assistance.
2Unlock Quick-Change lower mounting hooks
ARemove pin and drop hooks into unlocked position.
BRe-install pin in lower hole.
1Prepare Attachment
ARemove banding, set Clamp upright on
pallet. Use multiple chains to stabilize
Clamp while lifting.
BRemove bolt-on lower mounting hooks
(if equipped).
Tighten Capscrews:
Class II / III Mounting – 165 ft.-lbs. (225 Nm)
cascade
®
C-675514-1
CL0097.ill
A
Pin
LH lower
Hook
NOTE: Guides can be reversed to
reduce hook-to-carriage clearance
(See lower hook installation, Step 6).
Guide
5/8-in. (16 mm)
offset on top
provides max.
clearance.
B
CL0096.ill B
A
WARNING: Make sure overhead
hoist has a rated capacity of at least
3500 lbs. (1600 kg).
A
215204 Rev. 1 5
I
NSTALLATION
Prepare Hoses
ADetermine hose lengths required for hydraulic
supply configuration of truck.
BCut hoses to length, install end fittings.
CL0589.ill
CL0585.ill
Sideshifting – Double Hose Reels
Sideshifting – Double Internal Hose Reeving
Sideshifting with Solenoid – IHR and Cable Reel
Sideshifting with Solenoid – 6-N-1 Cable/Hose Reel
OpenSideshift Left
Sideshift Right Clamp
CL0588.ill
CL0586.ill
SSL / Open
(TANK Port)
SSR / Clamp
(PRESSURE Port)
Flush hydraulic supply hoses
AInstall hoses using union fittings.
BOperate auxiliary valves for 30 sec.
CRemove union
fittings.
4
GA0092.ill
Non-Sideshifting – Single Hose Reel
CL0587.ill
Clamp
Open
Solenoid
Cable
3IMPORTANT: Main valve options include LH or RH
CLAMP/OPEN porting, or dual porting which allows
hoses to be plumbed to either side of the Clamp to
match existing truck hydraulic supply configurations.
6 215204 Rev. 1
I
CL0241.ill
NSTALLATION
5Mount Clamp on truck carriage
ACenter truck behind Clamp.
BTilt forward and raise carriage into position.
CEngage top mounting hooks with carriage.
Make sure centering tab engages a notch
on the top carriage bar. NOTE: Centering
tab can be oriented in 4 different positions
to center the Clamp (see illustration).
DLift Clamp 2 in. (5 cm) off pallet.
AB
ADJUST
SD0066.ill
Tighten Capscrews:
Class II / III Mounting – 165 ft.-lbs. (225 Nm)
Lower
Carriage
Bar
6Install and engage lower hooks
Tap tight into position.
Inspect hooks for
excessive clearance.
(Reverse guides to reduce
clearance – See Step 2.)
cascade
®
C-675514-1
SD0065.ill
3/16 in.
(5 mm)
Max.
Lower
Carriage
Bar
BOLT-ON TYPEQUICK-CHANGE TYPE
Slide hook up
to engage
bar, install
pin in upper
hole (locked.)
CL0243.ill
4
12
3
ITA Class II – 0.60–0.66 in. (15–17 mm)
ITA Class III – 0.72–0.78 in. (18–20 mm)
ITA Class II – 0.32–0.36 in. (8–9 mm)
ITA Class III – 0.39–0.43 in. (10–11 mm)
CL0242.ill
Truck
Carriage
Engage Tab
C
C
C
Notch
Centering Tab
Positions
215204 Rev. 1 7
I
NSTALLATION
Solenoid Coil
Connect hoses prepared in
Step 3 to Attachment
7
CL0247.ill
9Install wiring –
(Solenoid-equipped units)
c
PRESS
BUTTON
TO POSITION SIDESHIF
CL0240.ill
Button
toward
driver
Truck control
valve handle
Adapter
8Install solenoid control knob –
(Solenoid-equipped units)
CL0258.ill CL0257.ill
Solenoid Coil
User-supplied wire
7.5-Amp
Fuse
White Black
7.5-Amp Fuse
White Black
Solenoid Coil
Diode
Diode
Knob
Button
CL0104.ill
Double Hose Reels Hydraulic Supply Internal Hose Reeving Hydraulic Supply
Control Lever Knob
with Pushbutton
8 215204 Rev. 1
I
10 Cycle Clamp functions
•With no load, cycle each Clamp function
several times.
•Check for operation in accordance with
ITA (ISO) standards.
•Clamp and lift a maximum load. Sideshift
left and right. Check for equal arm
movement and adequate sideshift speed.
If necessary, adjust relief valve cartridges
(see Section 5.3-4).
•Check for leaks at fittings, valve, manifold
and cylinders.
AUXILIARY VALVE
FUNCTIONS
NSTALLATION
WARNING: Make sure all personnel are
clear of the Clamp during testing.
BD
C
A
GA0005.ill
NON-SIDESHIFTING CLAMPS
ARelease Arms
BClamp Arms
C
(not used)
D
(not used)
SIDESHIFTING CLAMPS
ASideshift Left
BSideshift Right
CRelease Arms
DClamp Arms
SIDESHIFTING CLAMPS WITH
SOLENOID VALVE
ASideshift Left
ARelease Arms
(press knob button)
BSideshift Right
BClamp Arms
(press knob button)
B
AA
BCL0022.ill
CL0023.ill
CL0274.ill
A
B
AA
B
CDC
A
Tilt Forward
Hoist Up Tilt Back
Hoist Down
11 Adjust relief valves
•For over-pressure protection, the relief
valves for both CLAMP and SIDESHIFT
functions should be adjusted to match the
truck hydraulic flow rate. See Section 5.3-4
for adjustment procedure.
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