Cascade D Series Manuale utente
Cascade is a Registered Trademark of Cascade Corporation
cascade
corporation
ERVICE MANUAL
S
D-Series
25D through 100D
Non-Sideshifting &
Sideshifting Clamps,
40D Turnafork TM
Manual Number 669224-R5
i669224-R5
ONTENTS
C
Page Page
INTRODUCTION, Section 1 SERVICE, Section 5
Introduction 1 Attachment Removal 23
Special Definitions 1 Arms 24
INSTALLATION, Section 2 Arm Assembly Removal and Installation 24
Truck Requirements 2 Bolt-On Arm Removal 25
Recommended Hydraulic Supply 3 Multi-Purpose/Rigid and Drum Arm Contact
Surface Replacement 26
Installation Procedure 4
Custom Arm Installation 9 Rigid Arm Contact Pad Rotation and
Replacement 26
Prior to Operation 10
PERIODIC MAINTENANCE, Section 3 Arm Bearing Removal and Installation 27
100-Hour Maintenance 11 Turnafork Arm Service 28
500-Hour Maintenance 11 Turnafork Arm Indexing 29
1000-Hour Maintenance 11 Cylinders 30
2000-Hour Maintenance 11 Cylinder Removal and Installation 30
TROUBLESHOOTING, Section 4 Cylinder Service 32
General Procedures 12 Cylinder Disassembly 32
Truck System Requirements 12 Cylinder Inspection 32
Tools Required 12 Cylinder Reassembly 33
Troubleshooting Chart 12 Restrictor Cartridges 34
Plumbing – Top Mount Valve 13 Restrictor Cartridge Adjustment 34
Hosing Diagram, Non-Sideshifting 13 Check Valves 35
Circuit Schematic, Non-Sideshifting 13 Check Valve Removal – Top Mount Valve 35
Hosing Diagram , Sideshifting
(including Turnafork) 14
Check Valve Removal – Center Mount Valve 35
Check Valve Service – Top Mount Valve 36
Circuit Schematic, Sideshifting
(including Turnafork) 15
Check Valve Service – Center Mount Valve 37
Eliminating the Arm Opening Regenerative
Function 37
Plumbing – Center Mount Valve 16
Hosing Diagram, Non-Sideshifting 16 Base Unit 38
Circuit Schematic, Non-Sideshifting 16 Frame and Mounting Plate Disassembly and
Reassembly 38Hosing Diagram , Sideshifting 17
Circuit Schematic, Sideshifting 18 Solenoid Valve 39
Attachment Troubleshooting 19 Coil Service 39
Clamp Circuit Pressure Test 19 Valve Service 39
Check Valve Pressure Test 20 SPECIFICATIONS, Section 6
Cylinder Test 20 Specifications 40
Sideshift Circuit Pressure Test 21 Hydraulics 40
Electrical Circuit 22 Auxiliary Valve Functions 40
Truck Carriage 41
Torque Values 42
669224-R5 1
NTRODUCTION
I
1.1 Introduction
This Manual provides the Installation, Periodic
Maintenance, Troubleshooting, Service and Specifications
for Cascade D-Series Non-Sideshifting Clamps,
Sideshifting Clamps and 40D Turnaforks.
In any communication about the attachment, refer to the
product I.D. number stamped on the nameplate as shown.
If the nameplate is missing, the numbers can be found
stamped on the right front web of the baseplate.
IMPORTANT: All hoses, tubes and fittings on these
attachments are JIC.
NOTE: Specifications are shown in both inch 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
your job easier.
WARNING - A statement preceded by
WARNING is information that should be
acted upon to prevent bodily injury. A
WARNING is always inside a ruled box.
CAUTION - A statement preceded by CAUTION is
information that should be acted upon to prevent
machine damage.
IMPORTANT - A statement 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.
cascade
®
cascade
®
CL1159.eps Nameplate
Nameplate
2669224-R5
NSTALLATION
I
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.
GA0380.eps
Truck Relief Setting
2000 psi (140 bar) Recommended
2300 psi (160 bar) Maximum
Truck Flow Volume ➀
Min. ➁Recommended Max. ➂
25D 4 GPM
(15 L/min.)
5.5 GPM
(21 L/min.)
5.5 GPM
(21 L/min.)
35D 4 GPM
(15 L/min.)
7 GPM
(26 L/min.)
7 GPM
(26 L/min.)
40D, 50D 4 GPM
(15 L/min.)
10 GPM
(38 L/min.)
10 GPM
(38 L/min.)
70D, 80D, 100D
7 GPM
(26 L/min.)
12 GPM
(45 L/min.)
15 GPM
(57 L/min.)
➀Cascade D-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 unequal arm
movement.
➂ Flow greater than maximum can result in excessive heating,
reduced system performance and short hydraulic system life.
Carriage Mount Dimension (A) ITA (ISO)
Minimum Maximum
Class II
Class III
Class IV
14.94 in. (380.0 mm)
18.68 in. (474.5 mm)
23.44 in. (595.5 mm)
15.00 in. (381.0 mm)
18.74 in. (476.0 mm)
23.50 in. (597.0 mm)
A
GA0028.eps
Carriage – Clean and inspect
carriage bars. Make sure the bars
are parallel and that ends are flush.
Repair any damaged notches.
GA0082.eps
Hoist Down
Hoist Up
Tilt Forward
Tilt Backward
Sideshift Left
Sideshift Right
Open
Clamp
Auxiliary Valve Functions
Check for compliance with ITA (ISO) Standards:
2.1 Truck Requirements
3
669224-R5
NSTALLATION
I
2.2 Recommended
Hydraulic Supply
D-Series Clamps provide the best performance with one
of the hydraulic supply arrangements shown below. Refer
to Cascade Hose & Cable Reel Selection Guide, Part No.
212199, to select the correct hose reel for the mast and
truck. The hose and fitting requirements are:
• All hoses and fittings for CLAMP function should be
at least No. 8, minimum internal diameter of 13/32 in.
(10 mm).
• All hoses and fittings for SIDESHIFT function should
be at least No. 6, minimum internal diameter of 9/32 in.
(7 mm).
Non-Sideshifting
A or B
RH or LH THINLINETM 2-port hose reel group
OR
CMast single internal hose reeving group
Sideshifting
A and B
RH or LH THINLINETM 2-port hose reel group
OR
CMast double internal hose reeving group
Sideshifting with Solenoid
A6-N-1 cable/hose reel group
OR
A and C
Cable reel and single internal hose reeving group
GA0033.eps
AB
C
4669224-R5
NSTALLATION
I
2.3 Installation Procedure
Follow the steps shown to install the attachment on the truck.
Read and understand WARNING and CAUTION statements.
If you don't understand a procedure, ask your supervisor or
call the nearest Cascade Service Department for assistance.
CL0442.ai
1
2
Attach overhead hoist
A Remove banding, use multiple chains to
stabilize the attachment while lifting. Set the
attachment upright on the pallet.
B If equipped, remove bolt-on lower mounting
hooks.
Unlock quick-change lower
mounting hooks
A Remove pin and drop hooks into unlocked
position.
B Reinstall pin in lower hole.
WARNING: Check the attachment
weight (located on the nameplate)
to make sure the overhead hoist
and chains or straps are at least the
rated capacity of the attachment.
A
B
cascade
®
C-675514-1
CL0097.eps
A
B
Guide
Pin
LH Lower
Hook 5/8 in. (16 mm)
offset on top
provides maximum
hook clearance. Tighten capscrews to:
CL II/III – 110 ft.-lbs. (150 Nm)
CL IV – 190 ft.-lbs. (260 Nm)
NOTE: Guides can be reversed
to change hook-to-carriage
clearance. Refer to lower hook
installation, Step 6.
5
669224-R5
NSTALLATION
I
3Prepare hoses
CAUTION: Connect the hydraulic hoses to the attachment
using Cascade Attachment Installation Kit No. 659245
for non-sideshifting attachments and attachments with
solenoid adaption, Kit No. 659249 for sideshifting clamps
OR use hoses and fittings as shown.
A Position the truck carriage behind the attachment to
determine hose lengths required for hydraulic supply
configuration.
B Cut hoses to length and install end fittings or use hose
kits supplied.
WARNING: Do not remove the
fitting from the valve CLAMP (CL)
port. For No. 6 hose connection,
use a 6-8 reducer.
CL0448.ai
Sideshift Right – De-energized
Close – Energized
Sideshift Right – De-energized
Close – Energized
Sideshift Right – De-energized
Close – Energized
Sideshift Left – De-energized
Open – Energized
Sideshift Left – De-energized
Open – Energized
Sideshift Left – De-energized
Open – Energized
CL0444.ai
CL0447.eps
Hoses should not project
above the Check Valve
Bracket
No. 8 Hoses
(SAE 100 R5 Single
Wire Braid Rubber
Covered)
Remove fittings
and cut hoses
to length
No. 6 Hoses
(SAE 100 R5 Single Wire
Braid Rubber Covered)
(Sideshifting attachments only)
Top Mount Valve
Center Mount Valve
Top Mounted Valve and
Backrest Mounted Solenoid Adaption
Center Mount Valve
and Solenoid Adaption
Top Mounted Valve
and Solenoid Adaption
CL0911.ai
CL0910.ai
Sideshift Right/Left
(These hoses apply to
sideshifting attachments only)
No. 8 Hoses
(SAE 100 R5 Single Wire
Braid Rubber Covered)
Close/Open
6669224-R5
NSTALLATION
I
4
5
Flush hydraulic supply hoses
A Install hoses using union fittings.
B Operate valves for 30 Seconds.
C Remove union fittings.
Mount attachment on truck
carriage
A Center truck behind attachment.
B Tilt forward and raise carriage into position.
C Engage the mounting hook tab with the
closest upper carriage bar notch. Raise
the truck carriage into position behind the
attachment.
D Lift attachment off the pallet.
NOTE: The attachment may not be perfectly
centered on the carriage bar when the
mounting hook tab is engaged in the closest
carriage notch. This is normal.
NOTE: The lower hooks cannot be properly
installed if the upper hook tab is not engaged in
the carriage notch.
CL0449.ai
CL0912.ai
Tab
C
WARNING: The mounting hooks must
properly engaged with the upper carriage
bar. The tab on the left mounting hook
must be engaged in a mating notch on the
upper carriage bar.
7
669224-R5
NSTALLATION
I
6
7
Install and engage lower hooks
If equipped, install hydraulic
quick disconnect coupling kits
(part no. 671045)
NOTE: Use one kit for non-sideshifting
attachments and two kits for sideshifting
attachments. Refer to Installation 671422 for
complete installation procedures.
cascade
®
C-675514-1
GA0371.eps
ADJUST
SD0066.eps
Slide hook up to
engage bar, install
pin in upper hole
(locked)
Inspect hook for excessive
clearance. To change clearance,
reverse guides. Refer to Step 2.
Lower
Carriage
Bar
3/16 in.
(5 mm)
Maximum
Tap tight
into position
Lower
Carriage
Bar
Tighten capscrews to
165 Nm (120 ft.-lbs.)
QUICK-CHANGE TYPE BOLT-ON TYPE
CL0903.ai
Sideshift
Hoses
Hydraulic Quick
Disconnect Coupling
Kits 671045
Clamp Hoses
NOTE: Each pair of hoses
requires a coupling kit.
Hose terminal
up kits
Hydraulic Quick
Disconnect Coupling
Kits 671045
Hose terminal
up kits
8669224-R5
8Tighten fork or arm capscrews
Use drive extension tool 668020 (25D), 667699
(35D, 40D, 50D) or 676218 (70D, 80D, 100D) to
tighten capscrews to the following torque values:
25D – 190–220 ft.-lbs. (257–298 Nm)
35D, 40D, 50D – 380–320 ft.-lbs. (380-434 Nm)
70D, 80D, 100D – 680–720 ft.-lbs. (922–976 Nm)
IMPORTANT: Be careful not to damage the arm
bar. Premature bearing failure will occur.
Short adapters are commercially available:
Williams .50 in. drive to .625 in. hex (25D) and .5
in. drive to .625 in. hex (35D, 40D, 50D) and .75
in. drive to .75 in. hex (70D, 80D,100D). Drive
extension dimensions are provided to make the
tool from an allen wrench. Do no use mild steel
hex stock.
CL0913.ai
Drive Extension
Capscrew
Arm Bar
CL0456.eps
A
Hex BC
D
63
Dimensions – in. (mm)
Model A B C D
25D .50
(12.7)
.75
(19.0)
.46
(11.6)
3.50
(88.0)
35D
40D
50D
.62
(15.7)
.50
(12.7)
.58
(14.7)
3.50
(88.0)
70D
80D
100D
.75
(19.0)
.50
(12.7)
.75
(19.0)
5.00
(127.0)
NSTALLATION
I
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Questo manuale è adatto per i seguenti modelli
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