Documente Academic
Documente Profesional
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F-Series
Fixed & Swing
Frame Paper Roll
Clamps
cascade
corporation
Cascade is a Registered Trademark of Cascade Corporation
C ONTENTS
Page Page
INTRODUCTION, Section 1 Revolving Connection, 5.6 50
Introduction 1 Removal and Installation 50
Special Definitions 1 Shaft Only Service 51
INSTALLATION, Section 2 Seals-in-Shaft Service 52
Truck System Requirements 2 Seals-in-Body Service 53
Installation – Fixed Frame Clamps 3 Two-Piece Seals-in-Body Service 54
Recommended Hydraulic Supply 3 Split Long Arm Service 55
Clamp Installation 4 Counterbalance Valve Adjustment 55
Installation – Swing Frame Clamps 9 Cylinders, 5.7 56
Recommended Hydraulic Supply 9 Servicing Cylinders on Clamp 56
Control Valve Group 10 Cylinder Removal – Long or Short Arm 56
Control Valve Group (77F Model) 15 Cylinder Removal – Swing Frame 57
Clamp Installation 19 Cylinder Check Valve Service 57
PERIODIC MAINTENANCE, Section 3 Cylinder Bushing Service 58
100-Hour Inspection 24 Cylinder Service, 5.8 59
500-Hour Inspection 24 Cylinder Disassembly 59
2000-Hour Inspection 24 Cylinder Inspection 59
TROUBLESHOOTING, Section 4 Cylinder Reassembly 60
General Procedures 25 Base Unit, 5.9 61
Truck System Requirements 25 Swing Frame Service 61
Tools Required 25 Frame Bushing Service 61
Troubleshooting Chart 25 Rotation Bearing Torque Inspection 62
Plumbing, 4.2 26 Rotation Bearing Removal and Installation 63
Hosing Diagram – Fixed Frame 26 Adjustable Bumper Service 65
Hosing Diagram – Swing Frame 27 180-Degree Hydraulic Stop Group, 5.10 67
Schematic – Fixed Frame 29 Stop Valve Service 67
Schematic – Split Long Arm 30 Stop Position Adjustment 67
Schematic – Swing Frame 31 Electronic Rotational Control Group, 5.11 68
Schematic – Split Long Arm ERC Stop Valve Service 68
Clamp Function, 4.3 33 Stop Position Adjustment 69
Supply Circuit Test 33 Stop Troubleshooting 69
Clamp Circuit Test 33 Solenoid Valve Service, 5.12 71
Swing Circuit Test 34 SPECIFICATIONS, Section 6
Rotation Function, 4.4 35 Specifications, 6.1 72
Supply Circuit Test 35 Hydraulics 72
Rotation without Load 35 Auxiliary Valve Functions 73
Rotation with Load 35 Truck Carriage 73
Electrical Circuit, 4.5 36 Torque Values 74
SERVICE, Section 5
Clamp Removal, 5.1 37
Arms, 5.2 38
Arm Assembly 38
Contact Pad 39
Arm Tip Repair 39
Drive Group, 5.3 41
Removal and Installation 41
Disassembly and Service 42
Reassembly 43
Drive Motor, 5.4 45
Removal and Installation 45
Disassembly 46
Inspection 47
Reassembly 47
Rotator Drive Check Valve, 5.5 49
Check Valve Service 49
i 674512-R4
I NTRODUCTION
1.1 Introduction
This Manual provides installation instructions, periodic
maintenance requirements, troubleshooting procedures
and service procedures for the Cascade F-Series Paper
Roll Clamps.
In any communication about the Roll Clamp refer to the
product I.D. number stamped on the nameplate. If the
nameplate is missing, the numbers can be found stamped
on the front of the faceplate top or side.
IMPORTANT: All hoses, tubes and fittings on F-Series Roll
Clamps are JIC.
NOTE: Specifications are shown in both U.S. and (Metric)
units.
Nameplate Locations
c
�
ATTACHMENT CAPACITY
LIFT TRUCK ATTACHMENT POUNDS INCH LOAD
AT CENTER
SERIAL
NUMBER 674870 CAPACITY OF TRUCK AND ATTACHMENT COMBINATION
MAY BE LESS THAN ATTACHMENT CAPACITY SHOWN
CATALOG
NUMBER 60F-RCP-459 WEIGHT
LBS.
ABOVE. CONSULT TRUCK NAMEPLATE.
RECOMMENDED SYSTEM PRESSURE – 2000 PSI
ADDITIONAL MAXIMUM SYSTEM PRESSURE – 2300 PSI
EQUIPMENT
ADDITIONAL
�
EQUIPMENT FOR TECHNICAL ASSISTANCE, PARTS AND SERVICE
CONTACT:
ADDITIONAL 1-800-227–2233
EQUIPMENT PORTLAND, OREGON USA
70
7 48R 9
RC0720.eps 6 O 45
C P -
0 F-R
6
674512-R4
I NSTALLATION
Min. ➁ Recommended Max. ➂
Minimum Maximum
A Tilt
Class II 14.94 in. (380.0 mm) 15.00 in. (381.0 mm) Forward Rotate Release
Class III 18.68 in. (474.5 mm) 18.74 in. (476.0 mm) CCW
Class IV 23.44 in. (595.5 mm) 23.50 in. (597.0 mm) (Swing
Extend)
GA0028.eps Hoist Down
674512-R4
I NSTALLATION
2.2 Installation –
Fixed Frame Clamps
2.2-1 Recommended
Hydraulic Supply
F-Series Fixed Frame Paper Roll Clamps provide the best
performance with the hydraulic supply arrangement A
and B. Refer to Cascade Hose and Cable Reel Selection
Guide, Part No. 212199, to select the correct hose reel for
the mast and truck. The hose and fitting requirements are:
• ROTATE Function – Hoses and fittings should be No. 8
with 13/32 in. (10 mm) minimum I.D.
• CLAMP Function – Hoses and fittings should be No. 8
with 13/32 in. (10 mm) minimum I.D., except for internal
reeving arrangements where hoses and fittings may be
No. 6 minimum with 9/32 in. (7 mm) minimum I.D.
A and B
RH and LH THINLINE™ 2-Port Hose Reel Groups.
OR (optional)
A and C
RH THINLINE™ 2-Port Hose Reel Group and Mast
Single Internal Hose Reeving Group.
A B
GA0033.eps
674512-R4
I NSTALLATION
A A
RC0967.ill
®
CL0097.eps
d e
s ca
ca
-1
14
55
67
C-
5/8-in. (16 mm)
LH lower offset on top
Hook provides
maximum
Pin clearance.
Tighten Capscrews:
CL II, III 38F, 45F, 60F, 66F – 110 ft.-lbs. (150 Nm)
CL IV 60F, 66F, 77F – 195 ft.-lbs. (265 Nm)
CL IV 90F, 100F – 260 ft.-lbs. (360 Nm)
674512-R4
I NSTALLATION
3 Prepare Hoses
A Position truck carriage behind Roll Clamp.
B Determine hose lengths required.
CAUTION: Hoses should be 2600-psi working-
C Cut hoses to length, install end fittings. pressure rated for all Attachment functions.
Clamp Clamp
Open
RC0441.ill RC0442.ill
Open
Clamp
Clamp
RC1816.eps RC1815.eps
Open Open
674512-R4
I NSTALLATION
RC0139.eps
Remove rubber
vent cover.
C C
Notch
Engage locator
tab in notch
Connect hoses to
end block before
Clamp installation.
674512-R4
I NSTALLATION
Install hooks,
ST
tap tight AD
JU
e
®
into position. c ad
cas
Slide hook 14
-1
55
up to engage C-
67
bar, install
pin in locked
position 3/16 in.
(upper hole). (5 mm)
Max.
RC1130.eps RC1131.eps
Tighten Capscrews:
CL II & III 38F, 45F, 60F, 66F – 110 ft.-lbs. (150 Nm)
CL IV 60F, 66F, 77F – 195 ft.-lbs. (265 Nm)
CL IV 90F, 100F and larger – 260 ft.-lbs. (350 Nm)
RC0440.ill RC0765.eps
674512-R4
I NSTALLATION
each upper hook.
(NOTE: Do not
NOTE: Stop blocks may be located weld stop block
vertically on each end of carriage bar if on inside)
insufficient room exists outside of upper 1/16 in. Steel Stop
hooks. (1.5 mm) Blocks
• Preheat stop block and carriage bar
weld area to 325° F (180° C).
• Use AWS E-7018 low hydrogen rod and Truck Upper
weld a 6 mm (1/4 in.) fillet full length on Carriage Bar
three (3) sides of each stop block.
1/4-in. (6 mm)
fillet weld on RC0224.eps
three (3) sides.
during testing.
Tilt Forward
Hoist Down
• With no load, cycle all functions several
times. A C
• Check functions for operation in accordance
with ITA (ISO) standards.
• Clamp and rotate a maximum load, check
for smoothness and normal rotation. B D
• Check for leaks at fittings, revolving GA0005.eps
connection and cylinder rod ends. Hoist Up Tilt Back
A
D SHORT ARM
(45-degree position only)
C D C Open
C D Close
RC0030.eps RC0031.eps
674512-R4
I NSTALLATION
2.3 Installation –
Swing Frame Clamps
2.3-1 Recommended
Hydraulic Supply
F-Series Swing Frame Paper Roll Clamps provide the best
performance with the hydraulic supply arrangement A and
B. Refer to Cascade Hose and Cable Reel Selection Guide,
Part No. 212199, to select the correct hose reel for the mast
and truck. The hose and fitting requirements are:
• ROTATE Function – Hoses and fittings should be No. 8
with 13/32 in. (10 mm) minimum I.D.
• CLAMP & SWING Functions – Hoses and fittings should
be No. 8 with 13/32 in. (10 mm) minimum I.D., except for
internal reeving arrangements where hoses and fittings
may be No. 6 minimum with 9/32 in. (7 mm) minimum I.D.
A and B
RH THINLINE ™ 2-Port Hose Reel Group and
LH THINLINE™ 4-Port Hose Reel Group.
OR (optional)
A, B and C
RH and LH THINLINE™ 2-Port Hose Reel Groups and
Mast Single Internal Hose Reeving Group.
OR (optional)
A and C
RH THINLINE™ 2-Port Hose Reel Group and Mast
Double Internal Hose Reeving Group.
A
B
GA0033.eps
674512-R4
I NSTALLATION
1
Determine an appropriate mounting location for the HORIZONTAL MOUNT
control valve on the truck cowl. The valve can be
mounted horizontally or vertically. The valve must Check for
not extend outside the width of the cowl or interfere interference
with the truck mast when tilted back. with mast
tilted back.
2
Assemble the solenoid valve, fittings, cover and
subplate. Position the assembly on the truck cowl RC0725.eps
HORIZONTAL MOUNT
To RH 2-Port Hose
Reel (No. 8 SAE)
To LH 4-Port or
2-Port Hose Reel
(No. 6 SAE)
NOTE: Solenoid coil
must be rotated 90 To LH 4-Port or
degrees to clear cover 2-Port Hose Reel
when assembled. (No. 6 SAE)
RC0726.eps
10 674512-R4
I NSTALLATION
3
Mark the mounting location on the truck cowl. Grind
and clean the area in preparation for welding. Tack
weld the subplate to the cowl and mount the valve
to the subplate with the capscrews supplied in the
kit.
NOTE: Horizontal
mount only shown
RC0727.eps
Capscrews, 5/16-18
UNC x 3.5 in. long
4
Measure and assemble two hoses (user-supplied)
to run from the solenoid valve P and T ports to the
truck valve ports. Install the hoses.
Port P Port T
Installation with RH 2-Port and LH 4-Port
Hose Reels
LH 4-Port
5
Hose Reel
Rotate Function – Measure and assemble two RH 2-Port
hoses (user-supplied) to run from the control valve Hose Reel
4
C1 and C4 ports to the RH hose reel. Install hoses.
3
Swing Function – Measure and assemble two
hoses (user-supplied) to run from the control valve ROTATE
C2 and C3 ports to the LH 4-port hose reel 3 and 4 function
ports. Install hoses.
Ports 1 and
2 for CLAMP/
OPEN circuit
C4 only
SWING
C1
function
C3
C2
RC0729.eps
674512-R4 11
I NSTALLATION
6
Clamp Function – Measure and assemble two LH 4-Port
hoses (user-supplied) to run from the truck valve Hose Reel
ports to the LH 4-port hose reel 1 and 2 ports.
Install hoses.
CLAMP
function
(Port 2) OPEN
function
(Port 1)
RC0730.eps
Truck auxiliary
valve ports
LH 4-Port
4
Hose Reel
1 2
Carriage Hose
Terminal
RH 2-Port
Hose Reel
SWING
Function
C3
C2 Solenoid-operated
CLAMP/OPEN Control Valve
Function
C1
C4
ROTATE Carriage Hose
Function Terminal
Truck Auxiliary
Valve with push- P
button (ROTATE T
and SWING)
RC0731.eps
Truck Auxiliary
Valve (CLAMP)
12 674512-R4
I NSTALLATION
Installation (Continued)
Hose Reel
7
Internal
Rotate Function – Measure and assemble two Reeving
hoses (user-supplied) to run from the control valve Hoses
C1 and C4 ports to the RH hose reel. Install hoses.
C4
Swing Function – Measure and assemble two
hoses (user supplied) to run from the control valve
C2 and C3 ports to the internal hose reeving SWING
hoses. Install hoses. C1 Function
C3
C2
RC0732.eps
8
Clamp Function – Measure and assemble two LH 2-Port
hoses (user supplied) to run from the truck valve Hose Reel
ports to the LH 2-Port hose reel. Install hoses.
LH 2-Port
Hose Reel
CLAMP/OPEN
Function
C1
C4
Carriage Hose
C2 ROTATE Terminal
Function
P
Truck Auxiliary C3 T
Valve with Push-
button (ROTATE Solenoi
and SWING) Operated RC0734.eps
Truck Auxiliary Control Valve
Valve (CLAMP)
674512-R4 13
I NSTALLATION
9
Locate the auxiliary valve lever that operates the
hydraulic hoses connected to the solenoid control
valve P and T ports. Install a new knob with
pushbutton, or shrink-wrap the alternate pushbutton
switch onto the control lever.
IMPORTANT: Lever should control the ROTATE
function per ITA (ISO) standards. When the
pushbutton is depressed, the lever should activate
the SWING function.
CAUTION: Secure cable with cable ties to avoid
pinching at truck cowl during handle movement.
Cable Ties
10
Connect the wiring from the pushbutton and control
valve terminals to the truck electrical system as shown.
IMPORTANT: Fuse must be connected to an
unswitched positive terminal – control valve must be
able to energize with truck key in off position.
Control Knob
Control
Pushbutton with Pushbutton
Solenoid Coil Valve
shrink wrapped
to control lever
OR
Pushbutton RC0736.eps
14 674512-R4
I NSTALLATION
1
Determine an approximate mounting location for the with mast
control valve on the truck cowl. The valve must not tilted back.
extend outside the width of the cowl or interfere with
the truck mast when tilted back.
Valve must not
extend outside
width of cowl.
RC0737.eps
2
Assemble the control valve, fittings, cover and Internal Hose Reeving (No. 6 SAE)
subplate. Position the assembly on the truck cowl
noting any clearance problems.
Tack-weld
subplate to
truck cowl.
3
Mark the mounting location on the truck cowl. Grind
and clean the area in preparation for welding. Tack
weld the subplate to the cowl and mount the valve
RC0738.eps
to the subplate with the capscrews supplied in the
kit.
To RH 2-Port Hose
To truck auxiliary valve Reel (No. 8 SAE)
ports (No. 8 SAE)
4
Measure and assemble two hoses (user-supplied)
to run from the solenoid valve IN ports to the truck
valve ports. Install the hoses.
IN
Truck Auxiliary
Valve Ports
RC0739.eps
674512-R4 15
I NSTALLATION
3
IMPORTANT: Proceed to Step 7 if lift truck is equipped ROTATE
with mast internal hose reeving. function
5
Rotate Function – Measure and assemble two
hoses (user-supplied) to run from the control valve SWING
ROTATE ports to the RH 2-port hose reel. Install function
hoses. SWING
ROTATE
Swing Function – Measure and assemble two RC0740.eps
hoses (user-supplied) to run from the control valve
SWING ports to the LH 4-port hose reel 3 and 4 LH 4-Port
ports. Install hoses. Hose Reel
6
Clamp Function – Measure and assemble two
hoses (user-supplied) to run from the truck valve
ports to the LH 4-port hose reel 1 and 2 ports.
Install hoses.
CLAMP OPEN
LH 4-Port 4 function function
Hose Reel (Port 2) (Port 1)
Truck auxiliary
valve ports
1 2
RH 2-Port
Hose Reel
SWING
Function
CLAMP/OPEN
Function
ROTATE Carriage Hose
IN Function Terminal
Truck Auxiliary
Valve with push- IN
button (ROTATE Solenoid
and SWING) Operated
Control Valve RC0742.eps
Truck Auxiliary
Valve (CLAMP)
16 674512-R4
I NSTALLATION
7
Internal
Rotate Function – Measure and assemble two
Reeving
hoses (user-supplied) to run from the control valve Hoses
ROTATE ports to the RH 2-Port hose reel. Install
hoses.
SWING
Function
Swing Function – Measure and assemble two
hoses (user supplied) to run from the control valve SWING
SWING ports to the internal hose reeving hoses.
ROTATE
Install hoses.
RC0743.eps
LH 2-Port
Hose Reel
8
Clamp Function – Measure and assemble two
hoses (user supplied) to run from the truck valve
ports to the LH 2-Port hose reel. Install hoses.
LH 2-Port
Hose Reel
CLAMP
Truck Auxiliary Function
Valve Ports
Carriage Hose
Terminal
RC0744.eps
IHR
SWING Carriage RH 2-Port
Function Terminal Hose Reel
CLAMP/OPEN
Function
Carriage Hose
ROTATE Terminal
Function
Truck Auxiliary
Valve with Push- Solenoid
button (ROTATE Operated RC0745.eps
and SWING) Control Valve
Truck Auxiliary
Valve (CLAMP)
674512-R4 17
I NSTALLATION
9
Locate the auxiliary lever that operates the hydraulic
hoses connected to the solenoid control valve
IN ports. Install a new knob with pushbutton, or
shrink-wrap the alternate pushbutton switch onto the
control lever.
IMPORTANT: Lever should control the ROTATE
function per ITA (ISO) standards. When the
pushbutton is depressed, the lever should activate
the SWING function.
CAUTION: Secure cable with cable ties to avoid
pinching at truck cowl during handle movement.
Heat-Shrink Tubing
Cable Ties
10
Connect the wiring from the pushbutton and control valve
coil terminals to the truck electrical system as shown.
IMPORTANT: Fuse must be connected to an unswitched
positive terminal and control valve must be able to
energize with truck key in off position.
7.5-Amp
Pushbutton
Fuse
7.5-Amp Fuse
Truck Control
Cable
Power Valve
Source
(unswitched) RC0747.eps
Black
18 674512-R4
I NSTALLATION
A A
RC0839.eps
®
CL0097.eps
d e
s ca
ca
-1
14
55
67
C-
5/8 in. (16 mm)
LH lower offset on top
Hook provides
maximum
Pin clearance.
Tighten Capscrews:
CL II, III 38F, 45F, 60F, 66F – 110 ft.-lbs. (150 Nm)
CL IV 60F, 66F, 77F – 195 ft.-lbs. (265 Nm)
CL IV 90F, 100F, 120F – 260 ft.-lbs. (360 Nm)
674512-R4 19
I NSTALLATION
3 Prepare Hoses
A Position truck carriage behind Roll Clamp.
B Determine hose lengths required.
C Cut hoses to length, install end fittings. CAUTION: Hoses should be 2300 psi working
pressure rated for all Attachment functions.
Swing Swing
Clamp Clamp Swing Extend
Retract Extend
RC0769.ill RC0768.eps
4
Flush hydraulic supply hoses
A Install hoses as shown below.
B Operate auxiliary valves for 30 sec.
5 Check oil level and remove
rubber vent cover
RC0139.eps
Remove rubber
vent cover.
20 674512-R4
I NSTALLATION
RC0757.ill
Notch
C C
Engage locator
tab in notch
Connect hoses to
end block before
clamp installation.
ITA Class II – 0.32–0.36 in. (8–9 mm)
ITA Class III – 0.39–0.43 in. (10–11 mm)
ITA Class IV – 0.47–0.51 in. (12–13 mm) RC0843.eps
Center Spacer
Upper
Carriage Bar GA0079.eps Back (Driver's) View
Install hooks,
ST
tap tight AD
JU ®
de
into position. sc
a
ca
Slide hook 67
55
14
-1
up to engage C-
bar, install
pin in locked
position. 3/16 in.
(upper hole.) (5 mm)
Max.
RC1130.eps RC1131.eps
Tighten Capscrews:
CL II & III 38F, 45F, 60F, 66F – 110 ft.-lbs. (150 Nm)
CL IV 60F, 66F, 77F – 195 ft.-lbs. (265 Nm)
CL IV 90F, 100F, 120F and larger – 260 ft.-lbs. (350 Nm)
674512-R4 21
I NSTALLATION
RC0771.eps RC0772.eps
22 674512-R4
I NSTALLATION
RC0030.eps
SWING ROTATE
(Bilge handling shown) (Driver's view)
A (Push Button) Extend A Counterclockwise (CCW)
B (Push Button) Retract B Clockwise (CW)
B
A
A
D SHORT ARM
B (45-degree position only)
C Open
C D Close
RC0773.eps
RC0031.eps
Tilt Forward
Hoist Down
A C
B D
GA0005.eps
Hoist Up Tilt Back
674512-R4 23
P ERIODIC MAINTENANCE
3.2
500-Hour Maintenance
After each 500 hours of truck operation, in addition to the
100-hour maintenance, perform the following procedures:
• Check sample of baseplate capscrews for proper torque
value. See Sections 5.9-3 and 5.9-4 for checking and
replacement procedures.
• Check sample of faceplate capscrews for proper torque
value. See Sections 5.9-3 and 5.9-4 for checking and RC0749.eps
replacement procedures.
Arm, Cylinder
• Tighten mounting hook capscrews. See Section 6.1-4 Left Side and Swing Frame
for specific Roll Clamp Model torque specifications. Pivot Joints
• Tighten rotator drive assembly capscrews to 75 ft.-lbs.
(105 Nm). WARNING: Faceplate and baseplate bear-
• Lubricate rotator bearing assembly with multi-purpose ing assembly capscrew torque must be
extreme-pressure NLGI 2 grease (Whitmore 'Omnitask' checked initially at 500 hours and then every
or equivalent). Rotate Clamp one full turn during 2000 additional hours. Failure to keep the
procedure. capscrews tightened can result in attachment
• Check rotator drive gearcase lubricant level. Lubricant damage and serious injury.
should be up to bottom of fill plug hole. If necessary, fill
with Cascade Rotator Drive Lubricant, Part No. 656300,
or SAE 90 wt. gear lube (AGMA 'mild' 6 EP Gear Oil). Bearing Assembly-to- Rotator Drive
Faceplate Capscrews Capscrews
Replace plug. Baseplate-to-Bearing
(Access all through hole
Assembly Capscrews
• Inspect all arm, frame and cylinder pivot bushings for in baseplate)
wear and replace if necessary (see Sections 5.7-5 and
5.9-2 for wear limits).
• Inspect all load-bearing structural welds on arms, swing
frame pivots, arm pivots and cylinder pivot areas for
visual cracks. Replace components as required. Rotator
Drive
Fill Plug
3.3
2000-Hour Maintenance
After each 2000 hours of truck operation, in addition to
the 100 and 500-hour maintenance, perform the following
procedures:
• Check all rotation bearing capscrews for proper torque
value. See Section 5.9-3 and 5.9-4 for checking and
replacement procedures.
• Inspect all arm and cylinder pivot pins for wear and
replace if necessary (see Section 5.9).
RC0750.eps
• Perform CLAMP circuit hydraulic pressure check (see
Section 4.3-2). Back (Driver's) View Mounting Hook Capscrews
24 674512-R4
T ROUBLESHOOTING
Clamp Circuit No. 4-6 Pipe/JIC* No. 6-8 JIC No. 4, No.
Reducer
• Clamp drops roll after it has been picked up. 6* and No. 8
JIC/O-Ring
• Clamp will not pick up rolls to its rated capacity.
• Clamp arms will not function properly.
To correct one of these problems, see Section 4.3. Quick-Disconnect Couplers
Rotate Circuit Male Straight Thread
O-Ring Coupler:
• Clamp will not rotate.
No. 4 (Part No. 212282)*
• Clamp will not rotate rolls up to its rated capacity. No. 5 (Part No. 210378)
No. 6 (Part No. 678592)
• Clamp rotates in one direction only.
To correct one of these problems, see Section 4.4. Female JIC Thread
Coupler:
• Clamp will not stop smoothly with 180° stop valve or No. 4 (Part No. 210385)* AC0127.eps
rotational control. No. 6 (Part No. 678591)
To correct this problem, see Section 5.10 or 5.11.
* NOTE: Diagnostics Kit 394382
Swing Circuit includes items marked.
• Clamp swings slowly or not at all.
To correct this problem, see Section 4.3-3.
674512-R4 25
T ROUBLESHOOTING
4.2 Plumbing
4.2-1 Fixed Frame Clamp –
Hosing Diagram
Rotator
Drive CCW
CW
Long Arm
Cylinders Short Arm
Cylinders
(if equipped)
2-Port
Hose Reel
CLAMP NOTE: Short arm
cylinders operate
only when Clamp is
rotated to the
45-degree position.
OPEN
Revolving
Connection
2-Port
Truck Auxiliary
Hose Reel
Valve (ROTATE)
or Internal
Hose
Reeving
Truck Auxiliary
Valve (CLAMP)
RC0680.ill
26 674512-R4
T ROUBLESHOOTING
Rotator
Drive CCW
Revolving CW
Connection
Long Arm
Cylinders Short Arm
Cylinders
(if equipped)
4-Port
Hose Reel
CLAMP
NOTE: Short arm
cylinders operate
1 Swing only when Clamp is
Cylinder rotated to the
45-degree position.
2
OPEN
1
2
2-Port
Hose Reel
or Internal
Hose
Reeving
ROTATE
Truck Auxiliary
Valve (ROTATE IN
and SWING)
IN
77F Solenoid
Valve RC0682.eps
Truck Auxiliary
Valve (CLAMP)
C4
45F, 60F C1
Solenoid Valve
674512-R4 27
T ROUBLESHOOTING
Rotator
Drive
Revolving
Connection
Long Arm
Cylinders Short Arm
Cylinders
(if equipped)
4-Port
Hose Reel
NOTE: Short arm
cylinders operate
Port 3 only when Clamp is
Swing rotated to the
Port 4 Cylinder 45-degree position.
Port 3 SWING
EXTEND
Port 4
SWING
RETRACT
2-Port
Hose Reel
or Internal
Hose
Reeving
SWING
Truck Auxiliary
Valve (ROTATE IN
and SWING)
IN
77F Solenoid
Valve RC0681.eps
Truck Auxiliary
Valve (CLAMP)
C2 C3
45F, 60F
Solenoid Valve
SWING EXTEND SWING RETRACT
Pressure:
P
Return:
T
28 674512-R4
T ROUBLESHOOTING
G
G
G
G
CL CL
Revolving
Connection
OP OP
OP OP
CL CL
Clamp Relief
CLAMP (if equipped)
OPEN Rotator
Drive Motor
Motor
Check
Valve
CCW CW
2-Port
Hose Reel 2-Port
or Internal Hose Reel
Reeving
Truck Pump
Truck Relief Truck Tank
RC2477.eps
674512-R4 29
T ROUBLESHOOTING
G
G
G
G
CL CL
Split Long Arm Circuit Components
(variations shown below )
Revolving Shuttle
Connection OP Spool Valve
CL
OP Sequence
OP Valve
CL OP
Flow Divider
RC2454.eps
29
79
22
CLAMP
Rotator
Drive Motor
OPEN Shuttle Check Valve
Cross-Over Check
Relief (if Valve
equipped)
65
17
21
CL
Closing Free Arm
Orifice (if equipped) Adjustable
Relief Valve
Flow Divider
CL Sequence
Valve
CL
08
88
20
OP Shuttle
Valve
30 674512-R4
T ROUBLESHOOTING
G
G
Short Arm
Long Arm Cylinders
Cylinders (if equipped)
G
G
Revolving Connection
CL SWR
CL Swing
OP OP Cylinder
OP OP
CL
CL
SWE
Counterbalance
Valves
OPEN SWR
CAUTION: Outer most
hose on 4-port hose reel Rotator
CLAMP SWE Drive Motor
must connect to OPEN
port on attachment.
Check
Valve
CCW CW
Solenoid-Operated 4-Port Solenoid-Operated
Control Valve Hose Reel Control Valve
or Internal
77F Serial Numbers Reeving All Models 2-Port
675414–675467 (except as shown) Hose Reel
1 2 3 4
C C CC
1 2 3 4
P T
RC2466.eps
674512-R4 31
T ROUBLESHOOTING
G
G
Short Arm
Long Arm Cylinders
Cylinders (if equipped)
G
G Revolving Connection
CL OP
OP
SWR
Split Long Arm
Circuit Components Swing
(variations shown Cylinder
below) CL
CL Counterbalance
SWE Valves (2)
OP
OP
CL
Flow Divider
OPEN SWR
CCW CW
21
23
95
RC2457.eps
NOTE: Truck components not shown.
Adjustable Counterbalance
Relief Valve Valves
Shuttle Valve
CL
Sequence
Valve
73
87
20
CL
OP
Flow
Divider
Counterbalance
Valves
32 674512-R4
T ROUBLESHOOTING
4.3-1 Supply Circuit Test 4 Long Arm Cylinders – Close the long arm fully and
hold the handle in the CLAMP position a few seconds
to develop full truck system pressure. Watch the gauge
WARNING: Before removing hydraulic lines,
relieve pressure in the Attachment hydraulic pressure readings.
system. Turn the truck off and move the Short Arm Cylinders – Rotate the Roll Clamp to the 45-
truck auxiliary control valves several times degree position. Close the short arm fully and hold the
in both directions. handle in the CLAMP position a few seconds to develop
full truck system pressure. Watch the gauge pressure
1 Check the pressure delivered by the truck. Refer to the readings.
truck Service Manual. The pressure must be within 100
psi (7 bar) of specified truck pressure. Pressure to the • If the gauge pressure on the cylinder continues to
Clamp must not exceed the following: drop more than 150 psi (10 bar) initially, and ad-
45F–160F, 2300 psi (160 bar) ditional drop exceeds 25 psi (2 bar) per minute, the
38F, 2600 psi (180 bar)
cylinder piston seals are faulty (see Section 5.7).
2 Check the flow volume at the carriage hose terminal. • If the gauge pressure on the cylinder does not drop
See Section 6.1-1 for recommended flow volumes. If the more than 150 psi (10 bar) initially, and additional
truck pressure and flow are correct, proceed with the drop does not exceed 25 psi (2 bar) per minute, the
Clamp circuit pressure test. check valve (now in the other cylinder) is faulty and
requires replacement (see Section 5.7-4).
4.3-2 Clamp Circuit Test
WARNING: Before removing hydraulic 45F–160F
lines, position both arms at midstroke to
relieve cylinder pressure. Turn the truck
off and move the truck auxiliary control
valves several times in both directions.
2
onds to develop full truck system pressure. Watch the Port
gauge pressure readings. Pressure
Gauge
Short Arm Cylinders – Install a pressure gauge to each
short arm cylinder's gauge port. Rotate the Clamp to
the 45-degree position. Close the short arm fully and
hold the handle in the CLAMP position a few seconds
to develop full truck system pressure. Watch the gauge
pressure readings.
• If the initial gauge pressures are not within 100 psi
(7 bar) of system pressure measured at the hose
terminal, the revolving connection may be faulty and RC2005.eps
requires service. Refer to Section 5.6.
38F
674512-R4 33
T ROUBLESHOOTING
1
• If the roll drops suddenly, the counterbalance valve
requires adjustment (see Section 5.6-2.). Swing
Cylinder Short Arm
3 Raise the roll and rotate 180° to position the long arm
down. Retract the swing cylinder fully to swing the frame
upward.
• If the roll drifts downward, the revolving connection
Swing
counterbalance valve may require service (see Section Cylinder
5.6-4.).
• If the roll does not drift down, continue trouble
shooting.
4 Extend the swing cylinder to lower the roll: Swing Up
• If the roll drops suddenly, the counterbalance valve
requires adjustment (see Section 5.6-2.).
RC0790.ill
Long Arm
3
34 674512-R4
T ROUBLESHOOTING
4.4 Rotation Function • If the higher gauge reading is close to truck pres-
sure as measured at the carriage hose terminal and
no rotation occurs, the rotator motor output shaft or
There are four potential problem areas that can affect the drive box may need repair. Continue troubleshoot-
rotation function: ing.
• Operator may be handling roll incorrectly. Loads may
be too heavy or rotated off-center, exceeding capacity
2 Remove the motor from the drive box assembly as
described in Section 5.4.
of Clamp. Refer to Operator’s Guide for suggested
handling procedures. 3 Reinstall the hoses to the rotator motor fittings. Actuate
• Low hydraulic pressure or flow from lift truck. the rotate circuit.
• Worn or defective hydraulic rotator motor or check valve • If the rotator motor shows rotational output, the drive
assembly. box may require service (see Section 5.3).
• Worn or defective drive assembly or rotator frame • If the rotator motor shows little or no rotational out-
bearing assembly. put, the rotator motor requires service (see Section
5.4).
Flowmeter
4.4-1 Supply Circuit Test
WARNING: Before removing hydraulic
lines, relieve pressure in the Attachment
hydraulic system. Turn the truck off and
move the truck auxiliary control valves
several times in both directions.
4.5 Electrical Circuit 4 Disconnect the electrical leads from the solenoid coil ter-
minals. Use a voltmeter to determine if there is voltage
(Solenoid-equipped attachments) at the electrical lead terminals when the control knob
button is depressed.
Use the schematics shown and follow the steps below.
• If there is no current to the solenoid, troubleshoot the
electrical circuit for opens or shorts.
1 Check the control knob circuit fuse. Replace if neces-
sary. • If there is current to the solenoid, test for coil continu-
ity and proper rating.
2 Check for loose electrical connections at the truck igni-
tion switch, control knob button, solenoid coil terminals 5 Test for coil continuity and rating by placing an ohmme-
and diode. ter test lead on each solenoid coil terminal (ohmmeter
on Rx1 scale):
3 Remove the diode from the solenoid coil terminal. Test • If there is a reading, the coil is good. Check for proper
with an ohmmeter for high resistance in one direction ohm value for the truck.
and no resistance in the other direction. If there is no
resistance in both directions, replace the diode. • If the coil is good, but the solenoid does not 'click'
when the control knob button is depressed, the sole-
NOTE: When replacing the diode, the banded end must
noid cartridge may be jammed (see Section 5.12).
be connected to the coil and wiring as shown.
• If there is no ohmmeter reading, the coil is defective
and should be replaced (see Section 5.12).
ALL CLAMPS
(Except 77F swing frame early model) Pushbutton attached Control Knob
to control lever with with Pushbutton Solenoid Solenoid
heat shrink tubing Coil Valve
12V: 2.4–2.8 Ohm
24V: 9.5–11 Ohm
Coil 36V: 24–28 Ohm
48V: 40–46 Ohm
Pushbutton RC0736.eps
7.5-Amp
Fuse White Diode IMPORTANT:
7.5-Amp Fuse Banded end must con-
nect to positive (+) side
Diode of circuit.
Cable
Black
Diode
7.5-Amp
Pushbutton
Fuse
7.5-Amp Fuse
Control
Cable
Valve
Black RC0747.eps
36 674512-R4
S ERVICE
4
move the auxiliary control valves several
times in both directions.
3
RC0758.ill
Lower Hooks
2
Clamp
Rotate CCW
Rotate CW
RC0441.ill
Open
3 Disconnect the lower hooks:
Bolt-On Hooks – Remove the lower mounting hooks.
For reassembly, tap hooks tight against lower carriage
bar and tighten the capscrews to: Clamp Swing
Extend
CL II, III 38F, 45F, 60F, 66F – 110 ft.-lbs. (150 Nm)
CL IV 60F, 66F, 77F – 195 ft.-lbs. (265 Nm)
CL IV 90F, 100F, 120F – 260 ft.-lbs. (350 Nm)
Quick-Change Hooks – Pull out the locking pins and RC0446.ill
drop the lower hooks to the unlocked position. Reinstall Outer
the pins in the lower holes. For reassembly, slide the Hose Swing
hooks up to the locked position and install the locking Open Retract
pins in the top holes.
WARNING: Hose connected to
4 Set the Clamp on a pallet. Tilt the mast forward and
OPEN port must use outer-most
lower the carriage to remove the Clamp from the truck.
hose on 4-port hose reel.
5 For installation, reverse the above procedures with the
following exceptions:
• Refer to Section 2, Installation, for complete
installation procedures.
3 BOLT-ON HOOKS
Carriage Bar
RC0368.eps
QUICK-CHANGE HOOKS
Guide
RC0367.eps
®
ST de
U a
ADJ LH lower sc
ca
Hook
-1
14
55
67
C-
LH lower Hook in
unlocked position
Locking Pin
674512-R4 37
S ERVICE
3
other arm. Rotate the Clamp 90 degrees to position the
arm being removed on top.
2
RC0332.ill
4
spacers at the arm pivot points. It is recommended that
all Clamps be equipped with these spacers. Kits listed
5
below include spacers for the swing frames, arms, and
cylinder base pivots.
Clamp Model Spacer Kit
45F 681774
60F, 66F 681775
77F, 90F, 100F 681776
and larger
6 For reassembly, reverse the above procedures.
RC0333.ill
38 674512-R4
S ERVICE
2
Link
Clevis
1 Rotate the Clamp to the vertical roll handling position. Pin
Lower the unit until the contact pads lightly touch the
ground.
NOTE: If bolt-on pad surfaces are to be replaced,
remove and replace at this point. Tighten capscrews to
15 ft.-lbs. (20 Nm).
2 Remove the clevis pins fastening the links to the contact
pad.
3 Remove the pipe plug retainers or drive pin retainer
3
Pad Pivot
Pin, Plugs
from the contact pad pivot points and drive out the pivot
pins.
4 Remove the contact pad. Pad links can be removed
from the arm by rotating 90 degrees and pulling out.
Long arms links are held in by a spring. 45F–120F PADS
5 38F – Assure pad opener springs are installed as RC0334.ill
5
following exceptions: Pad Opener
• Inspect the arm tips and pivot pins for wear and Springs
repair/replace as necessary (see Section 5.2-3).
• 38F – Install drive pin-type retainer 2 mm below
outside surface of contact pad. Assure pin is an
interference fit. (Pin .312 in. dia. x 1.250 in long).
4
(38F), 674928 (45F, 60F, 66F) and 676810 (77F, 90F and Pivot
larger). Each kit includes four (4) replacement arm tips to OR
Pin
repair one (1) arm.
Drive Pin
WARNING: Cascade Corporation recom- Retainer
mends that a qualified welder experienced in 38F PADS
this type of repair be used for best quality. RC1987.eps
3
2 Scribe a cut line using dimension A, back from the inner Remove tips of
surface of the existing pivot pin hole on both sides of arm casting
the arm tip.
3 Remove the worn tip portion of the arm casting at
the cut line by grinding, sawing, or flame cutting.
Remove any contaminants from around the repair area. A
674512-R4
Cut line
2 39
S ERVICE
4
(75° C) for 2 hours. Apply weld holding a close arc.
Do not oscillate or use a wash bead pattern.
• Cool arm tip base metal as follows:
38F – 90F: normal air-cool.
100F: slow cool with insulating blanket cover.
8 Remove slag after each weld and inspect for defects. C
NOTE: Arc craters, undercut, overlap and porosity are
not permitted. Repair any weld defect as required.
9 Grind all welds to smooth transitions between parts. START
STOP
START
7 Weld Sequence:
START
B
STOP
START
RC0306.eps
40 674512-R4
S ERVICE
Drive
Group
7
Plate
2 Lay the drive group, pinion down, on two 4 x 4 in. (10 x
10 mm) wood blocks placed on both sides of the pinion.
3 Remove the four capscrews fastening the cover plate to
the housing.
4 Remove the center capscrew plug from the cover plate
and install a (early) 3/8 in. NC or (later) M10 capscrew Housing
5
with a minimum thread length of 2 in. (50 mm). Remove
the cover plate by turning the capscrew clockwise while
lightly tapping around the sides of the cover plate.
5 Drain the lubricant from the housing.
6 Remove the three capscrews fastening the end cover to
the housing.
7 Remove the drive motor as described in Section 5.4-1.
2 RC0172.eps
6
674512-R4 41
S ERVICE
8
RC0173.eps
Worm
9
Worm
Gear
9 Press the pinion gear, seal, pinion bearings and worm
gear out of the housing as an assembly.
RC0174.eps
Housing
Pinion Bearing
10 Remove the snap ring from the pinion gear shaft. Press
the pinion gear bearing from the worm ring gear and
cover plate pinion bearing. Remove the pinion shaft
key.
Pinion Gear
10
IMPORTANT: Heavy Duty Pinion uses two bearings with
the first bearing retained by an additional snap ring (see Seal (if equipped)
illustration next page).
42 674512-R4
S ERVICE
is inward as shown.
Key
Worm Gear,
Bearing, Snap Ring
4
2 RC2125.eps
3 Housing
RC0179.eps
6 5 RC0178.eps
674512-R4 43
S ERVICE
(For .010–.014 in. measured gap, use .015 in. total
shim thickness.)
(For .009 or less, use one (1) .010 in. shim, since a RC0180.eps
Housing 8 End cover
10
(540 ml) of Cascade Gear Lube Part No. 656300, or
SAE 90 wt. gear lube (AGMA 'mild' 6EP Gear Lube). RC0181.eps
12 Install the cover plate and gasket. Install the four cover
plate capscrews and tighten to 15 ft.-lbs.
(20 Nm). Install the center hole plug.
13 Reinstall the drive group on the rotator baseplate as
described in Section 5.3-1. 12
Cover plate
RC0182.eps
44 674512-R4
S ERVICE
8
assembly and drive motor. For reassembly, tighten the
7
O-Rings
capscrews to 15 ft.-lbs. (20 Nm).
Adapter
Plate
Check Valve
5 6
6 Remove the three capscrews fastening the adapter
plate to the gearcase housing. Tap on the drive motor
with a rubber mallet to separate the drive motor/
3
adapter plate assembly from the gearcase housing.
7 Remove the four capscrews fastening the adapter plate
4
RC0778.eps
to the drive motor and separate the motor from the
adapter plate. Fill Plug
(two locations)
8 For reassembly, reverse the above procedures except
as follows:
• Apply Loctite 515 sealant (Cascade Part No.
668184) to both sides of the drive motor/adapter
plate gasket. Apply sealant to the threads of the
four drive motor capscrews. Install the gasket and
adapter plate to the drive motor. Tighten capscrews
to 30–40 ft.-lbs. (50–55 Nm).
• Apply sealant to both sides of the adapter plate/
gearcase housing gasket. Apply sealant to the
threads of the three adapter plate capscrews. Install
the drive motor/adapter plate assembly and gasket
to the gearcase housing. Tighten the capscrews to
55–65 ft.-lbs. (75–90 Nm).
• Fill the drive group with fill with 56 fluid ounces (540
ml) Cascade Gear Lube Part No. 656300, or SAE 90
wt. gear lube (AGMA 'mild' 6 EP Gear Lube).
674512-R4 45
S ERVICE
4
needle thrust bearing and bearing race.
5 Turn the drive motor over, clamping the housing across
End
the port area with the flange upward.
Cap
6 Remove the four Loctited capscrews from the flange.
Do not use an impact wrench (see CAUTION below).
RR0092.ill
7 Flange
9 Spacer
Plate
Gerotor
Set
Splined
Drive
Shaft
Exclusion Thrust
Seal Bearing
5
Bearing
Race
Housing
O-ring
Pressure Seal
Capscrews 8 RC0186.eps
6 RC0187.eps
CAUTION: Thread-locker used on the capscrews may
9
Allen wrench
require that a small amount of heat be applied to the
housing (400° F / 200° C), to remove the capscrews.
Use a temperature indicator to prevent overheating the
housing.
7 Remove the flange from the housing.
8 Remove the exclusion seal and pressure seal from the
flange using a seal removal tool or modified screwdriver
as shown.
RC0188.eps
CAUTION: Do not scratch either of the seal cavities.
9 Using an Allen wrench, remove the metal plug and seal
from the housing.
46 674512-R4
S ERVICE
RC0189.eps
Capscrews
5.4-4 Drive Motor Reassembly Seal
Washers
Gerotor
1 Clamp the housing with the flange side upward. Set
Spacer
2 Install the plug and seal into housing if it was removed. Plate
Push plug into housing until flush with housing surface. End
Do not damage the seal. Cap
3 Install the flange without the exclusion seal and pres-
sure seal. Use two capscrews only.
RC0190.eps
Plug
Flange
Splined
5
Drive
Shaft
Exclusion
Thrust
5
Seal
Bearing
Bearing
Race
Pressure Seal
O-Ring
Housing
4 4
Capscrews
7
housing threaded holes.
6 Install the splined drive into the shaft with the longer
splined end (if applicable) down.
7 Install the seal and spacer plate to the housing.
674512-R4 47
S ERVICE
9
matches up with the timing marks on the spline drive.
Seal
9 Install the seal and end cap, seal washers and Washers
capscrews. Pre-tighten the capscrews to a torque of
15–40 in.-lbs. (2–5 Nm). Make sure the housing and End Cap
gerotor seals are properly seated. Final-tighten the
capscrews using a criss-cross tightening pattern to 200
in.-lbs. (22 Nm).
10 Turn the housing over and clamp across the port area
with the shaft upward. Seal
11 Remove the flange from the housing.
12 Lubricate the exclusion seal with petroleum jelly and
press into the flange.
13 Place the pressure seal on the shaft, flush against the
bearing race. Lubricate the outer surface of the seal
8
Gerotor Set
with O-ring lube or petroleum jelly.
14 Place the flange on the shaft flush against the pressure
seal. Install the four capscrews and tighten each Seal
capscrew one rotation at a time. The pressure seal Star Point,
must enter the flange seat evenly. Alternately tighten Timing
until the flange is tight against the housing. Marks
Wear Plate
12 Exclusion
seal
Flange
14
13Pressure seal
Flange
RR0094.eps
seal
Bearing race
Housing RC0213.eps
11
15 Remove the flange from the housing and inspect the
pressure seal for proper seating into the flange.
16 Clean the four capscrews and their corresponding
threaded holes in the housing. Use a non-petroleum
10
based solvent and blow dry. Apply Loctite Primer 'NF'
to the holes and allow to dry 1 minute minimum.
17 Apply 4 drops of Loctite 601 sealant to the threads of
each of the four housing holes. Wipe away any excess
sealant. Do not let the sealant dry more than 15 minutes
before installing the capscrews.
18 Apply a liberal amount of petroleum jelly to the exclusion
seal, pressure seal and shaft.
19 Install the flange seal into the flange, and install the
flange to the housing. Install the four capscrews and RC0212.eps
tighten in a criss-cross pattern to 250 in.-lbs. (28 Nm).
IMPORTANT: The capscrews must be clean and dry.
48 674512-R4
S ERVICE
W
Check Valve
C
3
CC
W
Cartridges
C
6
CW
W
RC0197.eps
RC2522.eps
6038929
CKCB-XCN
Sun
RC2519.eps
Back-Up Rings
674512-R4 49
S ERVICE
CL OP CL OP
LONG ARM
CL OP CL OP
SHORT ARM
RC0805.eps
Tighten to
8 ft.-lbs.
BRACKETS
(10 Nm)
Revolving
Connection
RC0785.eps
2 Disconnect the hoses and tubes from the front and rear
of the revolving connection. Tag for reassembly.
3 Remove the capscrews fastening the revolving
connection to the faceplate. For reassembly, tighten
capscrews as noted in the illustration opposite.
4 Remove the revolving connection from the faceplate.
5 For reassembly, reverse the above procedures with the RC0926.eps
following exceptions:
• Service revolving connection in a clean work area
(see Sections 5.6-2 through 5.6-6).
• Position shaft/end block so that CLAMP/OPEN
fittings are on the left side (driver's view), or the BRACKET PIN
'TOP' stamping (if marked) is upward.
'TOP' stamping
L
C
Clamp Swing
P
O
L
C
Tighten to
Extend
P
O
RC1972.eps
RC2479.eps
Open Swing
Retract
2
conection shaft. CAUTION: Remove all burrs and paint
5
from exposed shaft surface prior to removal from the
body. Burrs or paint chips pulled through the bore
will permanently damage the valve body. Keeper
Bracket
6 Remove the shaft from the body. (if equipped)
Snap Ring
RC0799.eps
674512-R4 51
S ERVICE
Connection Service
1 Remove the revolving connection from the attachment
as described in Section 5.6-1.
2 Remove the snap ring from the revolving connection
shaft.
CAUTION: Remove all burrs and paint from exposed RC2504.eps
shaft surface prior to removal from the body. Burrs or Back-up Rings
paint chips pulled through the bore will permanently
COUNTERBALANCE VALVE
damage the valve body.
CARTRIDGE
3 Remove the shaft from the body. Back-up Rings
4 Swing Frame Clamps – Remove the counterbalance
valve cartridges.
5 Remove the O-rings and back-up rings from the shaft
and counterbalance valve cartridges.
6 Remove the fittings from the shaft and body.
7 Clean all parts with clean solvent or kerosene.
8 Inspect the body bore for grooves and scratches. If the
bore is worn, replace the body.
FIXED FRAME SHAFT
9 For reassembly, reverse the above procedures with the O-Rings
following exceptions: O-Rings
Shaft
3 RC0803.eps
SWING FRAME SHAFT
Back-up Rings
SWING FRAME
REVOLVING CONNECTION
2
O-Rings, Snap
Back-up Ring
Rings
5 Counterbalance
Valve Cartridge
FIXED FRAME
REVOLVING CONNECTION 4
Body
5
O-Rings,
RC0779.eps
Back-up Rings
52 674512-R4
S ERVICE
7
5 Remove the O-rings and back-up rings from the body
and counterbalance valve cartridges using a hook-type
brass seal removal tool (Cascade Part No. 674424). SWING FRAME BODY
NOTE: Do not scratch grooved surfaces.
6 Clean all parts with clean solvent or kerosene and
inspect the following areas:
• Shaft sealing surface – Remove minor surface
imperfections with 320-grit emery paper. Sand
radially (around) shaft. Break sharp edges on front of
shaft. If severly worn, replace shaft.
• Body grooves – Remove minor nicks or projections
that may damage seals during installation. If severly Back-up
Rings O-Rings
worn, replace body.
7 For reassembly, reverse the above procedures with the
following exceptions:
• Install new back-up rings and O-rings as shown.
• Lubricate shaft and body with O-ring lube or
petroleum jelly. Use shaft/seal loader, rotate body
during installation.
RC0831.eps
Plug
End Block
4 O-Rings
3 Shaft
Plug
SWING FRAME
REVOLVING CONNECTION
O-Rings
Body
O-Rings,
5
Back-up Snap
Rings Ring Counter-
balance
Valve
Cartridges
FIXED FRAME 5
CL OP CL OP
REVOLVING CONNECTION
LONG ARM
CL OP CL OP
SHORT ARM
O-Rings,
Back-up
Rings
RC0782.eps
674512-R4 53
S ERVICE
5.6-5 Two-Piece Seals-in-Body • Clean all traces of oil and moisture from seal
grooves inside revolving connection body using
Revolving Connection a non-petroleum based cleaner. (Example:
electronic contact cleaner).
Service • Clean hands thoroughly to remove all traces of oil
and moisture prior to 2-piece seal installation.
1 Remove the revolving connection from the attachment
as described in Section 5.6-1. • Install square rubber rings into revolving connection
body grooves.
2 Remove the front snap ring from the revolving • Install Teflon rings over rubber rings. IMPORTANT:
connection shaft.
Use a seal installation tool, or form seal rings into
CAUTION: Remove all burrs and paint from exposed a 'kidney' shape as shown to install. Avoid sharp
shaft surface prior to removal from the body. Burrs or bends. Use finger pressure to smooth rings into
paint chips pulled through the bore will permanently grooves.
damage the valve body.
• Lubricate shaft and body with hydraulic fluid prior to
3 Remove the shaft from the body. reassembly.
4 Remove the end block from the shaft. Remove the relief • Use seal/shaft loader and
cartridge (if equipped). For reassembly, apply Loctite apply gentle pressure to install
271 (red) to the capscrews and tighten to 15 ft.-lbs. shaft in body. Rotate body to
(20 Nm). ease installation.
5 Remove the two-piece seals from the body using a Seal AC0044.eps
7
FIXED FRAME Installation Tool
brass hook-type seal removal tool (Cascade Part No.
BODY (Cascade Part
674424). CAUTION: Do not scratch grooved surfaces. No. 599514)
6 Clean all parts with clean solvent or kerosene and
inspect the following areas: Body
4
End Block, Form seals into 'Kidney'
Capscrews shape to install
7 O-Rings Body
RC0488.eps
3
Shaft
CL
SHORT ARM
RC01973.eps
CL
LONG ARM
L
Front
C
Snap
P
O
L
C
Ring
2
P
O
LONG ARM
Two-Piece
SHORT ARM
Seals
38F 45F–100F
54 674512-R4
S ERVICE
Body
GA0203.eps
Back-Up Ring
SHUTTLE CHECK VALVE CARTRIDGE
O-Rings Flow
Divider O-Rings
Rear Shaft
Snap Ring
RC2501.eps
Front RC0454.eps
Shuttle Check Snap Back-Up Rings
Valve Two-Piece Ring
Seals RELIEF VALVE CARTRIDGE
Valve Adjustment
1 Rotate the Clamp to the bilge (horizontal) position with
the short arm down.
2 Activate the SWING function and check for smooth
extend and retract at equal, moderate speeds.
SWR
• If Clamp moves upward suddenly when SWING Swing
EXTEND function is activated, adjust cartridge labeled Retract
'Swing Extend Adjust' (see illustration). Loosen nut Adjust
and turn adjustment screw counterclockwise (CCW) SWE
to reduce swing speed or clockwise (CW) to increase Swing
swing speed. Extend
• If Clamp moves downward suddenly when Adjust
SWING RETRACT function is activated, adjust
cartridge labeled 'Swing Retract Adjust' (see
RC0784.eps
illustration). Loosen nut and turn adjustment screw
counterclockwise (CCW) to reduce swing speed or
NOTE: Typical revolving connection, front view,
clockwise (CW) to increase swing speed.
Clamp rotated to bilge position, short arm down.
674512-R4 55
S ERVICE
5.7 Cylinders
Servicing Cylinders
2
5.7-1
on the Clamp
1 Close the arm attached to the cylinder being serviced.
Rotate the Clamp to the vertical roll handling position.
4
2 Remove the cylinder rod anchors from both cylinders.
For reassembly, tighten the anchor capscrews to
35 ft.-lbs. (45 Nm).
3 Retract the cylinder rods.Swing the cylinder to be
serviced outward to expose the cylinder rod and
retainer.
3
several times in both directions.
RC0307.eps
Cylinder Removal –
2
5.7-2
Long or Short Arm
1 Close the arm attached to the cylinder being removed.
Rotate the Clamp to the vertical roll handling position.
2 Remove the cylinder rod anchor pins from both
4
cylinders. For reassembly, tighten the anchor
capscrews to 35 ft.-lbs. (45 Nm).
1
ports. Plug the hose ends and tag for reassembly.
4 Remove the cylinder base anchor pins. Note the
location of shims. For reassembly, tighten the anchor
capscrews to 35 ft.-lbs. (45 Nm).
4
5 Service the cylinder as described in Section 5.8.
RC0308.eps
56 674512-R4
S ERVICE
2
WARNING: Before removing hydraulic Cylinder
hoses, relieve pressure in the attachment Check Valve
hydraulic system. Turn the truck off and Cartridge
move the auxiliary control valves several 45F–120F
times in both directions.
4
CHECK VALVE CARTRIDGE
O-Rings
RC0311.eps
Back-up Rings
674512-R4 57
S ERVICE
Bushing Driver Dimensions
A B
2
Bushings
Bearing I.D. Driver O.D.
38F, 45F 1.11 in. (28.2 mm) 1.36 in. (34.5 mm)
60F, 66F 1.23 in. (31.2 mm) 1.48 in. (37.6 mm)
77F, 90F 1.23 in. (31.2 mm) 1.48 in. (37.6 mm)
and larger
7 in.
1.5 in. (178 mm)
(38 mm)
B A
RC0362.eps
58 674512-R4
S ERVICE
5
1 Clamp the cylinder so that the vise jaws contact only the
extreme end of the cylinder base.
2 Screw the piston retainer out with a pin type spanner
wrench or special socket.
3 Remove the piston/rod/retainer assembly from the cylin-
der shell.
4 Clamp the piston/rod/retainer assembly across the rod RC0315.eps
4
end. IMPORTANT: Never clamp directly on the rod
sealing surface.
5 Remove the piston nut from the rod.
6 Clamp the piston on the top and bottom in a soft-jawed
vise. Pry the seals up with a brass seal removal tool and
cut to remove. RC0346.eps
CAUTION: Do not scratch the seal grooves.
RC0359.eps
6
Check Cartridge
Piston Nut
5 Piston / Rod
assembly
3 Retainer
2
Shell
RC1977.eps
5.8-2
Cylinder Inspection
• Inspect the rod, piston and retainer for nicks or burrs.
Remove minor nicks or burrs with 320 grit emery cloth.
If they cannot be removed, replace the parts.
• Inspect the cylinder shell bore and remove any minor
nicks or burrs with a butterfly hone (320 grit). If the
nicks or burrs cannot be removed, replaced the part.
• Inspect the outside of the shell for any deformities or
cuts that could impare performance or cause leaks
under pressure. If necessary, replace the part.
674512-R4 59
S ERVICE
Cylinder Reassembly
1
5.8-3 Chamfer
Angle
1 Polish the piston and retainer chamfer angle with 400
grit emery cloth to facilitate seal installation. Clean all
parts thoroughly.
2 Lubricate all new seals and O-Rings with O-Ring lube or
3
petroleum jelly.
3 Install new seals and O-Rings on the piston and retainer.
Hook one side of the seal in the groove and carefully
4
work it over the piston or retainer as shown. Note the Wear RC1982.eps
direction of the U-cup seals. Pressure seals must Ring
always be installed with the lip toward the high
pressure side of the cylinder.
4 Install the composite wear ring on the piston.
5 Install the retainer and then the piston on the cylinder Stop
rod. Tighten the piston retaining nut to the following Fins
torque value: Cylinder
Shell
6
38F – 90–110 ft.-lbs. (120–150 Nm). Piston
45F – 200–225 ft.-lbs. (270–305 Nm). Seal
60F, 66F 77F – 400–450 ft.-lbs. (545–610 Nm). Loader
90F, 100F – 400–450 ft.-lbs. (545–610 Nm).
RC0320.eps
6 Place the piston loader furnished with the seal kit into
the cylinder shell. Assure that the loader covers all Thread refief
the cylinder shell threads but does not contact the chamfer
thread relief chamfer. Trim the loader stop fins if more
engagement is needed.
CAUTION: The piston will not enter the cylinder shell Piston/Rod
properly if the loader contacts the thread relief chamfer. Assembly
4 4
Piston Retainer
Seals Seals
Swing
Cylinder
45F–100F Seal 38F Seal
O-Ring O-Ring
60
Piston Nut
5 RC1978.eps
11 Retainer
674512-R4
S ERVICE
Base Unit
5
Swing frame
5.9 Pivot Pins,
Retainers
5.9-1 Swing Frame Service
1 Rotate the Clamp to the vertical roll handling position. Connector Pin
Spacer
4
2 Remove the arms from the Clamp as described in
Section 5.2-1.
3 Remove the clamp and swing cylinders as described
in Sections 5.7-2 and 5.7-3.
Shims
4 Remove the pin connecting the swing casting and
rollers to the swing frames. For reassembly, tighten the
5
retainer capscrews to 35 ft.-lbs. (45 Nm).
5 Remove the swing frame pivot pins and spacers
(see note below). Note the location and quantity of
shims removed. For reassembly, tighten the retainer
capscrews to 35 ft.-lbs. (45 Nm).
Shims
NOTE: It is recommended that all Clamps be
equipped with spacers at the swing frame pivot points
as shown. Kits listed below include spacers for the
swing frame, arms and cylinder base pivots: Spacer
RC0323.eps
Clamp Model Spacer Kit
Swing Casting
45F 681774
60F, 66F 681775
1
77F, 90F,100F and larger 681776 2
6 For reassembly, reverse the above procedures. 1
2
clearance exceeds 1/16 in. (1.6 mm).
1 Swing Frame Clamps – Remove the swing frames
from the faceplate as described in Section 5.9-1.
Fixed Frame Clamps – Remove the arms from the
Clamp as described in Section 5.2-1. 1
2 Remove the bushings from the frames using a bushing 1
driver. NOTE: Bushing drivers can be machined using
the dimensions shown in the chart below.
3 Install new bushings in the frames (see chart below).
CAUTION: Bushings may be damaged if installed
without a proper bushing driver.
674512-R4 61
S ERVICE
2
capscrew inspection in Step 2. Bearing-to-Faceplate Baseplate
Capscrews
2 Check three (3) faceplate ews for oper torque
value as follows. Remove the acess plug from the
back of the baseplate and rotate the Clamp to the
predominent vertical roll-handling position. Locate
the three (3) capscrews closest
tighten each capscrew CW until torque is 10 ft.-lbs.
(14 Nm) above torque value listed below. Mark each
capscrew after checking:
38F–100F – 75 ft.-lbs. (100 Nm).
120F–160F – 220 ft.-lbs. (300 Nm).
• If any faceplate capscrews rotate, are loose or
broken, go to 2000-hour inspection criteria and
replace complete set of faceplate fasteners as RC2319.eps
described in Section .9-4. Access Plug
• If capscrews do not rotate, inspection is complete.
Faceplate
2000-Hour Inspection
Every 2000 hours perform the following inspection:
RC2316.eps
Back (Driver's) Views
62 674512-R4
S ERVICE
3
in counterbored holes only. Use
lockwashers if supplied in kit.
Baseplate-to-bearing capscrews –
A) Apply Loctite 242 (blue) to clean and dry
capscrews. Clean and dry the threaded holes in
the bearing. Threads must be clean and dry for WARNING: Make sure hoist used to
new Loctite to cure properly. remove the baseplate has a rated capacity
B) Tighten using the alternating cross-pattern shown of at least 1000 lbs. (450 kg).
to one-half the final torque value shown below.
C) Tighten using the alternating cross-pattern to the
final torque value, then double-torque by backing
off 1/2 turn and immediately retightening to the final
torque value shown below:
38F–100F – 75 ft.-lbs. (100 Nm). Faceplate
120F–160F – 220 ft.-lbs. (300 Nm).
Alternating
cross-pattern
tightening
sequence.
6
RC2306.eps RC0327.eps
Baseplate
NOTE: Remove center lower mounting spacer (if
Bearing
5
equipped) to gain access to bearing capscrews.
For reassembly, tighten capscrews to: Assembly,
Capscrews Center
60F, 66F, 77F – 15 ft.-lbs. (20 Nm). Lower
90F, 100F, 120F – 30 ft.-lbs. (40 Nm). Spacer
8
CAUTION: Do not reuse old capscrews or washers.
Use new hardware kit when installing a new bearing
assembly.
Alternating
cross-pattern
9
Felt Seal
tightening RC0328.eps
sequence.
7
RC2330.eps
10
grease (Whitmore 'OmniTask' or equivalent) to the RC0331.eps
teeth of the bearing assembly ring gear.
• After remounting the Clamp, apply chassis grease
to the bearing assembly grease fitting. Rotate the Back (Driver's) View
Clamp slowly during the procedure.
64 674512-R4
S ERVICE
2
Raise approximately 2 ft. (60 cm) off the ground. Cylinder Pivot Pin
Retainers
2 Remove the top and bottom cylinder pivot pin retainers. Tiedown
For reassembly, tighten the retainer capscrews to Capscrews
4
35 ft.-lbs. (50 Nm).
3
Cylinder
3 Pull the pivot pins out of engagement with the bumper Pivot
rollers approximately 2 in. ( 5 cm). Pins
CAUTION: Do not completely remove the cylinder pivot
pins.
4 Remove the tiedown capscrews from the arms. For
reassembly, tighten the capscrews to 15 ft.-lbs. (20 Nm).
5 Remove the capscrews fastening the belt anchor bars to
the arms. Remove the belt. For reassembly, tighten the
capscrews to 35 ft.-lbs. (50 Nm).
RC0683.eps
Bumper
Rollers
2
Cylinder Pivot Pin
Retainers Tiedown
Capscrews
Cylinder
Pivot
Pins
3 4
5
Belt Anchor Bar
Capscrews
RC0684.eps
674512-R4 65
S ERVICE
6 6
Adjust Adjust
Long Arm Belt flat Long Arm Belt flat
Anchor Bar against frame Anchor Bar against frame
RC0685.eps
66 674512-R4
S ERVICE
4
5 Clean all parts with kerosene or solvent.
6 For reassembly, reverse the above procedures with the
following exceptions:
• Install new O-Rings, Back-up Rings, Wiper Rings.
Gland Nut
RC0691.eps
O-Rings Plunger
Wiper
Spring
Ring
Plunger
Gland Nut
Back-up Ring
RC0692.eps
674512-R4 67
S ERVICE
2
O-Rings. For reassembly, tighten the capscrews to
35 ft.-lbs. (50 Nm).
4 Service the valve in a clean work area. Remove the Control
solenoid and cartridge valves. Remove all fittings
Box
from the valve block. Clean all parts with solvent or AC1102.eps
kerosene.
5 For reassembly, reverse the above procedures with the
5
following exceptions: 2-WAY
• Install new O-rings and back-up rings on cartridge SOLENOID
valves and valve block as shown. VALVE
O-Rings
• For complete installation procedures refer to
Electronic Rotational Control Installation Instructions
6048228.
Retainer Nut
4
DECEL Coil, Back-up Rings RC1014.eps
Two-Way Solenoid
Valve Tighten to:
80 ft.-lbs. (110 Nm)
RC1013.eps
Back-up Rings
O-Rings COUNTERBALANCE
VALVE
STOP Coil,
AC0339.eps
Wiring Harness
RC1015.eps
Valve Four-Way Solenoid
Block Valve Tighten to: Back-up Rings
18 ft.-lbs. (25 Nm)
68 674512-R4
S ERVICE
AC0242.eps
674512-R4 69
S ERVICE
STOP
Limit Switch DECEL NOTES:
(Normally Open) Solenoid (top)
1. All cables are 2 conductor with Deutsch type connectors.
Coil Cord
Power Supply/
Power
Communications
Group
ROTATE
Override Control
Push Button Lever
if equipped.
(Normally Closed)
Carriage
+
–
Relay
(12V–96V) Power Bus/Relay
(12V output only)
NOTE: Fuses inside:
Main Power – 20A
OR Circuits – 7.5A
+ – –+ –++–
3 4
+ +
2 1
Fuse,
7.5A@12V Unswitched Unswitched
Switched Switched
Truck Truck
Fuse Block Fuse Block
AC0662.eps
Truck 12V Truck
Battery Battery IC Trucks – Use chassis ground.
Electric Trucks – Use battery ground.
70 674512-R4
S ERVICE
Solenoid Valve
5.12
5.12-1 All Clamps 2 3
(Except 77F Models with serial numbers 675414–675467)
1 Remove the cover from the valve assembly.
4
2 Disconnect the wires and diode from the coil terminals.
3 Loosen the end cover capscrews. Remove the end
cover and coil. Note the position of the coil terminals in
relation to the valve body.
RC0204.eps
4 Install the new coil and end cover. Assure that the
terminals are positioned correctly.
5 For reassembly, reverse the above procedures with the
following exceptions: Coil
• Refer to the electrical schematic in Section 4.5 for
correct wire and diode installation. Solenoid Valve
Solenoid
5.12-2 Early Swing Frame Clamps Coil
3
Cartridges
4 2
(Serial numbers 675414–675467)
NOTE: No longer available, replaced by above.
1 Remove the cover from the valve assembly.
2 Disconnect the wires and diode from the coil terminals.
3 Remove the solenoid cartridge top nut and coil.
4 Remove the solenoid cartridges and check valve
cartridges from the valve body. Remove the seals from
the cartridges.
5 For reassembly, reverse the above procedures with the
following exceptions:
• Install new O-rings and back-up rings as shown.
• Lubricate the cartridge seals with O-ring lube or
petroleum jelly prior to installation.
• Refer to the electrical schematic in Section 4.5 for
correct wire and diode installation.
O-Rings
RC0687.eps
O-Rings
5
Back-up Rings RC0689.eps
RC0688.eps
Back-up Rings
674512-R4 71
S PECIFICATIONS
6.1 Specifications
6.1-1 Hydraulics
Min. ➁ Recommended Max. ➂
72 674512-R4
S PECIFICATONS
Tilt
Forward Release
Rotate
CCW
(Swing
Hoist Down Extend)
Minimum Maximum
A
Class II 14.94 in. (380.0 mm) 15.00 in. (381.0 mm)
Class III 18.68 in. (474.5 mm) 18.74 in. (476.0 mm)
Class IV 23.44 in. (595.5 mm) 23.50 in. (597.0 mm)
GA0028.eps
674512-R4 73
S PECIFICATIONS
4 37 6
shown in the table below in both U.S. and Metric units. All
torque values are also called out in each specific service (Access all
8
procedure throughout the Manual. through plug)
5
5/8 (M16) 110 150
1
Lower hook-to-baseplate (4)
Spacer, lower hook (4)
Center spacer-to-baseplate (4)
2 13
2
Bearing assy.-to-faceplate (✱) ■ ▲ 1/2 (M12) 75 100
Baseplate-to-bearing assy. (✱) ■ ▲ 5/8 (M16) 135 180
3 Rotator drive-to-baseplate (4)
3/4 (M20) 220 300
9 90F/100F/
15
1/2 (M12) 75 100 120F only
Center spacer-to-baseplate (2)
12
7
8
Rotator motor-to-drive box (4)
7/16 (M12) 60
50
80
3 1
9
Shaft end block bracket (4) 3/8 (M10)
35
10
45
1 ITA II 60F, 66F ITA III
✱ Number of fasteners varies depending on Model ITA IV 90F, 100F, 120F RC0447.eps
11
11
RC0436.eps
74 674512-R4
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Cascade Corporation 2006 9-2006 Part Number 674512-R4