cascade corporation 80G User manual

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ERVICE MANUAL
S
Original Instructions
80G–170G
Non-Revolving Clamps
Number 6828871-R1 EN

i
ONTENTS
C
6828871-R1 EN
Page
INTRODUCTION, Section 1
Introduction 1
Special Definitions 1
PERIODIC MAINTENANCE, Section 2
100-Hour Maintenance 2
500-Hour Maintenance 2
1000-Hour Maintenance 3
4000-Hour Maintenance 3
TROUBLESHOOTING, Section 3
General Procedures 4
Truck System Requirements 4
Tools Required 4
Troubleshooting Chart 4
Plumbing 5
Hosing Diagram 5
Hydraulic Circuit 6
Clamp Function 7
Supply Circuit Test 7
Clamp Circuit Test 7
Sideshift Function 9
Supply Circuit Test 9
Sideshift Circuit Test 10
Electrical Circuit 11
SERVICE, Section 4
Attachment Removal 12
Arms 13
Arm Assemblies 13
Custom Arm Bases (80G – 120G) 14
Arm Bearings – Removal and Installation 15
Valve 16
Valve Removal and Installation 16
Valve Service 17
Relief Adjustment – 80G-140G & 170G (Current) Valve 20
Relief Adjustment – 170G (Early) Valve 22
Clamp Cylinder 23
Removal and Installation 23
Cylinder Disassembly 24
Cylinder Inspection 24
Cylinder Reassembly 25
Solenoid Valve 27
Coil Service 27
Valve Service 27
SPECIFICATIONS, Section 5
Specifications 28
Hydraulics 28
Auxiliary Valve Functions 28
Truck Carriage 29
80G–140G Torque Values 30
170G Torque Values 31

NTRODUCTION
I
1
6828871-R1 EN
140G-PBS-C011
PTL123456-1R1
+
7
@
123
+
A2-Z
Cascade Corporation • www.cascorp.com • Icons & Patents: www.cascorp.com/support 6095754
140G-PBS-C011
PTL123456-1R1
CL6366.eps
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.
Nameplate
1.1 Introduction
This manual provides the Periodic Maintenance,
Troubleshooting, Service and Specifications for Cascade
80G–170G Non-Revolving Clamps.
In any communication about the attachment, refer to
the product catalog and serial numbers stamped on the
nameplate. If the nameplate is missing, the numbers
can be found stamped on the frame where the plate was
mounted.
IMPORTANT: Tubing connection and supply fitting types
vary depending on end-user. Specifications are shown in
Metric. All fasteners have a torque value range of ±10% of
stated value.
Weighted Emission Sound Pressure Level - Weighted
emission sound pressure level (LA) does not exceed
70 dB(A).
Measured Value of Whole Body Vibration - Measured
value of whole body vibration (m/s2) does not exceed
0,5 m/s2.
Measured Value of Hand-Arm Vibration - Measured value
of hand-arm vibration (m/s2) does not exceed 2,5 m/s2.

ERIODIC MAINTENANCE
P
2 6828871-R1 EN
WARNING: After completing any service
procedure, always test the attachment
through five complete cycles. First test
empty, then test with load to make sure
attachment operates correctly before
returning it to the job.
2.1 100-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 for loose or missing bolts, worn or damaged
supply hoses and hydraulic leaks.
• Inspect cylinder anchor joint for lubrication and correct
hold.
NOTE: Anchor joint operates with a loose clearance.
Lubricate with wheel bearing grease.
• Check for equal movement of arms.
• Check decals and nameplate legibility.
2.2 500-Hour Maintenance
After each 500 hours of truck operation, in addition to the
100-hour maintenance, perform the following procedures:
• Inspect arm bearings for wear and damage. If bearings
are worn in any area to less than 0.06 in. (1.5 mm)
thickness, replace bearings.
• Check lower mounting hooks for engagement. Hooks
should be tight against lower carriage. If adjustment
is necessary, refer to Installation Instructions 6526543,
Step 6.
• Tighten lower hook capscrews to:
Class III – 165 ft.-lbs. (225 Nm)
Class IV – 190 ft.-lbs. (260 Nm)
• Bolt-On Upper Hooks – Tighten upper hook capscrews
to 320 ft.-lbs. (435 Nm).
• Articulating Arms – Lubricate arm pivot joint zerk
fittings with chassis grease.
• Articulating Arms – Inspect the arm pivot wear plugs.
If either plug is worn to less than 0.12 in. (3 mm),
replace both wear plugs.
• Articulating Arms – Loosen retainer capscrews, adjust
retainer to wear pad clearance to 0.015 in. (0.5 mm).
Tighten retainer capscrews to 320 ft.-lbs. (435 Nm).
CL4908.eps
CL4907.eps
CL4364.eps
Upper
Arm
Bearings
Lower
Arm
Bearings
Arm Pivot Joint
Lube and inspect
wear plugs
Bolt-On
Lower Hook
Cylinder
Anchor
Joint
0.015 in.
(0.5 mm)
Retainer
Adjust

ERIODIC MAINTENANCE
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6828871-R1 EN
CL5924.eps
Bolt-On Arm Cap-
screws
Bolt-On
Upper Hook
Cylinder
Anchor
Joint
Bolt-On
Lower Hook
Attachments with Bolt-On Forks
Back (Drive's) View
2.3 1000-Hour Maintenance
After each 1000 hours of truck operation, in addition to
the 100 and 500-hour maintenance, perform the following
procedures.
• Bolt-On Arms – Tighten bolt-on arm capscrews to a
torque of 680 ft.-lbs. (924 Nm).
2.4 4000-Hour Maintenance
After each 4000 hours of truck operation, in addition to the
100, 500 and 1000-hour maintenance, perform the following
procedures:
• Due to normal mechanical wear and component service
life, cylinder seals should be replaced to maintain
performance and safe operation.

4
ROUBLESHOOTING
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6828871-R1 EN
3.1 General Procedures
3.1-1 Truck System Requirements
• Truck hydraulic pressure should be within the range
shown in Specifications, Section 5.1. PRESSURE TO
THE ATTACHMENT MUST NOT EXCEED:
• Truck hydraulic flow should be within the range shown in
Specifications, Section 5.1.
• Hydraulic fluid supplied to the attachment must meet the
requirements shown in Specifications, Section 5.1.
3.1-2 Tools Required
In addition to a normal selection of mechanic's hand tools,
the following are required:
• In-line Flow Meter Kit:
10 GPM (37 L/min.) – Cascade Part No. 671476.
OR
20 GPM (75 L/min.) – Cascade Part No. 671477.
• Pressure Gauge Kit:
5000 psi (345 bar) – Cascade Part No. 671212.
• Assorted fittings, hoses, and quick-disconnect couplers
as required.
WARNING: Before servicing any
hydraulic component, relieve pressure
in the system. Turn the truck off and
move the truck auxiliary control valves
several times in both directions.
After completing any service procedure, test the
attachment through several cycles. First test the
attachment empty to bleed any air trapped in the
system to the truck tank. Then test the attachment
with a load to be sure it operates correctly before
returning to the job.
Stay clear of the load while testing. Do not raise
the load more than 4 in. (10 cm) off the floor while
testing.
GA0013.eps
GA0014.eps
AC0127.eps
Flow Meter Kits
671476 – 10 GPM (37 L/min.)
671477 – 20 GPM (75 L/min.)
(2) No. 8
JIC/O-Ring Flow Meter
(2) No. 6-8
JIC Reducer
Pressure Gauge Kit
671212
Pressure
Gauge ▲No. 6-6 Hose ▲
No. 6 and No. 8
JIC Swivel Tee
No. 6-8 JIC
Reducer
No. 4, No. 6 ▲
and No. 8
JIC/O-Ring
No. 4-6
Pipe/JIC ▲
▲NOTE: Diagnostics Kit
394382 includes items
marked.
Male Straight Thread
O-Ring Coupler:
No. 4 (Part No. 212282) ▲
No. 5 (Part No. 210378)
No. 6 (Part No. 678592)
Female JIC Thread
Coupler:
No. 4 (Part No. 210385) ▲
No. 6 (Part No. 678591)
Quick-Disconnect Couplers
3.1-3 Troubleshooting Chart
Determine All The Facts
It is important that all the facts regarding the problem
are gathered before beginning service procedures.
The first step is to talk to the equipment operator.
Ask for a complete description of the malfunction.
Guidelines below and on the following pages can then
be used as a starting point to begin troubleshooting.
Clamp Circuit
• Attachment drops load after it has been picked up.
• Attachment will not carry load up to its rated
capacity.
• Attachment arms have uneven travel.
• Attachment arms travel slowly.
• Attachment arms will not move.
To correct these problems, see Section 3.3
Sideshift Circuit
• Attachment drops load while sideshifting.
• Attachment drops load at end of sideshift stroke.
• Attachment sideshifts left and right at different
speeds.
• Attachment will not sideshift
To correct these problems, see Section 3.4.
Model Maximum
80G-140G
Low Pressure 1455 psi (100 bar)
High Pressure 2760 psi (190 bar)
170G 2465 psi (170 bar)

ROUBLESHOOTING
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6828871-R1 EN
CL4994.eps
CL4995.eps
3.2 Plumbing
3.2-1 Hosing Diagram
CLAMP ARMS
PRESSURE
RETURN
NOTE: For OPEN ARMS,
reverse the colors shown.
SIDESHIFT LEFT
PRESSURE
RETURN
SLAVE
NOTE: For SIDESHIFT RIGHT,
reverse the pressure and return
colors shown.
SIDESHIFT CIRCUIT
CLAMP CIRCUIT
SSR Port
OP OPEN Port
Cylinders
Cylinders
Hose Reel
or Internal
Reeving
Hose Reel
or Internal
Reeving
SIDESHIFT Truck
Auxiliary Valve
CLAMP Truck
Auxiliary Valve
SSL Port
CL CLAMP
Port
Attachment
Valve
Attachment
Valve

6
ROUBLESHOOTING
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6828871-R1 EN
CL4996.eps
CL5001.eps
3.2-2 Hydraulic Circuit
Cylinders
Gauge Port CLCL OP
CL
OP
OP
G (CL)
G (OP)
OP
SSR
SSR
OP
Open
Check
Valves Open Check
Valves
Close
Check
Valve
Flow Divider/
Combiner
Flow Divider/
Combiner
CLAMP
Relief
CLAMP
Relief
OPEN
Relief
Equalizer
OPEN
Relief
Clamp Relief
Valve
Sideshift
Relief Valve
Sideshift
Relief Valve
Sideshift
Relief Valve
Adjustable
Compensation
Relief Valve
OP
CL
CL CL
SSL
SSL
Hose Reel or
Internal Reeving
Hose Reel or
Internal Reeving
CLAMP Truck
Auxiliary Valve
SIDESHIFT
Truck Auxiliary
Valve
Truck Relief
Valve
Truck Tank
Truck
Pump
80G–140G
Attachment Valve
170G
Attachment
Valve

ROUBLESHOOTING
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6828871-R1 EN
CL4998.eps
3.3 Clamp Function
There are five potential problems that could affect the
CLAMP function:
• Incorrect load handling. Refer to the Operator’s Guide
for suggested procedures.
• Incorrect hydraulic pressure or flow from the lift truck.
• External leaks.
• Defective solenoid coil or valve (if equipped).
• Worn or defective cartridge valves or cylinder seals.
3.3-1 Supply Circuit Test
1 Check the pressure supplied by the truck at the carriage
hose terminal. Pressure must be within the range shown
in Specifications, Section 5.1. See nameplate on the
attachment and sticker on valve. PRESSURE TO THE
ATTACHMENT MUST NOT EXCEED:
2 Check the flow volume at the carriage hose terminal.
Flow must be within the range shown in Specifications,
Section 5.1.
3 Fully close the arms, holding the lever in the CLAMP
position for a few seconds. Release the lever and
check for external leaks at fittings, hoses and valve.
3.3-2 Clamp Circuit Test
1 Solenoid equipped – Press the solenoid button. Listen
for a 'click' at the solenoid valve. If no sound is heard,
first check the fuse, wiring and coil. Make sure that the
valve is not jammed. Refer to Section 4.5.
IMPORTANT: Solenoid-operated valves must be
plumbed so that the solenoid is energized during the
CLAMP function.
2 Fully open and close the arms. Refer to illustration on
next page for cartridge location. Observe clamping and
opening as follows:
• While closing, if arms move slowly or not at all,
the CLAMP relief cartridge may be faulty or need
adjustment.
• While opening, if arms move slowly or not at all,
the OPEN relief cartridge may be faulty or need
adjustment. Replace or adjust cartridge(s).
• If arms move unequally, the flow divider cartridge
(80G–140G) or equalizer cartridge (170G) cartridge
may be faulty. Replace cartridge. Refer to
Section 4.3.
WARNING: Before removing hydraulic
lines or components, relieve pressure in the
hydraulic system. Turn truck off and open
the truck auxiliary control valve(s) several
times in both directions.
2Flow Meter on
CL circuit
Model Maximum
80G-140G
Low Pressure 1455 psi (100 bar)
High Pressure 2760 psi (190 bar)
170G 2465 psi (170 bar)

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ROUBLESHOOTING
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6828871-R1 EN
CL4999.eps
CL6288.eps
CLAMP
Check Valve
CLAMP
Check Valve
OPEN Check
Valve
OPEN Check
Valve
CLAMP Relief
CLAMP Relief
CLAMP Relief
OPEN Relief
OPEN Relief
OPEN
Relief
Equalizer
CLAMP Supply
CLAMP Supply
CLAMP Supply
Flow Divider/
Combiner
Flow Divider/
Combiner
120G, 140G
& 170G (Current)
Valve
80G & 100G
Valve
170G (Early) Valve
CL4997.eps
3.3-2 Clamp Circuit Test
(Continued)
3 Position the arms to mid-stroke. Turn the truck off and
connect a 5000 psi (345 bar) pressure gauge to the
gauge port on the valve.
4 Start the truck and clamp on a rigid load or clamp force
indicator. Hold the lever in the CLAMP position for a few
seconds.
5 Release the lever and watch the pressure gauge:
• If the pressure drop is less than 140 psi (10 bar)
initially, and additional drop does not exceed 30 psi
(2 bar) per minute, the problem is not hydraulic.
Refer to Section 3.3.
• If the pressure drop is more than 140 psi (10 bar)
initially, and additional drop exceeds 30 psi (2 bar)
per minute, the CLAMP check valve cartridge may be
faulty. Replace the cartridge. Refer to Section 4.3.
NOTE: 170G (Early) Valves – The OPEN check may
be faulty. Replace cartridge. Refer to Section 4.3.
6 Fully close the arms. Hold the lever in the CLAMP
position for a few seconds. If the pressure still drops
(refer to step 5), one of the cylinders is faulty and must
be serviced. Refer to Section 4.4.
3Pressure gauge on
valve gauge port
4
Front View
CLAMP Check Valve
Adjustable
Compensation
Relief Valve

ROUBLESHOOTING
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6828871-R1 EN
CL5088.eps
3.4 Sideshift Function
There are six potential problems that could affect the
sideshift function:
• Incorrect load handling. Refer to the Operator’s Guide
for suggested procedures.
• Incorrect hydraulic pressure or flow from the lift truck.
• External leaks.
• Defective solenoid coil or valve (if equipped).
• Worn or defective cartridge valves or cylinder seals.
• Bent or damaged arms, frames or bearing.
WARNING: Before removing hydraulic
lines or components, relieve pressure in the
hydraulic system. Turn truck off and open
the truck auxiliary control valve(s) several
times in both directions.
2Flow Meter
on SS Circuit
Back (Driver's) View
3.4-1 Supply Circuit Test
1 Check the pressure supplied by the truck at the carriage
hose terminal. Pressure must be within the range shown
in Specifications, Section 5.1. See nameplate on the
attachment and sticker on valve. PRESSURE TO THE
ATTACHMENT MUST NOT EXCEED:
2 Check the flow volume at the carriage hose terminal.
Flow must be within the range shown in Specifications,
Section 5.1.
3 Fully sideshift left or right. Hold the lever in the
SIDESHIFT position for a few seconds. Release the
lever. Check for external leaks at fittings, hoses, and
valve.
Model Maximum
80G-140G
Low Pressure 1455 psi (100 bar)
High Pressure 2760 psi (190 bar)
170G 2465 psi (170 bar)

10
ROUBLESHOOTING
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6828871-R1 EN
CL5075.eps
Front View
2
NOTE: Perform CLAMP circuit test first to make sure
cylinders are operating properly. Refer to Section 3.3-2.
1 Solenoid equipped – Press the solenoid button. Listen
for a 'click' at the solenoid valve. If no sound is heard,
check fuse, wiring and coil. Make sure that the valve is
not jammed. Refer to Section 4.5.
IMPORTANT: Solenoid-operated valves must be
plumbed so that the solenoid is not energized during
the SIDESHIFT function.
2 Clamp a maximum load. Sideshift LEFT and RIGHT
observing sideshifting movement:
• For each direction, if there is little or no movement,
adjust SSL (or SSR) relief clockwise (CW) until
attachment sideshifts. Then adjust counterclockwise
(CCW) 1/4 turn increments until sideshift speed
slows (relief opening). Finish by adjusting cartridge
clockwise (CW) 1/4 turn.
• If the attachment will not sideshift after attempted
relief adjustment, go to Step 3.
3 120G, 140G & 170G (Current) – Remove the setscrew
(4 mm allen socket) and equalization plug located in the
port on top of the valve, as shown. Re-adjust SSL and
SSR relief per Step 2.
4 If the attachment sideshifts at the proper speed in
one direction but not the other, the SSL and SSR relief
setting can be assumed OK, but the SSL or SSR check
valve may be faulty. Swap or replace check valve
cartridge(s).
• If the attachment still sideshifts improperly in one or
both directions, problem is not hydraulic. Refer to
Section 3.4.
3.4-2 Sideshift Circuit Test
CLAMP CLAMP
OPEN
OPEN
SSL
SSR
CL5000.eps
SSL
Check
Valve
SSR
Check
Valve
SSL Relief
SS Relief
SSL Relief
SSR Relief
Setscrew
Setscrew
SSR Relief
SIDESHIFT
Supply Hoses
SIDESHIFT
Supply
Hoses
SIDESHIFT
Supply Hoses
Orifice
Orifice
SSL
SSR
CLAMP GAGE CL CHK
SS RLF
FD ADJUST
BH REL
SS ORIFICE
OPEN GAGE
CL6289.eps
120G, 140G
& 170G (Current)
Valve
80G & 100G
Valve
170G (Early) Valve

ROUBLESHOOTING
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6828871-R1 EN
CL0258.eps
CL0257.eps
7.5 Amp
Fuse
White
Knob Button
(Normally
Open)
Black
Diode Solenoid Coil
Control Lever Knob
with Pushbutton
7.5 Amp
Fuse
White Black
Diode
User supplied wire Solenoid Coil
3.5 Electrical Circuit
(Solenoid-equipped attachments)
Use the schematic shown and follow the steps below.
1 Check the control knob circuit fuse. Replace if
necessary.
2 Check for loose electrical connections at the truck
ignition switch, control knob button, solenoid coil
terminals and diode.
3 Remove the diode from the solenoid coil terminal. Test
with an ohmmeter for high resistance in one direction
and no resistance in the other direction. If there is no
resistance in both directions, replace the diode.
NOTE: When replacing the diode, the banded (+) end
must be connected to the coil and wiring as shown.
4 Use a voltmeter to determine if correct voltage is present
at the electrical leads when the button is pressed.
• If there is no voltage to the solenoid, troubleshoot the
electrical circuit for shorts or open circuits.
• If there is insufficient voltage to the solenoid, check
the circuit for excessive voltage drop.
• If there is sufficient voltage to the solenoid, test for
coil continuity. Continue to Step 5.
5 Test the coil continuity by placing an ohmmeter test lead
on each solenoid coil terminal (ohmmeter on Rx1 scale).
• If there is an ohmmeter reading, the coil is good.
• If the coil is good, but the solenoid does not
'click' when the control knob button is pressed,
the solenoid cartridge may be jammed. Refer to
Section 4.5.
• If there is no ohmmeter reading, the coil is defective
and should be replaced. Refer to Section 4.5.

ERVICE
S
12 6828871-R1 EN
CL5074.eps
ADJUST
CL5002.eps
4.1 Attachment Removal
1 Position the attachment arms to frame width.
WARNING: Before removing hydraulic
lines, relieve pressure in the hydraulic
system. Turn the truck off and open the
truck auxiliary control valves several times
in both directions.
2 Disconnect and plug the hydraulic supply hoses to the
attachment. Tag hoses for reassembly.
3 Remove the capscrews and lower mounting hooks.
For reassembly, tap the hooks tight against the carriage
bar and tighten the capscrews to:
CL III – 165 ft.-lbs. (225 Nm)
CL IV – 320 ft.-lbs. (435 Nm)
4 Lower the attachment onto a pallet. Tilt the mast
forward and lower the carriage to disengage the upper
hooks.
5 For attachment installation, reverse the above
procedures. For complete installation procedure, refer
to Installation Instructions 6526543.
Sideshift Left
Sideshift Right Clamp
Open
2 2
4
3Lower Carriage Bar
LH Lower Hook
High Strength
Washer, Capscrew
BOLT-ON LOWER HOOKS

ERVICE
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6828871-R1 EN
CL4991.eps
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.
4 Attach an overhead hoist to the arm assembly. Position
the chain clear of the arm bearing surfaces.
CAUTION: Use a second chain and eyebolt or C-clamp
on the contact pads to stabilize the arms.
5 Slide the arm assembly out of the frame. Do not
damage the bearings when removing the arm.
6 For reassembly, reverse the above procedures with the
following exceptions:
• Cascade recommends upgrading cylinders with
spherical end caps to the latest spherical nut. Refer
to Installation Instructions 6818485.
• Inspect the upper and lower bearings for wear.
Bearing thickness should not be less than 0.06 in.
(1.5 mm) on any part of the bearing. Install new
bearings as a complete set as required.
• Lubricate the bearing portion of the arm bars with a
thin film of chassis grease.
• Spherical End Nuts – Lubricate the cylinder rod
threads, nut threads and spherical portion of the nut
with wheel bearing grease. Install hex washer on the
rod end with the beveled side facing the arm lug.
4.2 Arms
4.2-1 Arm Assemblies –
Removal and Installation
The following procedures can be performed with the
attachment mounted on the truck.
1 Position the arms to frame width and lower the
attachment arms 0.50 in. (13 mm) above the floor.
2 Spherical End Cap – Remove capscrews and cap from
cylinder rod to the arm lug. Remove split ring keepers.
For reassembly, tighten the end cap capscrews to
80 ft.-lbs. (110 Nm).
Spherical End Nuts – Remove the cotter pin, locking
cap and nut retaining the cylinder rod to the arm lug.
For reassembly, tighten nut to:
80G, 100G – 310 ft.-lbs. (420 Nm)
120G–170G – 250 ft.-lbs. (340 Nm)
To prevent the rod from turning by using a wrench on
the hex washer. Tighten against hex washer. Nut will
not be tight against the arm lug.
3 Fully retract the cylinder rods.
6
2
3
6
4
Arm
Bearings
Cylinder
Rod
C-Clamp
Cap
Spherical
Nut
Arm Lug
Spherical
End Nut
Hex Washer
Beveled Side
Facing Lug
CL5003.eps
Spherical
End Cap
Nut

ERVICE
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14 6828871-R1 EN
4.2-2 Custom Arm Bases (80G – 120G)
Attachments without arms are supplied with two arm
bases. Special forks can be welded directly to the arm
bases or they can be used as a base to fabricate custom
built arms.
CAUTION: Weld fabricated arms to the arm bases only.
do not weld or bolt special built arms or forks directly to
the arm bars.
The arm base material is AISI C-1020 HR with the following
specifications:
• TENSILE STRENGTH – 61,000 psi (420 mPa min.)
• YIELD STRENGTH – 43,000 psi (300 mPa min.)
• CARBON CONTENT – 23% max.
CAUTION: The surface flatness of the arm base must
remain within 0.010 in. (0.25 mm) in capscrew area and
arm must slide manually.
WARNING: Cascade requires that a
qualified or certified welder experienced
in this type of fabrication be used for best
quality.
1 Fasten the arm bases to the arm bars. Tighten the
capscrews to 680 ft-lbs. (924 Nm) with a drive extension
tool 676218 (0.75 in., 19 mm), required to clear the arm
bar.
IMPORTANT: Be careful not to damage the arm bar.
Premature bearing failure will occur.
Drive extension tool dimensions are provided to
fabricate the tool from an Allen wrench. Do not use mild
steel hex stock which will not withstand the torque value
required.
2 Lubricate the cylinder rod threads, nut threads and
spherical portion of the nut with wheel bearing grease.
3 Install the hex washer on the rod end with the beveled
side facing the lug.
4 Engage the rod end into the lug.
5 Tighten the rod end nut to a torque of:
80G, 100G – 310 ft.-lbs. (420 Nm)
120G – 250 ft.-lbs. (340 Nm)
6 Install the locking cap and cotter pin.
7 Lubricate the bearing portion of the arm bars with a thin
film of chassis grease, if required.
6 2 4
3 1 5
CL1520.eps
Capscrew
Tightening
Sequence
CL2532.eps
Drive Adapter
Arm Bar
Arm Base
1
CL0456.eps
A
HEX BC
D
6.3
Model ABCD
80G–120G 0.75 in.
(19 mm)
0.5 in.
(13 mm)
0.75 in.
(19 mm)
5.0 in.
(127 mm)

ERVICE
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6828871-R1 EN
CL4992.eps
4.2-3 Arm Bearings –
Removal and Installation
NOTE: Replace all arm bearings if wear exceeds 0.06 in.
(1.5 mm) thickness on any surface. Arms must be removed
to install new bearings as follows:
1 Remove attachment arms as shown in Section 4.2-1.
2 If equipped, remove capscrews with M10 allen wrench.
For reassembly, tighten capscrew to 24 ft.-lbs. (32 Nm).
3 Remove the bearing retainer plugs using a 40 mm OD
large washer and one of the following:
80G, 100G – M8 x 80L capscrew
120G, 140G – M10 x 80L capscrew
170G – M12 x 80L capscrew
4 Drive new bearings into the frame, displacing the old
bearing.
5 For reassembly, reverse the above procedures with the
following exceptions:
• Install new retainer plugs by using tool capscrew to
drive plug in. Make sure bearing retainer plugs are an
interference (tight) fit in the frames.
NOTE: Use small amount of
grease to ease installation. Bearing
Retainer
Plugs
Arm Bearing
If equipped, remove capscrew
4
3
2
5
Frame Bearing
Retainer Plug
Arm
Bearings
Turn nut washer CW to extract plug
Capscrew:
80G, 100G – M8 x 80L
120G, 140G – M10 x 80L
170G – M12 x 80L
40 mm OD Large Washer
REMOVAL
INSTALLATION

ERVICE
S
16 6828871-R1 EN
CL4993.eps
The following procedures can be performed with the
attachment mounted on the truck:
1 Raise the attachment 2 ft. (60 cm) so the valve is
accessible from behind. Do not reach or work through
the mast.
2 Remove valve guards or bumpers (if equipped).
WARNING: Before removing hydraulic
components, relieve pressure in the
hydraulic system. Turn the truck off and
move the auxiliary control valves several
times in both directions.
3 Disconnect all hydraulic supply hoses and cylinder
tubing at the Valve. Plug the hose/tubing ends and tag
for reassembly.
4 Remove the capscrews fastening the valve to the
attachment and remove the valve. For reassembly,
tighten the capscrews to:
80G, 100G – 14 ft.-lbs. (19 Nm)
120G, 140G – 6 ft.-lbs. (8 Nm)
170G – 30 ft.-lbs. (40 Nm)
5 For reassembly, reverse the above procedures with the
following exceptions:
• Service the valve as described in Section 4.3-2.
• Make sure all flareless hydraulic connections are
assembled using new seals.
• If required, adjust relief cartridges as described in
Section 4.3-3 (80G–140G) or 4.3-4 (170G).
4.3 Valve
4.3-1 Valve Removal and Installation
3
4
5
Supply Hoses,
Tubing to Cylinders
Capscrews
Rear Mounted
Valve

ERVICE
S
17
6828871-R1 EN
4.3-2 Valve Service
IMPORTANT: Service the valve in a clean work area.
Service procedures are the same for all valves:
1 Remove the valve from the attachment as described in
Section 4.3-1.
2 Remove the cartridges from the valve.
3 Remove the remaining threaded plugs and fittings.
Valve body must be completely stripped for proper
cleaning. Refer to illustrations on following page.
4 Remove the O-rings and back-up rings from the
cartridges.
5 Clean all parts with cleaning solvent.
6038929
CKCB-XCN
Sun
210377
CL2686.eps
CL2687.eps
210266
6034595
DFD
Deltrol
CL0341.eps
O-Rings O-Rings
Back-Up Rings Back-Up Rings
A B
PO Check Valve Cartridge PO Check Valve Cartridge
O-Rings
Back-Up
Rings
CAdjustable Relief Cartridge
O-Rings
Back-Up Rings
DFlow Divider / Combiner Cartridge
Back-Up Rings Back-Up Rings
E FRelief Cartridge Check Valve
O-Rings O-Rings O-Rings
6 For reassembly, reverse the above procedures with the
following exceptions:
• Replace O-rings and back-up rings on cartridges as
shown in illustration below.
• Lubricate cartridges, fittings and plugs with O-ring
lube or petroleum jelly prior to installation.
CAUTION: Make sure cartridges are installed in correct
port location in valve body. Refer to the illustrations on
following pages and stampings on valve body.
RC0454.eps
6038929
CKCB-XCN
Sun
RC2519.eps
GA0057.eps

ERVICE
S
18 6828871-R1 EN
SSL
SSR
CLAMP GAGE CL CHK
SS RLF
FD ADJUST
BH REL
SS ORIFICE
OPen GAGE
CL6290.eps
4.3-2 Valve Service (Continued)
PO Check Valve –
OPEN
PO Check Valve –
OPEN
PO Check Valve –
CLAMP
B
B
A
DFlow Divider/
Combiner
Adjustable Relief
Cartridge –
Sideshift Relief
Adjustable Relief Cartridge –
Flow Divider
Adjustable Relief
Valve – CLAMP
Adjustable Relief
Valve – OPEN
C
C
C
C
Body
Plug
Plug
Cylinder
Connection
Fittings
Test Port
"OPEN"
Test Port
"CLAMP"
80G & 100G Models
Setscrew
Orifice
Reference: 6862870-R1