cascade corporation G Series User manual

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corporation
Cascade is a Registered Trademark of Cascade Corporation
NSTALLATION INSTRUCTIONS
Iand PERIODIC MAINTENANCE
G-Series
Non-Revolving Clamps
Includes:
Non-Sideshifting Clamps,
Sideshifting Clamps,
Fork Positioners,
Independent Arm/Fork Control,
Carton Clamps &
White Goods Clamps
Number 6033701-R9 EN
Original Instructions

i6033701-R9 EN
i
CONTENTS
This manual provides instructions for installing Cascade
G-Series Non-Revolving Sliding Arm Clamps. Follow the
suggested installation procedures for best results. If you have
any questions or need more information, contact your nearest
Cascade Service Department for assistance (see back cover).
Read the WARNING Statements placed throughout this manual
to emphasize safety during attachment installation.
IMPORTANT: Field alterations may impair performance
or capability and could result in loss of warranty. Consult
Cascade for any required modifications.
Recommended Hydraulic Supply 1
Truck Requirements 2
Installation 3
Attachments without Arms 11
Contact Pad Extension – Carton Clamps 12
Load Troubleshooting – Carton Clamps 13
Adjusting Pad Camber – Carton Clamps
Standard (Shimmed) Design 15
Flexible (ADJUSTA-BLOCK) Design 16
Periodic Maintenance
General 17
Attachments with External Sideshift 18
Carton Clamp Attachments 19
Nameplate Icons 20
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.

1
6033701-R9 EN
RECOMMENDED HYDRAULIC SUPPLY
GA0033.eps
G-Series Non-Revolving Sliding Arm 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 (or FORK POSITION)
and SIDESHIFT functions should be at least M8 with a
minimum internal diameter of 7 mm.
Non-Sideshifting
A or B
RH or LH THINLINE™ 2-port hose reel group.
OR
C Mast single internal hose reeving group.
Sideshifting
A and B
RH and LH THINLINE™ 2-port hose reel groups.
OR
C Mast double internal hose reeving group.
Sideshifting with Solenoid
A 6-N-1 cable/hose reel group.
OR
A and C
Cable reel and single internal hose reeving group.
Independent Arm/Fork Control
A and B
RH and LH THINLINE™ 2-port hose reel groups.
OR
C Mast double internal hose reeving group.
B
A
C

26033701-R9 EN
TRUCK REQUIREMENTS
GA0390.eps
A
GA0082.eps
Carriage
Clean carriage bars and inspect
carriage bars. Make sure the bars
are parallel and that ends are flush.
Repair any damaged notches.
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.
Clamp
(or Close)
Sideshift
Right
Hoist Up
Auxiliary Valve Functions
Check for compliance with ISO standards:
Tilt Back
Hoist Down
Sideshift
Left
Tilt
Forward
Release
(or Open)
Truck Relief Setting (see attachment nameplate)
Low Pressure High Pressure
155 bar 190 bar - Recommended
189 bar 250 bar - Maximum
NOTE: The attachment valve has separate pressure
relief control, see Installation Step 11 for adjustment.
Truck Flow Volume ➀
Min. ➁Recommended Max. ➂
12G thru 64G 19 L/min. 28 L/min. 56 L/min.
70G, 77G 26 L/min. 45 L/min. 75 L/min.
➀Cascade Non-Revolving Clamps are compatible with SAE 10W
petroleum base hydraulic fluid meeting Mil. Spec. MIL-0-5606
or MIL-0-2104B. Use of synthetic or aqueous base hydraulic
fluid is not recommended. If fire resistant hydraulic fluid is
required, special seals must be used. Contact Cascade.
➁Flow less than recommended will result in reduced system
performance.
➂Flow greater than maximum can result in excessive heating,
reduced system performance and short hydraulic system life.
Carriage Mount Dimension (A) ISO
Minimum Maximum
Class II
Class III
Class IV
380.0 mm
474.5 mm
595.5 mm
381.0 mm
476.0 mm
597.0 mm

3
INSTALLATION
6033701-R9 EN
WARNING: Verify that the overhead
hoist and chains or straps are rated for
the weight of the attachment. Refer to
nameplate for attachment weight.
CL2795.eps
cascade
®
C-675514-1
CL0097.eps
A
B
B
A
A
Follow the steps shown to install the attachment on the
truck. Read and understand all WARNING and CAUTION
statements. If you don't understand a procedure,
ask a supervisor, or call the nearest Cascade Service
Department for assistance.
Unlock quick-change lower
mounting hooks
ARemove pin and drop hooks into unlocked
position.
BRe-install pin in lower hole.
Attach overhead hoist
ARemove banding, use multiple chains
to stabilize the attachment while lifting.
Set the attachment upright on pallet.
BRemove bolt-on lower mounting hooks
(if equipped).
Pin
LH Lower
Hook
NOTE: Guides can be reversed to
change hook-to-carriage clearance.
Refer to lower hook installation, Step 6.
Guide
16 mm offset
on top provides
max. hook
clearance.
2
1
Tighten capscrews to:
CL II, CL III – 225 Nm
CL IV – 435 Nm

4
INSTALLATION
6033701-R9 EN
CL6896.eps
CL3021.eps
CL2794.eps
CL2789.eps
CL2755.eps
Prepare Hoses
A Determine hose lengths required for
hydraulic supply configuration of truck.
BCut hoses to length and install end
fittings, or use hose kits supplied.
Non-Sideshifting – Single Hose Reel
IMPORTANT: Valve options include LH or RH supply
porting for Clamp and Sideshift. External sideshifter
has top center location porting suitable for both LH or
RH supply connections.
Open
Open
Sideshift Left
Sideshift Right Clamp (or Close) Clamp (or Close)
Clamp (or Close)
Clamp (or Close)
RH CLAMP (or FORK POSITION), LH SIDESHIFT Ports
RH CLAMP(or FORK POSITION) Ports
Sideshifting – Double Internal Hose Reeving
Sideshifting – Double Hose Reels
Open Sideshift Left
Sideshift Right
LH CLAMP (or FORK POSITION), RH SIDESHIFT Ports
EXTERNAL SIDESHIFTER-EQUIPPED
INDEPENDENT ARM CONTROL CLAMP
3
CL3378.eps
Back (Driver's) Views
External Sideshifting Clamp – Double Hose Reels
Independent Arm – Double Hose Reels Double Internal Hose Reeving
SSL / Open
(TANK Port)
SSR / Clamp
(or Close)
(PRESSURE
Port)
Solenoid Cable
Sideshifting with Solenoid – 6-N-1 Cable/Hose Reel
Open
Left Arm
Close
Right Arm
Close
Sideshift Left
Left Arm
Open
Sideshift Right
SOLENOID-EQUIPPED RH or LH CLAMP
(or FORK POSITION) Ports
Right Arm
Open
CL6901.eps
Left Arm
Close
Right Arm
Close
Left Arm
Open
Right Arm
Open

5
INSTALLATION
6033701-R9 EN
GA0092.eps
Flush hydraulic supply hoses
AInstall hoses using union fittings.
B Operate auxiliary valves for 30 sec.
CRemove union fittings.
4
CL2787.eps
CL2786.eps
CL0242.eps
5Mount attachment on truck carriage
A Center truck behind the attachment.
B Tilt forward and raise carriage into position.
C Engage upper mounting hooks with upper
carriage bar. Make sure a centering tab or
hook tab engages a notch on the carriage bar.
Refer to the illustration below.
D Lift the clamp 5 cm above pallet.
ITA Class II – 15–17 mm
ITA Class III – 18–20 mm
Truck
Carriage
Engage
Notch
ITA Class II – 8–9 mm
ITA Class III – 10–11 mm
Centering Tabs
Upper Hook Tab
(44G CL3 Only)
External
Sideshifter
A
B

6
INSTALLATION
6033701-R9 EN
ADJUST
GA0370.eps
cascade
®
C-675514-1
GA0371.eps
Install and engage lower hooks
BOLT-ON TYPE
w/ INTERNAL
SIDESHIFTING
QUICK-CHANGE TYPE
Inspect hooks for
excessive clearance.
To reverse guides to
change clearance,
refer to Step 2.
Lower
Carriage
Bar
Slide hook
up to engage
bar, install pin
in upper hole
(locked.) 5 mm
Max.
Tap tight into
position.
1.5 to 5 mm Max.
IMPORTANT: Adjust
lower hooks for
operating clearance.
Lower
Carriage
Bar
BOLT-ON TYPE
w/ EXTERNAL
SIDESHIFTING
6
Tighten capscrews to:
Bolt-On Hooks
CL II – 165 Nm
CL III – 225 Nm
CL IV – 435 Nm
Bolt-On with External Sideshifter
CL II, CL III – 165 Nm
CL IV – 435 Nm
CL2791.eps CL3407.eps
Connect hoses prepared in
Step 3 to attachment
Internal Hose Reeving Hydraulic Supply Hose Reels Hydraulic Supply (External Sideshifter)
7

7
INSTALLATION
6033701-R9 EN
CL0258.eps
CL0257.eps
9Install wiring –
(solenoid-equipped units)
Solenoid Coil
User-supplied wire
7.5-Amp Fuse
White Black
7.5-Amp Fuse White Black
Solenoid Coil
Diode
Diode
Knob Button
(Normally
Open)
Control Lever Knob
with Pushbutton
SIDESHIFT
PRESS
BUTTON
TO CLAMP
CL2785.eps
AC0898.eps
8Install solenoid control knob or
pushbutton switch (solenoid-equipped)
Button
toward
driver
Adapter
Nut
ID Plate
Snap Ring
60 mm
Typical
NOTE: Shrink tubing
may be removed around
button as desired.
Pushbutton
Switch
Foam Tape
Heat Shrink Tubing

8
INSTALLATION
6033701-R9 EN
BD
C
A
GA0005.eps
CL2477.eps
CL2478.eps
CL2478.eps
CL2479.eps
CL2479.eps
WARNING: Make sure all personnel
are clear of the clamp during testing.
10
NON-SIDESHIFTING CLAMPS
A Release Arms
B Clamp Arms
C (not used)
D (not used)
SIDESHIFTING CLAMPS
A Sideshift Left
B Sideshift Right
C Release Arms
D Clamp Arms
B
C
A
D
BD
C
C
A
A
A
B
Cycle attachment functions
•With no load, cycle CLAMP (or FORK POSITION)
function and SIDESHIFT function several times.
Check for equal arm movement and adequate
arm speed.
•Clamp and lift a maximum load. Sideshift left
and right.
•For Fork Positioning, open and close forks
several times. Check for adequate opening and
closing speeds.
• Check for operation in accordance with ISO
standards.
IMPORTANT: If necessary, adjust relief
valve cartridges and/or open internal CL line
equalization orifice. Refer to Step 11.
• Check for leaks at fittings, valve, manifold and
cylinders.
Tilt Forward
AUXILIARY VALVE
FUNCTIONS
Tilt Back
A
B
C
A
C
A
D
B
SIDESHIFTING FORK POSITIONER
A Sideshift Left
B Sideshift Right
C Open/Spread Forks
D Close Forks
INDEPENDENT ARM CONTROL
A Open Right Arm
B Close Right Arm
C Open Left Arm
D Close Left Arm
Hoist Down
Hoist Up
WARNING: Truck control handle
and attachment function activation
shown here conforms to ISO 3691
recommended practices. Failure
to follow these practices may lead
to serious bodily injury or property
damage. End user, dealer and
OEMs should review any deviation
from the practices for safe operation.
CL3270.eps
SIDESHIFTING CLAMPS WITH
SOLENOID VALVE
A Sideshift Left
A Release Arms
(press knob button)
BSideshift Right
BClamp Arms
(press knob button)
BA
BA
A
FORK POSITIONER
A Spread Forks
B Close Forks
C (not used)
D (not used)