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)

9
INSTALLATION
6033701-R9 EN
CL
CL3915.eps
CL
G
CL3916.eps
WARNING: Before removing hydraulic
lines or components, relieve pressure
in the hydraulic system. Turn the truck
off and open the truck auxiliary control
valves several times in both directions.
Clamp
Supply
Clamp
Relief
Cartridge
D
B
Sideshift
Supply
Adjust Relief Cartridges
To avoid over clamping or slow sideshifting speed,
relief cartridges should be adjusted to ensure correct
settings. Check the nameplate and decal on the valve for
correct CLAMP hydraulic pressure settings.
NOTE 1: Attachments used for fork positioning requires no
CLAMP relief adjustment. Contact Cascade before making
any adjustments.
NOTE 2: External SS function has no relief adjustment.
Clamp Relief Adjustment
AConfirm that TRUCK pressure delivered to the
attachment valve is within the range shown on the
attachment nameplate.
Low Pressure High Pressure
155 bar 190 bar Rec.
189 bar 250 bar Max.
B Install a 345 bar pressure gauge (with a No. 4 O-ring
fitting) to the valve TEST port (location varies).
CFrom fully open, close arms at normal speed to clamp
a rigid load (or clamp force indicator). Release truck
handle and read pressure gauge.
DAdjust the valve CLAMP relief cartridge to show a
maximum setting (see valve decal) of:
Low Pressure High Pressure
155 bar 190 bar Max.
Turn clockwise (CW) to increase pressure, counterclockwise
(CCW) to decrease pressure. Tighten the jam nut.
ERepeat steps C and D to confirm setting.
VALVE USED WITH
EXTERNAL SIDESHIFTER
SIDESHIFTING VALVE
RH CLAMP Ports
SIDESHIFTING VALVE
LH CLAMP Ports
Front of
Attachment
NON-SIDESHIFT VALVE
RH CLAMP Ports
11
B
D
D
D
Increase
Pressure
(CW)
Decrease
Pressure
(CCW)
Clamp
Relief
Cartridge
Clamp
Supply
Decrease
Pressure
(CCW)
Increase
Pressure
(CW)
Clamp
Relief
Cartridge
D
Clamp
Relief
Cartridge
Clamp
Supply
Clamp
Supply
Sideshift
Supply

10
INSTALLATION
6033701-R9 EN
OR
SS
G
CL
CL6637.eps
B
D
Sideshift
Relief
Cartridge
Sideshift
Supply
B
Increase
(CW)
Decrease
(CCW)
Sideshift Relief Adjustment (internal SS only)
A Clamp a maximum load and sideshift LEFT and RIGHT
observing sideshifting movement.
B If the attachment will not sideshift or sideshifts slowly,
adjust SIDESHIFT relief clockwise (CW) until the
attachment sideshifts. Then, adjust the relief cartridge
counterclockwise (CCW) in 1/4 turn increments until
sideshift speed slows (relief opening). Finish by
adjusting cartridge clockwise (CW) 1/4 turn. Tighten
jam nut.
CLAMP
Supply
SIDESHIFTING VALVE
RH CLAMP Ports
SIDESHIFTING VALVE
LH CLAMP Ports
SIESHIFT
Supply
Front of
Attachment
Clamp
Supply
Adjust Relief Cartridges (continued)
Clamp Relief Adjustment – Clamp Force Method
(Carton Clamp Attachments only)
A Cascade 4-Point Force Distribution Tester is required for
this procedure.
A Extend the arms to the most common load width.
Lower the contact pads to just above the floor.
B Position the tester between the contact pads. Adjust
the tester's spindle locations to be perpendicular to the
contact pad surfaces and to the desired position based
on the type of product being handled.
C Set the truck clamp circuit to the approximate pressure
for the required clamp force on the load.
D Clamp on the tester and hold activated for 5 seconds.
E The tester will display clamp force and percentage of
clamp force for each spindle location and total clamp
force (sum of force of the four spindles).
F Adjust the truck clamp circuit pressure to the required
total clamp force for the load.
AC2961.eps

11
6033701-R9 EN
ATTACHMENTS WITHOUT ARMS
CL2532.eps
CL2624.eps
CL0456.eps
Model A B C D
20G
28G 14 mm 13 mm 11.3 mm 90 mm
36G
44G
52G
64G
70G
77G
17 mm 13 mm 14.5 mm 90 mm
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 – 420 mPa min.
• YIELD STRENGTH – 300 mPa min.
• CARBON CONTENT – 23% max.
CAUTION: The surface flatness of the arm base must
remain within 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.
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.
1Fasten the arm bases to the arm bars. Tighten the
capscrews to the torque values indicated below with
a drive extension tool*, required to clear the arm bar:
20G, 28G – 275 Nm
36G, 44G, 52G – 535 Nm
64G, 70G, 77G – 585 Nm
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.
2Place the rod ends on the cylinder rods. Install the split
ring keepers.
3Install the anchor bar through the cylinder rod end
and fasten to the arm anchor. Tighten the anchor bar
capscrews as follows:
Standard Attachments
20G – 63 Nm
28G, 36G – 90 Nm
44G, 52G, 64G, 70G, 77G – 225 Nm
Attachments with External Sideshift
20G – 63 Nm
28G, 36G – 90 Nm
44G – 274 Nm
52G, 64G, 70G, 77G – 225 Nm
ABC
D
63
Arm Bar
Arm Base
Drive Adapter
Hex
*Cascade Drive Extension Tool Part Numbers:
6040284 (14 mm hex), 6040285 (17 mm hex).
1
2
3
Split
Ring
Keepers

12 6033701-R9 EN
CONTACT PAD EXTENSION
CARTON CLAMPS
CL5658.eps
Attachments supplied with contact pad extensions are
installed as follows:
1Install pivot block to contact pad. Tighten capscrews
to 90 Nm.
2Loosen lever on pivot block. Position the lever to the
front face of the pivot block.
3Insert the lower lock plate into the pad extension.
4Install pad extension to contact pad. Tighten
capscrews to 90 Nm. The pad extension lock flange
should be flush with the top of the pivot block.
5Position the lever to the top face of the pad extension
lock flange.
6Adjust the lock lever to firmly clamp the lock flange to
the pivot block when in the lock position.
7Fully lock the lever by positioning the lever in the
downward position.
NOTE: The face of the pad extension should be flush with
the contact pad surface. Shim as required.
CL5645.eps
4
6
7
4
3
1
2
5
Shim
Pad Extension
Contact Pad
Lever
Pivot Block
Pad Extension
Lock Flange
Lower
Lock
Plate
NOTE: If the pad extension
assembly is removed, install
the lower lock plate with the
pivot block.

13
6033701-R9 EN
LOAD TROUBLESHOOTING
CARTON CLAMPS
CL2503.eps
CL2504.eps
IF FRONT STACK OF LOAD TILTS OUT:
Re-clamp
load against
backrest
Check for bent
pads, straighten
or replace
Check for bent
stabilizers,
straighten or
replace
Position center
of load between
pad pivot and
backrest
IF LOWER TIER OF LOAD BRIDGES
DOWN OR SLIDES OUT:
Check for bent
pads, straighten
or replace
Check
hydraulics for
low supply
pressure
Add or increase
positive camber
(Contact Cascade
Service)
Re-clamp load
so bottom edge
is even with
bottom of pads
Check for worn
lower surfaces,
rotate pads 180 °
and exchange
sides or replace
1
2
3
4
1
2
3
4
5

14 6033701-R9 EN
LOAD TROUBLESHOOTING
CARTON CLAMPS
CL2505.eps
CANNED / BOTTLED / DENSE CASE GOODS Neutral to positive
SOFT CASE GOODS Neutral to Negative
APPLIANCE / LARGE CASE GOODS Neutral to Negative
UNKNOWN LOADS
Start with neutral, look for
creases and adjust camber
as required.
IF LOWER TIER OF LOAD IS
CREASED:
Re-clamp load
so bottom edge
is even with bot-
tom of pads
Check for bent
pads, straighten
or replace
Check
hydraulics for
high supply
pressure
Add or increase
negative camber
(Contact Cascade
Service)
Re-clamp load
squarely
between pads
1
2
3
4
5
CL0093.eps
TYPICAL PAD CAMBER FOR HANDLING CARTON CASE LOADS

15
6033701-R9 EN
CL2802.eps
CL0556.ill
The following procedure is performed on attachments with
standard (shimmed) design for contact pad and stabilizer.
This procedure can be performed with the arms in place
and the attachment mounted on the truck. A Cascade
4-Point Force Distribution Tester can also be used to verify
the clamp force over the contact pad surface.
1 Extend the arms to frame width. Lower the contact
pads so that they just touch the floor.
2 Without Tester – Measure the distance between the
pads in two places: at the bottom center (in-line with the
pivot pins) and 73 cm above the pad bottom centers as
shown. The difference between the two measurements
is the pad camber.
With Tester – First, perform Steps 1–5 on the following
page. Then, continue to Step 4 in this procedure.
3 Determine the camber required for the product being
handled. Refer to the Pad Camber Chart found in the
Load Troubleshooting section (page 13).
4 Loosen the contact pad capscrews and nuts.
NOTE: It is not necessary to remove the capscrews
and nuts to insert the shims.
5 Install shims as required.
• Installing shims at the bottom and middle of the pad
to provide positive camber (increase clamp force).
• Installing shims at the top and middle of the pad to
provide negative camber (decrease clamp force).
CAUTION: Use an equal number of shims on each
contact pad. Pad camber must be the same on both
sides of the attachment for proper load handling.
IMPORTANT: If equipped with "U" shims, refer to the
adjustment procedure, Step 7, on the following page.
CL0095.eps
1
2
3
Position contact
pads to frame
width
Positive
Camber
73 mm
Negative
Camber
Measure from
pad centers
STANDARD (SHIMMED) DESIGN
CL5078.eps
"U" Shim
4
4
5
5
5
5
Top Shim
Contact Pad
Pad
Capscrews
and Nuts
Pivot
Arm
Buttom Shim
Pad Stabilizer
Middle Shim
FOR MINIMUM POSITIVE
CAMBER:
FOR MAXIMUM
POSITIVE CAMBER:
Middle Shim:
Long Shim –
One Each, 1.6 mm
"U" Shim –
One Each, 2 Places
1 mm
Middle Shim:
Long Shim –
Two Each, 1.6 mm
"U" Shim –
Two Each, 2 Places
1 mm
Bottom Shim:
Long Shim –
One Each, 3.2 mm
"U" Shim –
One Each, 2 Places
2 mm
Bottom Shim:
Long Shim –
Two Each, 3.2 mm
"U" Shim –
Two Each, 2 Places
2 mm
ADJUSTING PAD CAMBER – CARTON CLAMPS

16 6033701-R9 EN
FLEXIBLE (ADJUSTA-BLOCK) DESIGN
The following procedure is performed on attachments
with flexible (ADJUSTA-BLOCK) design for contact pad
and stabilizer. This procedure can be performed with the
arms in place and the attachment mounted on the truck.
A Cascade 4-Point Force Distribution Tester is required for
this procedure.
IMPORTANT: Clamp circuit pressure should be adjusted,
if required, prior to adjusting the pad camber. Refer to
Installation Step 11 (page 9).
1 Extend the arms to the most common load width.
Lower the contact pads to just above the floor.
2Position the tester between the contact pads. Adjust
the tester spindle locations to be perpendicular to the
contact pad surfaces and to the desired position based
on the type of product being handled.
3Clamp on the tester and hold activated for 5 seconds.
4The tester will display clamp force and percentage of
clamp force for each spindle location and total clamp
force (sum of force of the four spindles).
5Clamp force distribution should be within the desired
percentages and tolerances.
If the tolerance difference is greater than allowable
tolerance difference, the contact pads require pivot
block adjustment. Continue to Step 6 for adjustment.
CL5053.eps
Locking Nut
Capscrew
Collar
8mm
Allen Wrench
ADJUSTA-BLOCK Assembly
6Clamp force distribution can be changed at the
ADJUSTA-BLOCK locations on the right hand contact
pad. Tune as follows:
• Loosen the locking nuts 3 turns. Use an 8 mm allen
wrench to hold the capscrews.
• Adjust the collar using a 32 mm socket. Turn
the collar CW to increase clamp force, CCW to
decrease clamp force. One full turn of the collar is
approximately 2 mm linear travel or 10% of force.
Follow adjustment sequence, Step 7.
AC2961.eps
3
CL5054.eps
3
4
1
2
C
B
A
C
B
A
7Adjustment Sequence –
• Adjust force at location 2to the desired specification.
Validate clamp force with tester and adjust as
required.
• Adjust force at location 4to the desired specification.
Validate clamp force with tester and adjust as
required.
• Adjust force at location 1to the desired specification.
Validate clamp force with tester and adjust as
required.
• Adjust force at location 3to the desired specification.
Validate clamp force with tester and adjust as
required.
IMPORTANT: When adjustments are made in Rows
Aor C, Row Bmust be adjusted by 1/2.
Example 1: If location 2in row Cis increased
by 2 mm, the location above 2in row Bmust be
increased by 1 mm.
Example 2: If location 3 in row A is decreased
by 2 mm, the location below 3in row Bmust be
decreased by 1 mm.
Rows
Locations
RH Pad
ADJUSTING PAD CAMBER – CARTON CLAMPS

17
6033701-R9 EN
PERIODIC MAINTENANCE
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.
CL5701.eps
NOTE: Refer to the following pages for periodic
maintenance specific to attachments with external sideshift
(page 18) and carton clamps attachments (page 18).
Daily Inspection
Prior to each shift of truck operation, complete the following
procedures:
• Check for loose or missing bolts, worn or damaged
supply hoses and hydraulic leaks.
• Inspect cylinder rod ends and anchor bars (or anchor
nuts) for damage.
NOTE: The rod end anchors operate with a loose
clearance and require no lubrication.
• Check for equal arm movement.
• Check decals and nameplate for legibility.
General
Mounting
Plate
Capscrews
Cylinder Rod
End Anchor Bar
(if equipped)
Bolt-On Lower
Mounting Hook
Quick-Change
Lower Mounting
Hook
1000-Hour Maintenance
After each 1000 hours of truck operation, in addition to the
daily inspection, perform the following procedures:
• Inspect arm bearings for wear or damage. If bearings
are worn in any area to less than 1.5 mm thickness,
replace bearings.
• Check lower mounting hooks for engagement
clearance:
Quick-Change Hooks – 5 mm Max.
Bolt-on Hooks – Tight against lower carriage bar
If adjustment is necessary, refer to Installation Step 6.
• Tighten lower bolt-on hook capscrews:
CL II – 165 Nm
CL III – 225 Nm
CL IV – 435 Nm
• Tighten accessible mounting plate capscrews.
Double-torque capscrews by tightening to final torque
value, loosen 1/2 turn, then retighten.
20G – 108 Nm
28G, 36G, 44G – 270 Nm
52G, 64G*, 70G* – 520 Nm
* Applies only to mounting plates not welded.
IMPORTANT: If any capscrews are found loose,
remove attachment from truck and check all mounting
plate and sideshifter mount capscrews for proper torque
values.
• Tighten cylinder rod end anchor bar capscrews.
20G – 63 Nm
28G, 36G – 110 Nm
44G, 52G, 64G – 275 Nm
• Tighten bolt-on fork arm capscrews.
20G, 28G – 275 Nm
36G, 44G, 52G – 535 Nm
64G, 70G, 77G – 585 Nm
CL5703.eps
Upper Arm
Bearings
Lower Arm
Bearings
Cylinder Rod End
Anchor Bar Capscrews
Standard Attachments
Back (Driver's) View
RH Side
(Bale Clamp shown)
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.

18 6033701-R9 EN
PERIODIC MAINTENANCE
CL5702.eps
External Sideshifter
Grease Fittings
Socket Capscrew
Hex Capscrew
External Sideshifter
Lower Bearing
Grease Areas
External Sideshift Cylinder
Mounting Capscrews
Lower Hook
Capscrews
External Sideshifter
Lower Spacer
Capscrews
Type 1
Type 2
External Sideshifting Clamp
Back (Driver's) View
Lower Spacer Types
External Sideshifter
Attachments with
External Sideshift
In addition to (or in place of, where necessary) the periodic
maintenance found in the "General" periodic maintenance
schedule (page 17), perform the following for attachments
with external sideshift equipped:
1000-Hour Maintenance
• Tighten external sideshift cylinder mounting capscrews:
Socket Capscrew (Upper):
20G–36G, 44G (CL II) – 285 Nm
44G (CL III), 52G – 520 Nm
64G, 70G – 445 Nm
Hex Capscrew (Lower):
20G–36G, 44G (CLII) – 235 Nm
44G (CL III), 52G – 520 Nm
64G, 70G – 445 Nm
IMPORTANT: If any capscrews are found loose, remove
attachment from truck and check all sideshifter mount
capscrews for proper torque values.
• Tighten the following accessible mounting plate and
lower spacer capscrews. Double-torque capscrews by
tightening to final torque value, loosen 1/2 turn, then
retighten.
Mounting Plate and Type 1 Lower Spacer:
20G – 108 Nm
28G, 36G, 44G – 270 Nm
52G –435 Nm
Mounting Plate and Type 2 Lower Spacer:
20G – 108 Nm (M12), 225 Nm (M16)
28G, 36G, 44G – 270 Nm
52G – 270 Nm (M16), 520 Nm (M20)
IMPORTANT: If any capscrews are found loose, remove
attachment from truck and check all mounting plate and
lower spacer capscrews for proper torque values.
• Tighten cylinder rod end anchor bar capscrews.
12G-18G (Carton Clamps only)– 225 Nm
20G – 63 Nm
28G, 36G – 90 Nm
44G-70G – 225 Nm
500-Hour Maintenance
• Inspect external sideshifter bearings for wear or
damage. If upper bearings are worn to less than 1.5
mm thickness, replace bearings. If lower bearings are
worn to less than 1.5 mm exposed thickness, replace
bearings.
• Apply general-purpose chassis grease to external
sideshifter upper bearing grease fittings and lower
bearing areas.
• Check lower mounting hooks for engagement clearance
of 1.5 to 5 mm.
• Tighten lower bolt-on hook capscrews:
CL II, CL III – 165 Nm
CL IV – 435 Nm
CL6118.eps
CL6157.eps