Cascade E Series User manual

Cascade is a Registered Trademark of Cascade Corporation
cascadeT
Manual Number 221093
ERVICE MANUAL
E-Series
Revolving Clamps
S

ONTENTS
C
i
Page
INTRODUCTION, Section 1
Introduction, 1.1 1
Special Definitions, 1.2 1
INSTALLATION, Section 2
Truck System Requirements, 2.1 2
Recommended Hydraulic Supply Options, 2.2 3
Revolving Clamp Installation Procedure, 2.3 4
PERIOD MAINTENANCE, Section 3
100-Hour Maintenance, 3.1 10
500-Hour Maintenance, 3.2 10
1000-Hour Maintenance, 3.3 10
TROUBLESHOOTING, Section 4
General Procedures, 4.1 11
Truck System Requirements, 4.1-1 11
Tools Required (metric), 4.1-2 11
Troubleshooting Chart, 4.1-3 11
Plumbing, 4.2 12
Hosing Diagram, 4.2-1 12
Hydraulic Circuit, 4.2-2 13
Clamp Function, 4.3 14
Supply Circuit Test, 4.3-1 14
Clamp Circuit Test, 4.3-2 14
Rotate Function, 4.4 15
Supply Circuit Test, 4.4-1 15
Rotate Circuit Test, 4.4-2 16
Electrical Circuit, 4.5 17
SERVICE, Section 5
Revolving Clamp Removal, 5.1 18
Arms, 5.2 19
Arm Assemblies – Removal and Installation, 5.2-1 19
Drum Arm Pad Surface Replacement, 5.2-2 20
Rigid Arm Pad Replacement/Rotation, 5.2-3 21
Clamps without Arms, 5.2-4 22
Arm Bearings – Removal and Installation, 5.2-5 23
Drive Group, 5.3 24
Drive Group Removal and Installation, 5.3-1 24
Drive Group Disassembly and Service, 5.3-2 24
Drive Group Reassembly, 5.3-3 26
Drive Motor, 5.4 28
Drive Motor Removal and Installation, 5.4-1 28
Drive Motor Disassembly, 5.4-2 29
Drive Motor Inspection, 5.4-3 30
Drive Motor Reassembly, 5.4-4 30
Drive Check Valve, 5.5 32
Check Valve Service, 5.5-1 32
Revolving Connection/Manifold, 5.6 33
Rev.Conn. Removal and Installation, 5.6-1 33
Manifold Removal and Installation, 5.6-2 33
Rev.Conn. Service, 5.6-3 35
Relief Valve Adjustment, 5.6-4 37
Cylinders, 5.7 38
Cylinder Service, 5.7-1 38
Cylinder Disassembly, 5.7-2 38
Cylinder Inspection, 5.7-3 39
Cylinder Reassembly, 5.7-4 40
Cylinder Replacement, 5.7-5 42
Base Unit, 5.8 43
Rotation Bearing Removal and Installation, 5.8-1 43
180-Degree Stop Group, 5.9 45
Stop Valve Adjustment, 5.9-1 45
Stop Valve Service, 5.9-2 46
Solenoid Valve, 5.10 46
Coil Service, 5.10-1 46
Valve Service, 5.10-2 46
SPECIFICATIONS, Section 6
Specifications, 6.1 47
Hydraulics, 6.1-1 47
Auxiliary Valve Functions, 6.1-2 47
Truck Carriage, 6.1-3 47
Torque Values, 6.1-4 48
Page

221093 Rev. 0 1
NSTALLATION
I
1.1 Introduction
This Manual provides the Installation, Periodic Mainte-
nance, Troubleshooting, Service and Specifications for
Cascade E-Series Revolving Clamps.
E-Series Clamps are designed for three-shift-a-day
continuous-duty operations with minimal maintenance.
They offer exceptional visibility for the lift truck driver and
provide optimized clamp force and load handling.
In any communication about the Clamp, refer to the
product I.D. number stamped on the nameplate as shown.
If the nameplate is missing, the numbers can be found
stamped on the back of the baseplate.
IMPORTANT: All hoses, tubes and fittings on E-Series
Clamps are JIC.
NOTE: Specifications are shown
in both U.S. and (Metric) units.
1.2 Special Definitions
The statements shown appear throughout this Manual
where special emphasis is required. Read all WARNINGS
and CAUTIONS before proceeding with any work.
Statements labeled IMPORTANT and NOTE are provided
as additional information of special significance or to
make the job easier.
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 the 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.
I
NTRODUCTION
33E-MR-00001
cascade
LIFT TRUCK ATTACHMENT
ATTACHMENT CAPACITY
SERIAL
NUMBER
CATALOG
NUMBER
ADDITIONAL
EQUIPMENT
ADDITIONAL
EQUIPMENT
ADDITIONAL
EQUIPMENT
FOR TECHNICAL ASSISTANCE, PARTS AND SERVICE
CONTACT:
1-800-227–2233
PORTLAND, OREGON USA
WEIGHT
LBS.
POUNDS
AT INCH LOAD
CENTER
CAPACITY OF TRUCK AND ATTACHMENT COMBINATION
MAY BE LESS THAN ATTACHMENT CAPACITY SHOWN
ABOVE. CONSULT TRUCK NAMEPLATE.
RECOMMENDED SYSTEM PRESSURE – 2000 PSI
MAXIMUM SYSTEM PRESSURE – 2300 PSI
cascade
T
T
c
S/N 33E-MR-00001
CL0792.ill
Nameplate

2 221093 Rev. 0
NSTALLATION
I
GA0082.ill
GA0080.ill
Clamp
Rotate
CW
Tilt
Forward
Hoist Up
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.
Carriage
Clean carriage bars and inspect for
damaged notches
Tilt
Back
Hoist Down
Release
Rotate
CCW
GA0028.ill
Carriage Mount Dimension (A) ITA (ISO)
Minimum Maximum
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)
Truck Relief Setting
2300 psi (160 bar) Recommended
2600 psi (180 bar) Maximum
Truck Flow Volume ➀
Min. ➁Recommended Max. ➂
30E, 33E, 5 GPM 7.5 GPM 10 GPM
40E, 45E (19 L/min.) (28 L/min.) (38 L/min.)
➀Cascade E-Series 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 a rotate speed of less
than 2 RPM and possible unequal arm movement.
➂Flow greater than maximum can result in excessive heating,
reduced system performance and reduced hydraulic system life.
A
2.1 Truck System
Requirements
E-Series Revolving Clamps will provide maximum operat-
ing capability when the following requirements are met.
Auxiliary Valve Functions
Check for compliance with
ITA (ISO) standards:

221093 Rev. 0 3
NSTALLATION
I
A and B
RH and LH THINLINE™2-port hose reel groups.
OR
A
Solenoid Adaption using RH 6-N-1 Cable/Hose Reel
Group
OR
A and C
RH THINLINE™2-Port Hose Reel Group for ROTATE
function, and Mast Single Internal Hose Reeving Group
for CLAMP function.
B
A
GA0033.ill
C
2.2 Recommended
Hydraulic Supply
Options
E-Series Revolving Clamps can be operated with any 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:
• Hoses and fittings for the CLAMP function should be
No. 6 with 9/32 in. (7 mm) minimum I.D.
• Hoses and fittings for the ROTATE function should be
No. 8 with 13/32 in. (10 mm) minimum I.D.

4 221093 Rev. 0
NSTALLATION
I
Follow the steps shown to install the Revolving Clamp on the truck.
Read and understand all WARNING and CAUTION statements. If
you don't understand a procedure, ask your supervisor, or call the
nearest Cascade Service Department for assistance.
2Unlock Quick-Change lower
mounting hooks
AMove hooks into unlocked position.
BReinstall pin in lower hole.
1
Tighten Capscrews:
Class II / III Mounting – 165 ft.-lbs. (225 Nm)
cascade
®
C-675514-1
CL0097.ill
A
Pin
LH lower
Hook
NOTE: Guides can be reversed to
reduce hook-to-carriage clearance
(See Step 7).
5/8-in. (16 mm)
offset on top
provides max.
clearance.
Guide
WARNING: Make sure overhead
hoist has rated capacity of at least
3500 lbs. (1600 kg).
B
CL0333.ill
A
B
A
Attach overhead hoist
ARemove banding, set Revolving
Clamp upright on pallet. Use
lifting eyes and multiple chains to
stabilize Clamp while lifting.
BRemove bolt-on lower mounting
hooks (if equipped).
Lifting
Eye
Lower
Hooks
2.3 Installation Procedure

221093 Rev. 0 5
NSTALLATION
I
CL0334.ill
CLAMP
OPEN
Prepare Hoses
ADetermine hose lengths required for hydrau-
lic supply configuration of truck.
BCut hoses to length, install end fittings.
3
Flush hydraulic supply hoses
AInstall hoses as shown.
BOperate auxiliary valves for 30 sec.
CRemove union fittings, hoses.
DConnect hoses to Revolving Clamp
fittings as shown in Step 3 above.
4
RH & LH 2-PORT THINLINE™HOSE REELS:
Open
Rotate CCW
Rotate CW
CAUTION: Use hoses that are working
pressure rated to 2600-psi (18,000 kPa)
for all Attachment functions.
Clamp
5Check oil level and remove
rubber vent cover
RC0139.ill
If necessary, fill gearbox with Cascade Gear Lube 656300 or
equivalent SAE 90 wt. gear lube (AGMA 'mild' 6EP Gear Oil).
Oil level must
be up to
fill plug hole.
Remove rubber
vent cover.
GA0081.ill
SOLENOID ADAPTION USING RH 6-N-1
CABLE/HOSE REEL:
CL0489.ill
CLAMP
OPEN
Rotate CCW / Release
(TANK Port)
Rotate CW / Clamp
(PRESSURE Port)
Back (Driver"s) View

6 221093 Rev. 0
NSTALLATION
I
CL0336.ill
6
D
Index Block (ASME)
7Install and engage lower hooks
GA0079.ill
C
BOLT-ON TYPE
RC0148.ill
ADJUST
Tap tight
into position.
Tighten Capscrews:
Class II / III Mounting – 165 ft.-lbs. (225 Nm)
RC0147.ill
F
F
cascade
®
C-675514-1
Slide hook up
to engage
bar, install
pin in locked
position.
(upper hole.)
QUICK-CHANGE TYPE
(optional)
Lower
Carriage
Bar
Inspect hooks for
excessive clearance.
(Reverse guides to
reduce clearance –
See Step 2.)
3/16 in.
(5 mm)
Max.
Lower
Carriage
Bar
ITA Class II – 0.60–0.66 in. (15–17 mm)
ITA Class III – 0.72–0.78 in. (18–20 mm)
ITA Class II – 0.32–0.36 in. (8–9 mm)
ITA Class III – 0.39–0.43 in. (10–11 mm)
CL0335.ill
Notch
Truck
Carriage
Engage
locater tab
C
A
B
IMPORTANT: Hoses must be con-
nected to revolving connection before
mounting unit on truck carriage.
Mount Clamp on truck carriage
ACenter truck behind Revolving Clamp.
BTilt mast forward and raise carriage into
position.
CEngage upper mounting hooks with carriage.
Make sure locater tab on left hook engages
closest notch on top carriage bar.
DLift Revolving Clamp 2 in. (5 cm) off pallet.
Make sure lower index block (if equipped)
engages fork slot on lower carriage bar.

221093 Rev. 0 7
NSTALLATION
I
RC0137.ill
8Connect hoses prepared in
Step 3 to hose terminals 9Install stop block kit
• Preheat each stop block and carriage
bar weld area to 325°F (180°C).
• Use AWS E7018 low hydrogen rod
and weld a 1/4-in (6 mm) fillet around
each stop block.
Truck Upper
Carriage Bar Back View
Upper
Mounting Hook
Steel
Stop
Block
(each
side)
1/16 in.
(1.5 mm)
CL0408.ill
11 Install wiring –
(Solenoid-equipped units)
ROTATE
PRESS BUTTON
TO CLAMP
CL0974.ill
Button
toward
driver
Truck control
valve handle
Adapter
10 Install solenoid control knob –
(solenoid-equipped units)
CL0258.ill
CL0257.ill
Solenoid Coil
User-supplied wire
7.5-Amp
Fuse
White Black
7.5-Amp Fuse
White Black
Solenoid Coil
Diode
Diode
Knob
Button
Control Lever Knob
with Pushbutton

8 221093 Rev. 0
NSTALLATION
I
BD
C
A
GA0005.ill
12 Check Revolving Clamp functions
•With no load, cycle CLAMP and ROTATE
functions several times.
•Check functions for operation in accordance
with ITA (ISO) standards.
•Clamp and rotate a maximum load, check
for equal arm movement and normal rotation.
If necessary, adjust 180-degree stop valve
and relief valve cartridges (see Step 13).
•Check for leaks at fittings, revolving connec-
tion and cylinders.
AUXILIARY VALVE FUNCTIONS
Check for compliance with
ITA (ISO) standards:
REVOLVING CLAMP
(Driver's view)
ACounterclockwise (CCW)
BClockwise (CW)
CRelease Arms
DClamp Arms
Hoist Down Tilt Forward
Hoist Up Tilt Back
WARNING: Make sure all
personnel are clear of the
Clamp during testing.
CL0591.ill
SOLENOID-ACTIVATED
CLAMP
ACounterclockwise (CCW)
ARelease Arms
(press knob button)
BClockwise (CW)
BClamp Arms
(press knob button)
CL0592.ill
BA
A
B
A
B
CDCA