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Cascade E Series User manual

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Cascade is a Registered Trademark of Cascade Corporation
cascadeT
Manual Number 212116 R-1
NSTALLATION INSTRUCTIONS
E-Series
Carton Clamp
I
i
ONTENTS
ECOMMENDED HYDRAULIC SUPPLY OPTIONS
R
This Manual provides instructions for installing a Cascade
E-Series Carton Clamp. Follow the suggested installation
procedures for best results. If you have any questions or
need more information, contact your nearest Cascade
Service Department (see back cover).
Read the WARNING Statements placed throughout this
Manual to emphasize safety during Clamp 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
i
Truck Requirements 1
Installation Procedures 2
Load Troubleshooting 8
Periodic Maintenance 10
E-Series Carton 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:
• All hoses and fittings for clamp and sideshift functions
should be at least No. 6 with 9/32 in. (7 mm) minimum I.D.
GA0033.ill
Non-Sideshifting
A or B
RH or LH THINLINE™2-port hose reel group.
OR
CMast single internal hose reeving group.
Sideshifting
A and B
RH and LH THINLINE™2-port cable hose reel groups.
OR
CMast 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.
AB
C
C
1
GA0080.ill
GA0082.ill
RUCK REQUIREMENTS
Clamp
Sideshift
Right
Tilt
Forward
Hoist Up
Auxiliary Valve Functions
Check for compliance with ANSI standards:
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
T
Tilt
Back
Hoist Down
Release
Sideshift
Left
GA0028.ill
A
Carriage Mount Dimension (A) ITA (ISO)
Minimum Maximum
Class II 14.96 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
20E, 30E, 5 GPM 7.5 GPM 10 GPM
40E, 45E (19 L/min.) (28 L/min.) (38 L/min.)
➀Cascade E-Series Carton 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.
2
I
Follow the steps shown to install the 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 Depart-
ment for assistance.
NSTALLATION
2Unlock quick-change lower
mounting hooks
ARemove pin and drop hooks into unlocked
position.
BReinstall pin in lower hole.
1Prepare Attachment
ARemove banding.
BRemove bolt-on lower
mounting hooks (if equipped).
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 lower hook installation, Step 6).
B
Guide
5/8-in. (16 mm)
offset on top
provides max.
clearance.
B
CL0244.ill
Bolt-On
Lower Hooks
3
Prepare Hoses
ADetermine hose lengths required for hydraulic
supply configuration of truck.
BCut hoses to length, install end fittings.
NSTALLATION
I
CL0589.ill
CL0585.ill
Sideshifting – Double Hose Reels
Sideshifting – Double Internal Hose Reeving
Sideshifting with Solenoid – IHR and Cable Reel
Sideshifting with Solenoid – 6-N-1 Cable/Hose Reel
OpenSideshift Left
Sideshift Right Clamp
CL0588.ill
CL0586.ill
SSL / Open
(TANK port)
SSR / Clamp
(PRESSURE Port)
Flush hydraulic supply hoses
AInstall hoses using union fittings.
BOperate auxiliary valves for 30 sec.
CRemove union
fittings.
4
GA0092.ill
Non-Sideshifting – Single Hose Reel
CL0587.ill
Clamp
Open
Solenoid
Cable
IMPORTANT: Attachment hydraulic lines can be
plumbed to either side of the dual-ported main valve if
required, to match existing truck supply configurations.
3
4
Centering Tab
Positions
CL0243.ill
4
12
3
5Mount Clamp on truck carriage
ACenter truck behind Clamp.
BTilt forward and raise carriage into position.
CEngage top mounting hooks with carriage.
Make sure centering tab engages a notch
on the top carriage bar. NOTE: Centering
tab can be oriented in 4 different positions
to center the Clamp (see illustration).
DLift Clamp 2 in. (5 cm) off pallet.
I
NSTALLATION
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)
CL0242.ill
Truck
Carriage
Engage upper hooks
and centering tab
ADJUST
SD0066.ill
Tighten Capscrews:
Class II / III Mounting – 165 ft.-lbs. (225 Nm)
Lower
Carriage
Bar
6Install and engage lower hooks
Tap tight into position.
Inspect hooks for
excessive clearance.
(Reverse guides to reduce
clearance – See Step 2.)
cascade
®
C-675514-1
SD0065.ill
3/16 in.
(5 mm)
Max.
Lower
Carriage
Bar
BOLT-ON TYPEQUICK-CHANGE TYPE
Slide hook up
to engage
bar, install
pin in locked
position.
(upper hole.)
CL0241.ill
A
B
CC
C
5
I
NSTALLATION
Connect hoses prepared in
Step 3 to Attachment
7
9Install wiring –
(Solenoid equipped units)
PRESS
BUTTON
TO POSITION SIDESHIFT
CL0240.ill
Button
toward
driver
Truck control
valve handle
Adapter
8Install 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
Double Hose Reels Hydraulic Supply Internal Hose Reeving Hydraulic Supply
Control Lever Knob
CL0593.ill CL0588.ill
6
10 Cycle Clamp functions
•With no load, cycle each Clamp function
several times.
•Check for operation in accordance with
ITA (ISO) standards.
•Clamp and lift a maximum load. Sideshift
left and right. Check for proper clamp
force, equal arm movement and ad-
equate speed. If necessary, adjust relief
valve cartridges (see Step 11).
•Check for leaks at fittings, valve, manifold
and cylinders.
AUXILIARY VALVE
FUNCTIONS
I
NSTALLATION
WARNING: Make sure all personnel are
clear of the Clamp during testing.
GA0005.ill
BD
C
A
NON-SIDESHIFTING CLAMPS
ARelease Arms
BClamp Arms
C
(not used)
D
(not used)
A
B
A
B
CC
D
SIDESHIFTING CLAMPS
ASideshift Left
BSideshift Right
CRelease Arms
DClamp Arms
SIDESHIFTING CLAMPS WITH
SOLENOID VALVE
ASideshift Left
ARelease Arms
(press knob button)
BSideshift Right
BClamp Arms
(press knob button)
A
CL0461.ill
CL0085.ill
B
AA
B
A
CL0085.ill
Tilt Forward
Hoist Up Tilt Back
Hoist Down
7
3/4-in. (19 mm)
Jam Nut
11 Adjust relief cartridges
For over-pressure protection, the relief valve
cartridges for both the CLAMP and SIDE-
SHIFT functions should be adjusted to
match the truck hydraulic flow rate.
I
NSTALLATION
Sideshift relief adjustment:
EWith a maximum load clamped, sideshift full left
and full right while checking for an arm speed of
8–10 in./sec.
FUsing an Allen wrench, adjust the SIDESHIFT
relief cartridge counterclockwise (CCW) 1/4-turn.
Repeat Steps E and F until sideshift speed slows
(relief opening).
GReadjust cartridge clockwise (CW) 1/4-turn.
Tighten jam nut and replace cap.
CL0435.ill
B
C
NON-SIDESHIFTING VALVE SIDESHIFTING VALVE SIDESHIFTING VALVE
WITH REGENERATION
CL0622.ill
Sideshift Relief CartridgeF
Clamp Relief Cartridge
D
FRONT
E
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.
CL0623.ill
Relief Valve
Cartridge
Increase
Pressure
(CW)
Decrease
Pressure (CCW)
5/16-in. (8 mm)
Allen Wrench
Adjustment
Screw
Cap
Clamp relief adjustment:
AConfirm that the truck pressure is
between 2300–2600 psi (160–180 bar)
at the carriage hose terminal.
BInstall a 3000-psi (200 bar) pressure
gauge on the test port of the main valve.
(No. 4 O-ring fitting required).
CCycle arms to full open. Slowly close
arms while clamping a maximum rigid
load (or clamp force indicator). Hold the
lever in the CLAMP position and acceler-
ate the engine to develop full pressure.
DAdjust the CLAMP relief cartridge for an
indicated 2300 psi (160 bar). Turn
clockwise to increase pressure, counter-
clockwise to decrease. Tighten jam nut
and replace cap.
3/4-in. (19 mm)
Jam Nut
C
8
L
OAD TROUBLESHOOTING
CL0086.ill
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
Assure center of
load is between
pad pivot and
backrest
1
2
3
4
CL0087.ill
IF LOWER TIER OF LOAD BRIDGES
DOWN OR SLIDES OUT:
Re-clamp load
so bottom edge
is even with
bottom of pads
Check for bent
pads, straighten
or replace
Check
hydraulics
for low
supply
pressure
Add or increase
positive camber
(Contact Cascade
Service)
Check for worn
lower surfaces,
rotate pads 180
°
and exchange
sides or replace
1
2
3
4
5