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Summary of Contents for cascade corporation 80G
- Page 1 ERVICE MANUAL 80G–170G Non-Revolving Clamps Original Instructions Number 6828871-R1 EN cascade corporation Cascade is a Registered Trademark of Cascade Corporation...
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Page 2: Table Of Contents
Custom Arm Bases (80G – 120G) Arm Bearings – Removal and Installation Valve Valve Removal and Installation Valve Service Relief Adjustment – 80G-140G & 170G (Current) Valve Relief Adjustment – 170G (Early) Valve Clamp Cylinder Removal and Installation Cylinder Disassembly... -
Page 3: Introduction, Section
Specifications are shown in Metric. All fasteners have a torque value range of ±10% of stated value. A2-Z 140G-PBS-C011 PTL123456-1R1 Cascade Corporation • www.cascorp.com • Icons & Patents: www.cascorp.com/support 6095754 Nameplate CL6366.eps Special Definitions The statements shown appear throughout this manual where special emphasis is required. -
Page 4: 100-Hour Maintenance
ERIODIC 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. 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: •... -
Page 5: 1000-Hour Maintenance
ERIODIC MAINTENANCE 1000-Hour Maintenance After each 1000 hours of truck operation, in addition to the 100 and 500-hour maintenance, perform the following Bolt-On Arm Cap- Bolt-On procedures. screws Upper Hook • Bolt-On Arms – Tighten bolt-on arm capscrews to a torque of 680 ft.-lbs. -
Page 6: General Procedures
Model Maximum system to the truck tank. Then test the attachment with a load to be sure it operates correctly before 80G-140G returning to the job. Low Pressure 1455 psi (100 bar) High Pressure 2760 psi (190 bar) Stay clear of the load while testing. -
Page 7: Plumbing
ROUBLESHOOTING Plumbing Hosing Diagram Attachment 3.2-1 OP OPEN Port Valve CLAMP CIRCUIT CL CLAMP Port CLAMP ARMS PRESSURE RETURN NOTE: For OPEN ARMS, reverse the colors shown. Cylinders Hose Reel or Internal Reeving CL4994.eps CLAMP Truck Auxiliary Valve SSR Port SIDESHIFT CIRCUIT SSL Port Attachment... -
Page 8: Hydraulic Circuit
Combiner CLAMP Relief Sideshift Relief Valve Flow Divider/ OPEN Combiner Relief G (OP) CLAMP Equalizer Relief 80G–140G Sideshift Attachment Valve Relief Valve OPEN Relief CL5001.eps Hose Reel or Hose Reel or Internal Reeving Internal Reeving SIDESHIFT CLAMP Truck Truck Auxiliary... -
Page 9: Clamp Function
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. 6828871-R1 EN... - Page 10 (refer to step 5), one of the cylinders is faulty and must be serviced. Refer to Section 4.4. CLAMP Check Valve OPEN Relief CLAMP Relief CLAMP Relief CL6288.eps 80G & 100G Valve CLAMP Supply Flow Divider/ Combiner CLAMP Check Valve Equalizer OPEN Check...
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Page 11: Sideshift Function
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: Model Maximum 80G-140G Low Pressure 1455 psi (100 bar) High Pressure 2760 psi (190 bar) 170G 2465 psi (170 bar) Check the flow volume at the carriage hose terminal. -
Page 12: Sideshift Circuit Test
Swap or replace check valve cartridge(s). SS Relief • If the attachment still sideshifts improperly in one or both directions, problem is not hydraulic. Refer to Section 3.4. S S L 80G & 100G Setscrew Valve CL6289.eps Orifice SIDESHIFT Check... -
Page 13: Electrical Circuit
ROUBLESHOOTING Electrical Circuit (Solenoid-equipped attachments) Use the schematic shown and follow the steps below. Check the control knob circuit fuse. Replace if necessary. Check for loose electrical connections at the truck ignition switch, control knob button, solenoid coil terminals and diode. Remove the diode from the solenoid coil terminal. -
Page 14: Attachment Removal
ERVICE Attachment Removal Position the attachment arms to frame width. WARNING: Before removing hydraulic Sideshift Left Open lines, relieve pressure in the hydraulic Sideshift Right Clamp system. Turn the truck off and open the truck auxiliary control valves several times in both directions. -
Page 15: Arms
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) Cylinder To prevent the rod from turning by using a wrench on the hex washer. -
Page 16: Custom Arm Bases (80G - 120G)
Engage the rod end into the lug. Tighten the rod end nut to a torque of: 80G, 100G – 310 ft.-lbs. (420 Nm) 120G – 250 ft.-lbs. (340 Nm) Install the locking cap and cotter pin. -
Page 17: Arm Bearings - Removal And Installation
For reassembly, tighten capscrew to 24 ft.-lbs. (32 Nm). 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 Drive new bearings into the frame, displacing the old bearing. -
Page 18: Valve
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) For reassembly, reverse the above procedures with the following exceptions: •... -
Page 19: Valve Service
ERVICE Valve Service 4.3-2 IMPORTANT: Service the valve in a clean work area. For reassembly, reverse the above procedures with the Service procedures are the same for all valves: following exceptions: • Replace O-rings and back-up rings on cartridges as Remove the valve from the attachment as described in shown in illustration below. - Page 20 Adjustable Relief Cartridge – Sideshift Relief Flow Divider/ Test Port Combiner "CLAMP" Test Port Plug "OPEN" Body Adjustable Relief Cartridge – Flow Divider PO Check Valve – CL6290.eps OPEN Cylinder Connection Fittings 80G & 100G Models Reference: 6862870-R1 6828871-R1 EN...
- Page 21 ERVICE Valve Service (Continued) 4.3-2 120G, 140G & Adjustable Relief Cartridge - 170G (Current) Equalizer Relief PO Check Adjustable Relief Models Valve – CLAMP Valve – CLAMP PO Check Adjustable Relief Valve – OPEN Valve – OPEN Plug Setscrew Orifice Test Port G Adjustable Relief...
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Page 22: Relief Adjustment - 80G-140G & 170G (Current) Valve
ERVICE Valve Relief Adjustments – 4.3-3 80G–140G & 170G (Current) Valve To avoid over clamping or slow sideshifting speed, relief cartridges should be adjusted. Check nameplate and decal on the valve for correct circuit hydraulic pressure settings. NOTE: Attachments used for fork positioning requires no CLAMP relief adjustment. - Page 23 ERVICE Valve Relief Adjustments – 4.3-3 80G–140G & 170G (Current) Valve (Continued) SIDESHIFT Circuit Arm Synchronization Open arms to half way and sideshift the attachment. Open and close the arms until one arm bottoms or is fully open. Adjust the flow divider relief cartridge in 1/4 turn CL6418.eps...
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Page 24: Relief Adjustment - 170G (Early) Valve
ERVICE Relief Adjustments – 4.3-5 170G (Early) Valve To avoid over clamping or slow sideshifting speed, relief cartridges should be adjusted. Check nameplate and decal on the valve for correct CLAMP hydraulic pressure settings. Install pressure gauge into CL (clamp) test port. Loosen jam nut on sideshift right relief cartridge (SSL–>SSR). -
Page 25: Clamp Cylinder
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. -
Page 26: Cylinder Disassembly
ERVICE Cylinder Disassembly 4.4-2 Clamp the cylinder in a soft-jawed vise at the extreme base end only. Do not clamp on the shell. Unscrew and remove the retainer using a claw-type spanner wrench (Cascade Part No. 678598), as shown. Remove the piston/rod assembly from the cylinder. Clamp the piston/rod or retainer in a soft-jawed vise. -
Page 27: Cylinder Reassembly
ERVICE Cylinder Reassembly 4.4-4 Polish the piston and retainer chamfer angle with emery cloth. This allows the seal to slide over the chamfer easier. Lubricate all new seals and O-rings with O-ring lube or petroleum jelly. CL2652.eps Chamfer Wear Ring Install the new seals on the piston and retainer. - Page 28 ERVICE Cylinder Reassembly (Continued) 4.4-4 80G, 100G, 120G, 140G Backup Ring Dual Seal O-Ring Piston/Rod Two-Piece Seal Piston Assembly Rod U-Cup (not removable Pressure Seal from rod) Note seal direction Anti-Roll Wiper Seal CL6370.eps Cylinder Retainer Rod Bearing Wear Ring...
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Page 29: Solenoid Valve
ERVICE Solenoid Valve Coil Service 4.5-1 Disconnect the wires and diode from the coil terminals. Remove the end cover capscrews. Remove the end cover and coil. Install the new coil and end cover. Make sure that the terminals are positioned correctly. For reassembly, reverse the above procedures except as follows: •... -
Page 30: Specifications
(38 L/Min.) (57 L/Min.) (90 L/Min.) ➀ Cascade 80G–170G 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. -
Page 31: Truck Carriage
PECIFICATIONS Truck Carriage 5.1-3 Carriage Mount Dimension (A) ITA (ISO) Minimum Maximum Class III 18.68 in. (474.5 mm) 18.74 in. (476.0 mm) Class IV 23.44 in. (595.5 mm) 23.50 in. (597.0 mm) GA0389.eps 6828871-R1 EN... -
Page 32: 80G-140G Torque Values
PECIFICATIONS 80G–140G Torque Values 5.1-4 Fastener torque values for 80G, 100G, 120G and 140G Clamps are shown in the table below in US and metric. All torque values are also called out in each specific service procedure section through out the manual. -
Page 33: 170G Torque Values
PECIFICATIONS 170G Torque Values 5.1-5 Fastener torque values for 170G Clamps are shown in the table below in Metric. All torque values are also called out in each specific service procedure section through out the manual. NOTE: All fasteners have a torque value range of ±10% of stated value. - Page 34 Pte. Ltd. Rocklea, QLD 4107 East Tamaki, Auckland 18 Tuas South Street 5 Australia New Zealand Singapore 637796 Tel: 1-800-227-223 Tel: +64-9-273-9136 Tel: +65-6795-7555 Fax: +61 7 3373-7333 Fax: +64-9-273-9137 Fax: +65-6863-1368 © Cascade Corporation 2017 08-2017 Part Number 6828871-R1 EN...
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