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cascade corporation 10H Service Manual

Fixed frame pivot arm paper roll clamps
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ERVICE MANUAL
10H
Fixed Frame
Pivot Arm
Paper Roll Clamps
Manual Number 6862661-R1
cascade
corporation
Cascade is a Registered Trademark of Cascade Corporation

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  • Page 1 ERVICE MANUAL Fixed Frame Pivot Arm Paper Roll Clamps Manual Number 6862661-R1 cascade  corporation Cascade is a Registered Trademark of Cascade Corporation...
  • Page 2 BLANK...

  • Page 3: Table Of Contents

    ONTENTS Page Page INTRODUCTION, Section 1 SERVICE, Section 4, Continued Introduction Valve Special Definitions Valve Removal PERIODIC MAINTENANCE, Section 2 Valve Service 100-Hour Maintenance Revolving Connection 500-Hour Maintenance Revolving Connection Removal 1000-Hour Maintenance and Installation 2000-Hour Maintenance Revolving Connection Service 4000-Hour Maintenance Cylinders Servicing Cylinders on the Attachment...

  • Page 4: Introduction, Section

    Introduction This manual provides the Periodic Maintenance, Troubleshooting, Service and Specifications for Cascade 10H Fixed Frame Paper Roll Clamps. In any communication about the attachment, refer to the product catalog and serial numbers stamped on the nameplate as shown. If the nameplate is missing, the numbers can be found stamped on the lower front of the faceplate.

  • Page 5: 100-Hour Maintenance

    ERIODIC MAINTENANCE 100-Hour Maintenance WARNING: After completing any service procedure, always test the attachment Every time the lift truck is serviced or every 100 hours through five complete cycles. First test of truck operation, whichever comes first, complete the the attachment empty, then test with a load following maintenance procedures: to make sure the attachment operates correctly before returning it to the job.

  • Page 6: 1000-Hour Maintenance

    ERIODIC MAINTENANCE 1000-Hour Maintenance After the initial 1000 hours of truck operation, in addition to the 100 and 500-hour maintenance, perform the following Upper Hook procedure: Rotator Drive Capscrews Capscrews • Initial 1000 Hours – Check rotator drive gearcase lubricant level (remove vent cap). Oil should be filled Fill and up to the bottom of the fill plug hole.

  • Page 7: General Procedures

    ROUBLESHOOTING General Procedures WARNING: Before servicing any hydraulic component, relieve pressure in the system. Turn the truck off and Truck System Requirements 3.1-1 move the truck auxiliary control valves several times in both directions. • Truck hydraulic pressure should be within the range After completing any service procedure, test the shown in Specifications, Section 5.1.

  • Page 8: Troubleshooting Chart

    ROUBLESHOOTING Troubleshooting Chart 3.1-3 Determine All The Facts – It is important that all the facts regarding the problem are gathered before beginning service procedures. The first step is to talk to the equipment operator. Ask for a complete description of the malfunction. The following guidelines can then be used as a starting point to begin troubleshooting procedures: Clamp Circuit...

  • Page 9: Plumbing

    ROUBLESHOOTING Plumbing Hosing Diagram 3.2-1 CLOSE ARMS Long Arm PRESSURE Cylinder RETURN NOTE: For OPEN ARMS, reverse the colors shown. Rotator Drive Short Arm Revolving ROTATE Cylinder Connection Truck (if equipped) Auxiliary Valve CLAMP Truck Auxiliary Valve NOTE: Short arm cylinders operate only when the attachment is rotated to the OPEN...

  • Page 10: Hydraulic Schematic

    ROUBLESHOOTING Hydraulic Schematic 3.2-2 Revolving Connection Check Valve Test Port Short Arm Cylinder (if equipped) Long Arm Cylinder Rotator Drive Motor Relief Cartridge Valve Check Valve Internal Internal Hose Hose Reeving Reeving CLAMP Truck ROTATE Truck Auxiliary Valve Auxiliary Valve Truck Relief Valve Truck Pump...

  • Page 11: Clamp Function

    ROUBLESHOOTING Clamp Function There are four potential problem areas that can affect the clamp function: • Operator may be handling roll incorrectly. Loads may be too heavy, exceeding capacity of the attachment. Clamp Circuit Test Continued, Step 2 Continued Refer to the attachment's Operator’s Guide (Cascade part no.

  • Page 12: Rotation Function

    ROUBLESHOOTING Rotation Function There are four potential problem areas that can affect the rotation function: • Operator may be handling roll incorrectly. Loads may be too heavy or rotated off-center, exceeding capacity of attachment. Refer to the attachment's Operator’s Guide (Cascade part no.

  • Page 13: Rotation With Load

    15645 in.-lbs. @ 2300 psi (1326 Nm @ 160 bar) 10H – 20,860 in.-lbs. @ 2300 psi Metric (2355 Nm @ 160 bar) Roll Roll 10H (low flow) – 13,689 in.-lbs. @ 2300 psi Diameter Roll weight Diameter Roll weight (1545 Nm @ 160 bar) 20 in.

  • Page 14: 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 15: Attachment Removal

    ERVICE Attachment Removal Rotate the attachment to the vertical roll handling position. Extend the arm outside the frame width. WARNING: Before removing hydraulic lines, relieve pressure in the hydraulic system. Turn the truck off and open the truck auxiliary control valves several times in both directions.

  • Page 16: Arms

    ERVICE Arm Assembly – 4.2-1 Removal and Installation Rotate the attachment to the vertical roll handling position. Remove the retainer and cylinder rod anchor pin from the arm being removed. Retract the cylinder rod. For reassembly, tighten the retainer capscrews to 28 ft.-lbs.

  • Page 17: Contact Pad Removal And Installation

    ERVICE Contact Pad – 4.2-2 Pivot Pin Removal and Installation Rotate the attachment to the vertical roll handling position. Lower the unit until the contact pads are approximately 1 in. (25 mm) off the ground. Clevis Pin Remove cotter pins from the clevis pins that fasten the links to the contact pad.

  • Page 18: Arm Tip Repair

    ERVICE Arm Tip Repair 4.2-4 Kit Tool Place the tool against the tip with raised ribs on the inner arm surface and the spacers in between each tip. Tack weld two blocks (user equipped) to the inside of the arm as a marker at the edge of the tool. Remove the tool.
  • Page 19 ERVICE Arm Tip Repair (Continued) 4.2-4 Tubes and Kit Tool Position the new tubes on the arm tips using the kit tool. Place existing pivot pin through all tubes and kit tool for Pivot Pin alignment. All repairs should be done in the flat position. RC3961.eps Start weld this side Preheat arm tip base metal to 70°F (21°C) minimum.

  • Page 20: Drive Group

    ERVICE Drive Group Drive Group Removal 4.3-1 and Installation Remove the attachment from the truck as described in Section 4.1. Remove the valve from the motor and baseplate as described in Section 4.5. Remove the four capscrews fastening the drive group Oil Level to the baseplate.
  • Page 21 ERVICE Drive Group Disassembly 4.3-2 and Service (Continued) Tap the worm and bearings out through the end cover side of the housing. Note direction of bearings. Bearings are directional. RR0571.eps Press the pinion gear, seal, pinion bearings and worm gear out of the housing as an assembly. Worm RR0611.eps Pinion Shaft Key...

  • Page 22: Drive Group Reassembly

    ERVICE Drive Group Reassembly 4.3-3 PINION AND BEARING WITH EXTERNAL SEAL Build up the pinion/worm gear assembly vertically with the Pinion pinion gear down. Outer Housing Gear Pinion Bearing Position outer bearing and snap ring on the pinion shaft outer bearing seating area. Second Install pinion seal onto seal seating area.
  • Page 23 ERVICE Drive Group Reassembly 4.3-3 Housing (Continued) Temporarily install the end cover without shims. Tighten the capscrews sequentially to 115 in.-lbs. (13 Nm). Measure the gap between the end cover and housing in three places with a feeler gauge or 'Plastigage' thread RC5194.eps and determine the minimum gap.

  • Page 24: Drive Motor

    ERVICE Drive Motor Drive Motor Removal and 4.4-1 WARNING: Before removing hydraulic lines, relieve pressure in the hydraulic Installation system. Turn the truck off and open the truck auxiliary control valves several times Remove the attachment from the lift truck as described in both directions.

  • Page 25: Drive Motor Disassembly

    ERVICE Drive Motor Disassembly 4.4-2 Output Shaft Cascade provides service replacement parts for the seals indicated with a ▲ below. Due to cost, if other parts need replacement, the complete drive motor assembly should be replaced. Remove the drive motor from the drive group as described in Section 4.4-1.

  • Page 26: Drive Motor Inspection

    ERVICE Drive Motor Disassembly 4.4-2 (Continued) Remove wiper seal and pressure seal from the bearing housing using a seal removal tool or modified screwdriver as shown. IMPORTANT: Note the direction of the seals and thickness. RR0593.eps CAUTION: Do not scratch either of the seal cavities. Modified Screwdriver Drive Motor Inspection 4.4-3...
  • Page 27 ERVICE Drive Motor Reassembly 4.4-4 Pressure Seal (Continued) RR0775.eps Apply a coating of a lithium based bearing grease, such as Mobilith SCH220, to inner edges of wiper seal, pressure seal, thrust bearing and washer. Install wiper seal with the u-shape facing outward from its seat.

  • Page 28: Valve

    ERVICE Valve Valve Removal 4.5-1 WARNING: Before removing any hoses, relieve pressure in the hydraulic system. With the truck off, open the truck auxiliary control valve(s) several times in both directions. Disconnect the hydraulic hoses to the drive group valve. Tag hoses for reassembly.

  • Page 29: Revolving Connection

    ERVICE Revolving Connection Revolving Connection 4.6-1 Removal and Installation Revolving Connection WARNING: Before removing any hydraulic lines, relieve pressure in the hydraulic system. Turn the truck off and open the truck auxiliary control valves several times in both directions. Remove the attachment from the lift truck as described in Section 4.1.

  • Page 30: Revolving Connection Service

    ERVICE Revolving Connection Service 4.6-2 Remove the revolving connection from the attachment as described in Section 4.6-1. Remove the front snap ring from the revolving connection shaft. CAUTION: Remove all burrs and paint from the exposed shaft surface prior to removal from the body. Burrs or paint chips pulled through the bore may permanently damage the body.
  • Page 31 ERVICE Revolving Connection 4.6-2 Service (Continued) Form Teflon ring into For reassembly, reverse the previous procedures with 'kidney' shape to install the following exceptions: AC0044.eps • Install new O-rings and back-up rings on relief cartridge valve, as shown. • Clean all traces of oil and moisture from the 2-piece Seal Install Tool seal grooves inside the revolving connection body (Cascade Part...

  • Page 32: Cylinders

    ERVICE Cylinders Servicing Cylinders 4.7-1 on the Attachment Rotate the attachment to the vertical roll handling position. Fully close arm. Remove the cylinder rod anchor pin. For reassembly, tighten retainer capscrews to 28 ft.-lbs. (38 Nm). Retract the cylinder rod. Swing the cylinder outward to expose the cylinder rod and retainer.

  • Page 33: Cylinder Check Valve Service

    ERVICE Cylinder Check Valve 4.7-3 Service Rotate the attachment to the vertical roll handling position. Close the arm attached to the cylinder being serviced to gain access to the cylinder check valve. WARNING: Before removing hydraulic lines, relieve pressure in the hydraulic system.

  • Page 34: Cylinder Bushing Service

    ERVICE Cylinder Bushing Service 4.7-4 NOTE: Bushings require replacement if bushing-to-pin clearance exceeds 1/16 in. (1.6 mm). Remove the cylinder from the attachment as described in section 4.7-2. RC2894.eps Remove the bushings from the cylinder using a bushing driver. NOTE: Bushing drivers can be machined using the dimensions shown below.

  • Page 35: Cylinder Service

    ERVICE Cylinder Service – 1.77 in. (45 mm) Bore Diameter Cylinder Disassembly 4.8-1 Retainer Clamp the cylinder so that the vise jaws contact only the extreme end of the cylinder base. NOTE: Use a soft-jawed vise for all cylinder disassembly and assembly procedures. Unscrew the retainer from the cylinder with a claw-type spanner wrench, as shown (Cascade Part No.

  • Page 36: Cylinder Reassembly

    ERVICE Cylinder Service – 1.77 in. (45 mm) Bore Diameter (Continued) Cylinder Reassembly 4.8-3 Lubricate all new seals and with petroleum jelly. Polish the piston and retainer chamfer angle with emery cloth to facilitate seal installation. Retainer Threads Install new seal on the retainer. Hook one side of the seal in the groove and carefully work it over the retainer.

  • Page 37: 2.95 In. (75 Mm) Bore Diameter

    ERVICE Cylinder Service – 2.95 in. (75 mm) Bore Diameter RC0314.eps Cylinder Disassembly 4.9-1 Clamp the cylinder so that the vise jaws contact only the extreme end of the cylinder base. NOTE: Use a soft-jawed vise for all cylinder disassembly and assembly procedures. Remove the cylinder retainer by unscrewing it with a pin-type spanner wrench.

  • Page 38: Cylinder Reassembly

    ERVICE Cylinder Service – 2.95 in. (75 mm) Bore Diameter (Continued) Cylinder Reassembly 4.9-3 Lubricate all new seals and O-rings with petroleum jelly. Note the direction of the U-cup seals. Pressure seals must always be installed with the lip toward the high pressure side of the cylinder.

  • Page 39: Base Unit

    ERVICE Base Unit 4.10 Frame Bushing Service Spacer 4.10-1 Remove the arm from the attachment as described in Section 4.2-1. Remove the arm pivot bushings from the frame using a bushing driver. Bushings NOTE: Bushing drivers can be machined using the dimensions shown in the chart below.

  • Page 40: Rotation Bearing Assembly - Removal And Installation

    ERVICE Rotation Bearing Assembly – 4.10-2 Removal and Installation Remove the attachment from the lift truck as described in Section 4.1. Remove the valve as described in Section 4.5-1. Remove the drive group as described in Section 4.3-1. Remove lower spacers. For reassembly, apply Loctite 242 (Blue) to capscrew threads and tighten capscrews to 165 ft.-lbs.
  • Page 41 ERVICE Rotation Bearing Assembly – 4.10-2 Removal and Installation (Continued) Attach two eyebolts to the bearing assembly. Attach an overhead hoist. Remove the capscrews fastening the bearing to the faceplate. For reassembly, tighten the capscrews using the following technique: Bearing-to-faceplate capscrews – Apply Loctite 242 (Blue) to capscrew threads and threaded holes in the faceplate.

  • Page 42: Solenoid Valve

    ERVICE Solenoid Valve 4.11 Coil Service 4.11-1 Disconnect the wires and diode from the coil terminals. Remove the end cover capscrews and remove the end cover and coil. Note the position of the coil terminals. Install the new coil and end cover. Make sure that the terminals are positioned correctly.

  • Page 43: Specifications

    8 GPM (11 L/min.) (18 L/min.) (30 L/min.) Cascade 10H Roll Clamps are compatible with SAE 10W petro- ➀ leum base hydraulic fluid meeting Mil. Spec. MIL-0-5606 or MIL- 0-2104B. Use of synthetic or aqueous base hydraulic fluid is not recommended.

  • Page 44: Truck Carriage

    PECIFICATIONS Truck Carriage 5.1-3 Carriage Mount Dimension (A) ITA (ISO) Minimum Maximum 14.94 in. (380.0 mm) 15.00 in. (381.0 mm) Class II GA0389.eps 6862661-R1...

  • Page 45: Torque Values

    Torque Values 5.1-4 NOTE: All fasteners have a torque value Fastener torque values for the 10H Roll Clamps are shown range of ±10% of stated value. in the table below in both US and Metric units. All torque values are also called out in each specific service procedure...
  • Page 46 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 05-2017 Part Number 6862661-R1...

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