Cascade D Series Service Manual
Non-sideshifting & sideshifting clamps
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Summary of Contents for Cascade D Series
- Page 1 ERVICE MANUAL D-Series 25D through 100D Non-Sideshifting & Sideshifting Clamps, 40D Turnafork Manual Number 669224-R5 cascade corporation Cascade is a Registered Trademark of Cascade Corporation...
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Page 2: Table Of Contents
ONTENTS Page Page INTRODUCTION, Section 1 SERVICE, Section 5 Introduction Attachment Removal Special Definitions Arms INSTALLATION, Section 2 Arm Assembly Removal and Installation Truck Requirements Bolt-On Arm Removal Recommended Hydraulic Supply Multi-Purpose/Rigid and Drum Arm Contact Installation Procedure Surface Replacement Custom Arm Installation Rigid Arm Contact Pad Rotation and Prior to Operation... -
Page 3: Introduction, Section
Introduction This Manual provides the Installation, Periodic Maintenance, Troubleshooting, Service and Specifications for Cascade D-Series Non-Sideshifting Clamps, Sideshifting Clamps and 40D Turnaforks. In any communication about the attachment, refer to the product I.D. number stamped on the nameplate as shown. -
Page 4: Truck Requirements
70D, 80D, 100D (26 L/min.) (45 L/min.) (57 L/min.) ➀ Cascade D-Series 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 GA0380.eps is not recommended. If fire resistant hydraulic fluid is required, special seals must be used. -
Page 5: Recommended Hydraulic Supply
D-Series 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 function should be... -
Page 6: Installation Procedure
Follow the steps shown to install the attachment on the truck. Read and understand WARNING and CAUTION statements. If you don't understand a procedure, ask your supervisor or call the nearest Cascade Service Department for assistance. Attach overhead hoist WARNING: Check the attachment... -
Page 7: Service, Section
Prepare hoses Sideshift Right – De-energized CAUTION: Connect the hydraulic hoses to the attachment Close – Energized using Cascade Attachment Installation Kit No. 659245 Sideshift Left – De-energized for non-sideshifting attachments and attachments with Open – Energized solenoid adaption, Kit No. 659249 for sideshifting clamps OR use hoses and fittings as shown. -
Page 8: Specifications, Section
NSTALLATION Flush hydraulic supply hoses Install hoses using union fittings. Operate valves for 30 Seconds. Remove union fittings. CL0449.ai Mount attachment on truck carriage Center truck behind attachment. Tilt forward and raise carriage into position. Engage the mounting hook tab with the closest upper carriage bar notch. - Page 9 NSTALLATION Install and engage lower hooks QUICK-CHANGE TYPE BOLT-ON TYPE Inspect hook for excessive Lower clearance. To change clearance, Lower Carriage reverse guides. Refer to Step 2. Carriage Tap tight ® into position Slide hook up to engage bar, install pin in upper hole 3/16 in.
- Page 10 NSTALLATION Tighten fork or arm capscrews Use drive extension tool 668020 (25D), 667699 Drive Extension (35D, 40D, 50D) or 676218 (70D, 80D, 100D) to tighten capscrews to the following torque values: 25D – 190–220 ft.-lbs. (257–298 Nm) 35D, 40D, 50D – 380–320 ft.-lbs. (380-434 Nm) 70D, 80D, 100D –...
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Page 11: Custom Arm Installation
Special forks can be welded directly to them or they can be used as a base to fabricate custom built arms. WARNING: Cascade requires that a qualified or certified welder experienced in this type of fabrication be used for best quality. -
Page 12: Prior To Operation
NSTALLATION Prior to Operation Check the cylinder anchor nuts for properly installed locking caps and cotter pins. Check for external leaks at the fittings and rod ends. CL0459.eps 25D, 35D, 40D and 50D Clamps – The clamp utilizes a regenerative hydraulic circuit in the arm opening mode. The arms will open at a faster speed than when closing. -
Page 13: 100-Hour Maintenance
Cylinder Anchor Joint • 70D, 80D, 100D Clamps – Tighten the upper hook capscrews to 210 ft.-lbs. (285 Nm). 70D, 80D Upper • Check clamp force. Cascade Clamp Force Indicators Hook Capscrews 35G-DFI-8RF and 35G-CFI-8RF are available for this test. 1000-Hour Maintenance... -
Page 14: General Procedures
• Hydraulic fluid supplied to the attachment must meet Stay clear of the load while testing. Do not raise the the requirements shown in Specifications, Section 6.1. load more than 4 in. (10 cm) off the floor while testing. Tools Required 4.1-2 Flow Meter Kits: 671476 & 671477 In addition to a normal selection of mechanic's hand tools, the following are required: Flow Meter (2) No. 8-12 JIC/O-Ring • In-Line Flow Meter Kit: 10 GPM (37 L/min) – Cascade Part No. 671476 GA0013.eps 20 GPM (75 L/min) – Cascade Part No. 671477 (2) No. 6-8 JIC • Pressure Gauge Kit: Reducer 5000 psi (345 bar) – Cascade Part No. 671212 • Assorted fittings, hoses and quick-disconnect couplers, as required. Pressure Gauge Kit: 671212 No. 6 and Troubleshooting Chart Pressure No. 8 JIC... -
Page 15: Plumbing - Top Mount Valve
ROUBLESHOOTING Plumbing – Top Mount Valve Hosing Diagram, Non-Sideshifting 4.2-1 Cylinder Cylinder Cylinder Cylinder Check Check Valve Valve ARMS OPENING ARMS CLOSING Hose Hose PRESSURE Terminal PRESSURE Terminal REGENERATING RETURN Clamp Clamp Auxiliary Auxiliary Hose Reel Hose Reel Valve Valve CL2200.eps CL2201.eps Circuit Schematic, Non-Sideshifting 4.2-2 Cylinders... -
Page 16: Hosing Diagram, Sideshifting (Including Turnafork)
ROUBLESHOOTING Hosing Diagram, Sideshifting (including Turnafork) 4.2-3 Cylinder ARMS OPENING PRESSURE REGENERATING Junction Cylinder To Cylinders Block/ Hose Terminal Hose Reel Check Valve Solenoid Valve Check Valve Attachments with Sideshift Auxiliary Solenoid Adaption Valve Hose Terminal Hose Clamp Auxiliary Terminal Auxiliary Valve Valve Hose Reel Hose Reel CL2203.eps CL2204.eps... -
Page 17: Circuit Schematic, Sideshifting (Including Turnafork)
ROUBLESHOOTING Hosing Diagram, Sideshifting (Continued) 4.2-3 SIDESHIFTING Cylinder (Sideshift Left Shown) PRESSURE RETURN REGENERATING Hose Cylinder Terminal To Cylinders Hose Reel Check Solenoid Valve Valve Check Hose Valve Terminal Attachments with Sideshift Auxiliary Solenoid Adaption Valve Hose Clamp Auxiliary Terminal Auxiliary Valve Valve Hose Reel Hose... -
Page 18: Plumbing - Center Mount Valve
ROUBLESHOOTING Plumbing – Center Mount Valve Hosing Diagram, Non-Sideshifting 4.3-1 Cylinder Cylinder Cylinder Cylinder Check Check Valve Valve ARMS CLOSING ARMS OPENING Hose Hose PRESSURE PRESSURE Terminal Terminal RETURN RETURN Clamp Clamp Auxiliary Auxiliary Hose Reel Hose Reel Valve Valve CL2211.eps CL2212.eps Circuit Schematic, Non-Sideshifting 4.3-2 Cylinders... -
Page 19: Hosing Diagram, Sideshifting
ROUBLESHOOTING Hosing Diagram, Sideshifting 4.3-3 ARMS OPENING Cylinder PRESSURE RETURN Hose Terminal To Cylinders Cylinder Check Solenoid Valve Valve Hose Reel Hose Attachments with Sideshift Terminal Auxiliary Solenoid Adaption Valve Hose Auxiliary Clamp Terminal Valve Auxiliary Valve Hose Reel Hose Reel CL2214.eps CL2215.eps ARMS CLOSING PRESSURE Cylinder RETURN... -
Page 20: Circuit Schematic, Sideshifting
ROUBLESHOOTING Hosing Diagram, Sideshifting (Continued) 4.3-3 SIDESHIFTING (Sideshift Left Shown) Cylinder PRESSURE RETURN Hose Terminal To Cylinders Cylinder Solenoid Valve Hose Reel Hose Sideshift Terminal Auxiliary Valve Clamp Hose Auxiliary Auxiliary Terminal Valve Valve Hose Reel Hose Reel CL2218.eps CL2219.eps Circuit Schematic, Sideshifting 4.3-4 Cylinders Attachments with Solenoid Adaption... -
Page 21: Attachment Troubleshooting
ROUBLESHOOTING Attachment Troubleshooting There are five potential problem areas that could affect the CLAMP function. • Incorrect load handling. Refer to the Operator's Guide for suggested procedures. WARNING: Before removing hydraulic • Insufficient hydraulic pressure from the lift truck. lines or components, relieve pressure in the hydraulic system. Turn truck off and open • External leaks. the truck auxiliary control valve(s) several • Warn or defective cartridge valves or cylinder seals. times in both directions. • Defective solenoid coil or valve, if equipped. Clamp Circuit Pressure Test Install gauge and 4.4-1 hose in port 'G' Check the pressure supplied by the truck at the carriage hose terminal or junction block. Refer to the truck 90° fitting service manual, as needed. Pressure must be within and hose the range shown in Specifications, Section 6.1. TRUCK PRESSURE MUST NOT EXCEED 2300 psi (160 bar). Check the flow volume at the carriage hose terminal. -
Page 22: Check Valve Pressure Test
ROUBLESHOOTING Check Valve Pressure Test 4.4-2 WARNING: Before removing hydraulic lines or components, relieve pressure in the Mount hydraulic system. Turn truck off and open Valves the truck auxiliary control valve(s) several times in both directions. Remove bumper. Disconnect hydraulic lines at the rod end of both cylinders. Cap ports and plug lines. Disconnect the hydraulic lines Start the truck. Hold the CLAMP control handle in the at the rod end of both cylinders. clamp position. Cap the port and plug the lines. Return the handle to neutral. Watch the gauge pressure reading. • If the pressure drops more than 150 psi (10 bar) Center initially and additional drop exceeds 25 psi (2 bar) Mount per minute, the check valve is faulty and requires Valves service. Refer to Section 5.5-3 • If the pressure does not drop more than 150 psi (10 bar) initially and additional drop does not exceed 25 psi (2 bar) per minute, one or both cylinders require service. Proceed with the troubleshooting check list to isolate the faulty component. -
Page 23: Sideshift Circuit Pressure Test
ROUBLESHOOTING Sideshift Circuit Install fitting, hose 4.4-4 and gauge Pressure Test Top Mount If the clamp does not sideshift right and left at equal Valves speeds or drops a load while sideshifting, one of the sideshift check valve cartridges is faulty. The two outer cartridges on the front of the valve are for the sideshift circuit. IMPORTANT: Attachments equipped with solenoid adaption must be plumbed to the check valve so the solenoid will be energized for the clamp/open functions. WARNING: Before installing the pressure gauge, relieve pressure in the hydraulic Sideshift Right system. Turn truck off and open the truck Cartridge auxiliary control valves several times in both directions. Clamp Cartridge Top Mount Valves – Install the pressure gauge and Sideshift Left CL2229.eps hose assembly in the valve test port marked 'G', located Cartridge on the back of the valve body. Center Mount Valves – Remove the bumper. Install a tee fitting, hose and gauge between the cylinder rod end supply hose and tee fitting. -
Page 24: Electrical Circuit
ROUBLESHOOTING Electrical Circuit (Solenoid Equipped Attachments) Along with the following procedure, use the electrical schematic and diagram shown. 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. Test with an ohmmeter for high resistance in one direction and no resistance in the other direction. If there is no resistance in both directions, replace the diode. NOTE: When replacing the diode, the banded (+) end must be connected to the coil and wiring as shown. Disconnect the electrical leads from the solenoid coil terminals. Use a voltmeter to determine if voltage is present at the electrical leads when the button is depressed. • If there is no current to the solenoid, troubleshoot the electrical circuit for shorts. • If there is current to the solenoid, test for coil continuity. Test for coil continuity by placing an ohmmeter test lead on each solenoid coil terminal (ohmmeter on Rx1 scale). • If there is an ohmmeter reading, the coil is good. • If the coil is good, but the solenoid does not 'click' when the control knob button is depressed, the solenoid cartridge may be jammed. Refer to Section 5.8. • If there is no ohmmeter reading, the coil is defective and should be replaced. Refer to Section 5.8. -
Page 25: Attachment Removal
ERVICE Attachment Removal Extend the arms outside the width of the frame. Disconnect the lower mounting hooks. Bolt On Type – Remove the lower mounting hooks. For reassembly, tighten the capscrews to a toque of: Class II/III Mounting – 105–115 ft.-lbs. (140–155 Nm) Class IV Mounting –... -
Page 26: Arms
ERVICE Arms Arm Assembly Removal 5.2-1 and Installation The following procedures can be performed with the attachment mount on the truck. Extend the arms. Lower the attachment to position the forks or arms .50 in. (12 mm) above the floor. Remove the cotter pin, locking cap and nut retaining the cylinder rod to the arm lug. -
Page 27: Bolt-On Arm Removal
ERVICE Bolt-On Arm Removal Drive 5.2-2 Extension The following procedures can be performed with the attachment on the truck and with the arm assemblies on the attachment. If the arm assemblies have been removed (Section 5.2-1), lay the arm assembly down with the arm back on the ground. -
Page 28: Multi-Purpose/Rigid And Drum Arm Contact Surface Replacement
ERVICE Multi-Purpose/Rigid and Drum Arm 5.2-3 Contact Surface Replacement Drill out the rivets using .187 in. (4.8 mm) drill bit. Drill from the front side of the arm. Multi-Purpose/Rigid Arm Contact Pad Service Kits include rivets and optional capscrews to be used instead of rivets, if required. -
Page 29: Arm Bearing Removal And Installation
ERVICE Arm Bearing Removal and 5.2-5 Installation Frame Arm bearings can be remove with the attachment mounted on the truck. Remove the arm assemblies from the attachment as described in Section 5.2-1. Remove the bearing spacer located between the upper and lower bearing in each arm carrier slot. -
Page 30: Turnafork Arm Service
ERVICE Turnafork Arm Service 5.2-6 The Turnafork arm assemblies can be disassembled with the attachment mounted on the truck. Full extend the arm assemblies. Position the bottom of the fork arm .25 in. (6 mm) above a pallet as shown. Remove the front cover. -
Page 31: Turnafork Arm Indexing
ERVICE Turnafork Arm Service (Continued) 5.2-6 Crank Bar Remove the crank bar from the fork arm by driving out the pivot pin from the front side of the fork arm. Tap the bearing out of the fork arm from the back side with a rubber mallet. -
Page 32: Cylinders
ERVICE Cylinders Cylinder Removal and 5.3-1 Installation The following procedures can be performed with the attachment mounted on the truck. Extend the arms outside the width of the frame. Remove the bumper from the attachment. Remove the cotter pins, locking caps and nuts retaining the cylinder rods to the arm lugs. - Page 33 ERVICE Cylinder Removal and 5.3-1 Installation (Continued) For reassembly, reverse the above procedures except for the following special instructions for the cylinder anchor nuts and the bumper: • Install the bumper. Tighten the self-locking nuts to leave .050–.080 in. (1.3–2.0 mm) end play for each capscrew.
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Page 34: Cylinder Service
ERVICE Cylinder Service Cylinder Disassembly 5.4-1 AC1434.eps Clamp the extreme base end of the cylinder in a soft-jawed vise . Remove the retainer by using a claw type spanner wrench. Remove the rod assembly from the cylinder. Clamp the rod assembly on the wrench flats. Never clamp directly on the rod sealing surface. -
Page 35: Cylinder Reassembly
ERVICE Cylinder Reassembly 5.4-3 Lubricate all new seals and rings with petroleum jelly or equivalent. Note the direction of the U-cup seals. If installed backwards, the seals will not work properly. For proper CL1070.eps seal replacement see illustration below. Polish the piston and retainer chamfer angle with emery cloth. -
Page 36: Restrictor Cartridges
ERVICE Restrictor Cartridges Restrictor Cartridge 5.5-1 Restrictor Cartridge Adjustment (Current location in cylinder rod end port) The restrictor cartridges must be adjusted so that the arms have equal travel during opening and closing. NOTE: Current production cylinders have the restrictor cartridge installed in the rod end port. -
Page 37: Check Valves
ERVICE Check Valves Check Valve Removal – 5.6-1 Top Mount Valves Remove the attachment from the truck as described in Section 5.1. Disconnected the four hydraulic tubes or hoses at the bottom of the check valve. Remove the four capscrews fastening the valve guard to the frame. -
Page 38: Check Valve Service - Top Mount Valve
ERVICE Check Valve Service – 5.6-3 Sideshift Cartridge Top Mount Valves Back-Up Ring IMPORTANT: Service the check valve in a clean work area. Remove the cartridge valves. The non-sideshifting check valve has one cartridge valve, the sideshift check valve has three cartridge valves. Remove the special fitting and spool. -
Page 39: Check Valve Service - Center Mount Valve
ERVICE Check Valve Service – 5.6-4 Center Mount Valves IMPORTANT: Service the check valve in a clean work O-Ring area. Remove the cartridge valves. The non-sideshifting check valve has one cartridge valve, the sideshift check valve has three cartridge valves. Remove all plugs and fittings. -
Page 40: Base Unit
ERVICE Base Unit Frame and Mounting Plate 5.7-1 Disassembly and Reassembly Remove the attachment from the truck as described in Section 5.1 25D, 35D, 40D & 50D – Remove the check valve as described in Section 5.6-1. 70D, 80D, 100D – Remove the check valve as described in Section 5.6-2. -
Page 41: Solenoid Valve
ERVICE Solenoid Valve Coil Service 5.8-1 Disconnect the wires and diode from the coil terminals. Remove the end cover capscrews. Remove the end cover and coil. Install the new coil end cover. Verify that the terminals are positioned correctly. For reassembly, reverse the above procedures, except as follows: RC0204.eps • Refer to the electrical schematic in Section 4.5 for... -
Page 42: Specifications
70D, 80D, 100D (26 L/min.) (45 L/min.) (57 L/min.) ➀ Cascade D-Series Clamps are compatible with SAE 10W petroleum GA0403.eps 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 43: Truck Carriage
PECIFICATIONS Truck Carriage 6.1-3 Carriage Mount Dimension (A) ITA (ISO) Minimum Maximum Class II 14.94 in. (380.0 mm) 15.00 in. (381.0 mm) 18.68 in. (474.5 mm) 18.74 in. (476.0 mm) Class III Class IV 23.44 in. (595.5 mm) 23.50 in. (597.0 mm) GA0389.eps 669224-R5... -
Page 44: Torque Values
PECIFICATIONS Torque Values 6.1-4 Torque values for D-Series attachments are shown in he table below in both US and metric units. All torque values are also called out in each specific service procedure section throughout the manual. Ref. Fastener Location Size Ft.-lbs. - Page 45 PECIFICATIONS Top Mount Valve CL4426.eps Center Mount Valve 669224-R5...
- Page 46 Do you have questions you need answered right now? Call your nearest Cascade Service Department. Visit us online at www.cascorp.com AMERICAS Cascade Corporation Cascade Canada Inc. Cascade do Brasil U.S. Headquarters 5570 Timberlea Blvd. Rua João Guerra, 134 2201 NE 201st...
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