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Cascade E-Series Service Manual

Non-sideshifting and sideshifting clamps, carton clamps
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S
ERVICE MANUAL
E-Series
Non-Sideshifting and
Sideshifting Clamps,
Carton Clamps
Manual Number 215204 R-1
cascade
Cascade is a Registered Trademark of Cascade Corporation

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Summary of Contents for Cascade E-Series

  • Page 1 ERVICE MANUAL E-Series Non-Sideshifting and Sideshifting Clamps, Carton Clamps Manual Number 215204 R-1 cascade Cascade is a Registered Trademark of Cascade Corporation...

  • Page 2: Table Of Contents

    ONTENTS Page Page INTRODUCTION, Section 1 SERVICE, Section 5 Introduction, 1.1 Clamp Removal, 5.1 Special Definitions, 1.2 Arms, 5.2 Arm Assemblies – Removal and Installation, 5.2-1 26 INSTALLATION, Section 2 Truck System Requirements, 2.1 Drum Arm Pad Surface Replacement, 5.2-2 Recommended Hydraulic Supply Options, 2.2 Carton &...

  • Page 3: Introduction

    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.

  • Page 4: Truck System Requirements

    (28 L/min.) (38 L/min.) 40E, 45E Cascade E-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 is not recommended. If fire resistant hydraulic fluid is required, special seals must be used.

  • Page 5: Recommended Hydraulic Supply Options

    Recommended Hydraulic Supply Options E-Series Clamps provide the best performance with one of the hydraulic supply arrangements shown below. Refer to Cascade Hose and Cable Reel Selection Guide , Part No. 212119, to select the correct hose reel for the mast and truck.
  • Page 6 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. Prepare Attachment...
  • Page 7 NSTALLATION IMPORTANT: Main valve options include LH or RH Prepare Hoses CLAMP/OPEN porting, or dual porting which allows Determine hose lengths required for hydraulic hoses to be plumbed to either side of the Clamp to supply configuration of truck. match existing truck hydraulic supply configurations. Cut hoses to length, install end fittings.
  • Page 8 NSTALLATION Mount Clamp on truck carriage Center truck behind Clamp. Tilt forward and raise carriage into position. Engage 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).
  • Page 9 NSTALLATION Connect hoses prepared in Step 3 to Attachment CL0247.ill CL0104.ill Internal Hose Reeving Hydraulic Supply Double Hose Reels Hydraulic Supply Install solenoid control knob – (Solenoid-equipped units) PRESS BUTTON SIDESHIF TO POSITION Button toward driver Adapter Truck control valve handle CL0240.ill Install wiring –...
  • Page 10 NSTALLATION Cycle Clamp functions WARNING: Make sure all personnel are • With no load, cycle each Clamp function clear of the Clamp during testing. several times. • Check for operation in accordance with ITA (ISO) standards. • Clamp and lift a maximum load. Sideshift left and right.

  • Page 11: 100-Hour Maintenance

    ERIODIC MAINTENANCE ROUBLESHOOTING IMPORTANT: E-Series Clamps are prelubed at the factory. WARNING: After completing any service Lubrication is not necessary for installation. procedure, always test the Clamp through five complete cycles. First test 100-Hour the Clamp empty, then test with a load to...

  • Page 12: General Procedures

    In addition to a normal selection of hand tools, the following are required: Pressure Gauge Kit 671212 • 20 GPM (75 L/min) inline flow meter. (Cascade Flow Meter Kit, part no. 671477.) Pressure No. 6 and No. 8 • 3500 psi (240 bar) pressure gauge.

  • Page 13: Troubleshooting Chart

    ROUBLESHOOTING Troubleshooting Chart 4.1-3 Determine All The Facts – It is important to gather all the facts about the problem before beginning any service procedures. The first step is to talk to the equipment operator. Ask for a complete description of the malfunc- tion.
  • Page 14 Clamp is being used correctly and is not damaged. Use the Trouble- shooting procedure shown and, if necessary, adjust the contact pad camber using a Cascade Shim Service Kit. IF FRONT STACK OF LOAD TILTS OUT:...
  • Page 15 CL0088.ill Add or increase Re-clamp load negative camber so bottom edge (Contact Cascade is even with Service) bottom of pads TYPICAL PAD CAMBER FOR HANDLING CARTON CASE LOADS Front View – Pads CANNED / BOTTLED / DENSE CASE GOODS...

  • Page 16: Plumbing

    ROUBLESHOOTING Plumbing Non-Sideshifting Clamps – 4.2-1 Hosing Diagram OPEN Port Attachment Valve CLOSE Port Cylinders (4) Manifold Hose Reel or Internal Reeving Truck Auxiliary Valve CL0347.ill CLAMP ARMS RELEASE ARMS Pressure: Return: 215204 Rev. 1...

  • Page 17: Non-Sideshifting - Hydraulic Circuit

    ROUBLESHOOTING Non-Sideshifting Clamps – 4.2-2 Hydraulic Circuit Manifold Release Clamp Cylinders (4) TEST Attachment Valve Clamp Check Clamp Valve Relief Valve Flow Divider/Combiner OPEN CLOSE Port Port 2-Port Hose Reel or Internal Reeving Truck Auxiliary Valve (Clamp/Release) Truck Relief Valve Truck Pump Truck Tank CL0345.ill...
  • Page 18 ROUBLESHOOTING Sideshifting Clamps – 4.2-3 Hosing Diagram, Clamp Circuit Port Port SOLENOID ADAPTION OPEN Solenoid Valve Port (energized) Attachment Valve CLOSE SSL / Release Port (PRESSURE Port) Cylinders (4) OPEN Port Manifold Hose Reel or Internal Reeving CLOSE SSR / Clamp Port (TANK Port) Manifold,...
  • Page 19 ROUBLESHOOTING Sideshifting Clamps – 4.2-4 Hosing Diagram, Sideshift Circuit Port Port SOLENOID ADAPTION OPEN Port Solenoid Valve Attachment Valve (not energized) CLOSE Port SSL / Release (PRESSURE Port) Port Cylinders (4) Manifold Port Hose Reel or Internal Reeving SSR / Clamp (TANK Port) Manifold, Cylinders...

  • Page 20: Sideshifting - Hydraulic Circuit

    ROUBLESHOOTING Sideshifting Clamps – 4.2-5 Hydraulic Circuit Manifold Release/Sideshift NOTE: Standard sideshift valve shown. Clamp For sideshift with regeneration valve (arms open faster than close), see Section 4.2-6. Cylinders (4) Clamp Check Valve TEST Attachment Valve Sideshift Check Sideshift Valves (2) Relief Valve Clamp...
  • Page 21 ROUBLESHOOTING Sideshifting Clamps with 4.2-6 Regeneration* – Manifold Release/Sideshift Hydraulic Circuit Clamp *Arms open faster than close. Cylinders (4) Clamp Check Valve TEST Attachment Valve Sideshift Check Valve (2) Regeneration Directional Valve Optional Sideshift Relief Clamp Relief Solenoid Adaption Flow Divider/Combiner OPEN CLOSE Port...

  • Page 22: Clamp Function

    ROUBLESHOOTING Clamp Function WARNING: Before removing hydraulic lines or components, relieve pressure in the hydraulic system. Turn the truck off and There are five potential problems that could affect the open the truck auxiliary control valves CLAMP function: several times in both directions. •...

  • Page 23: Sideshift Function

    ROUBLESHOOTING Release the lever and watch the pressure gauge: Close the arms fully and hold the lever in the CLAMP position for a few seconds. If the pressure still drops as • If the pressure drop is less than 150 psi (10 bar) before, the cylinders are faulty and must be serviced initially, and additional drop does not exceed 25 psi (see Section 5.4).

  • Page 24: Sideshift Circuit Test

    ROUBLESHOOTING Sideshift Circuit Test 4.4-2 Press the solenoid button (if equipped) and listen for a 'click' at the solenoid valve. If no sound is heard, first check the fuse, wiring and coil (see Section 4.5). Then assure that the valve is not jammed (see Section 5.5). IMPORTANT: Solenoid-operated valves must be plumbed so that the solenoid is not energized during the SIDESHIFT function.

  • Page 25: Electrical Circuit

    ROUBLESHOOTING Electrical Circuit (Solenoid-equipped Clamps) Use the electrical schematic and diagram 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.
  • Page 26 ROUBLESHOOTING (page intentionally blank) 215204 Rev. 1...

  • Page 27: Clamp Removal

    ERVICE Clamp Removal Sideshift Left Open Sideshift Right Clamp Position the Clamp's arms to the width of the frame. 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 28: Arms

    ERVICE Arms Arm Assemblies – 5.2-1 Removal and Installation The following procedures can be performed with the Clamp mounted on the truck. Position the arms to frame width. Lower the Clamp to position the contact pads 1/2 in. (13 mm) above the floor. Remove the upper and lower cylinder rod anchor bars on the arm to be removed.

  • Page 29: Drum Arm Pad Surface Replacement

    ERVICE Rivet (6) Drum Arm Contact Pad – 5.2-2 Surface Replacement The following procedures can be performed with the Clamp mounted on the truck. Single Drum Arms. Drill out the rivets using a 3/16-in (5 mm) drill bit. Drill from the back side of the arm. Align the new contact surface to the arm.
  • Page 30 ERVICE Rigid Arm, Carton Clamp 5.2-3 Arm Contact Pad – Replacement or Rotation The following procedures can be performed with the Clamp mounted on the truck. NOTE: Contact pad surfaces that are worn or damaged over the entire pad area will require pad replacement. If only the lower surface is worn, the pads can be rotated 180 °...
  • Page 31 New wear tiles (Part No. 208860) can be ordered from CL0405.ill Cascade Parts Sales, 888-CASCADE (227-2233). IMPORTANT: If wear extends into the stabilizer bottom Pin Retainers, surface, build up with weld and grind flat to within 1/16...
  • Page 32 ERVICE Carton Clamp Contact Pad 5.2-5 Camber Adjustment The following procedures can be performed with the arms Position contact in place and the Clamp mounted on the truck. pads to frame width Extend the arms to frame width. Lower the contact Positive pads so that they just touch the floor.

  • Page 33: Clamps Without Arms

    ERVICE Clamps without Arms 5.2-6 Customer-supplied arms can be welded to the vertical Sliding arm bases that connect the Clamp's parallel sliding arm bars. bar assembly Sliding arm assemblies must be removed from the Clamp to accomplish this procedure. WARNING: Use a certified welder and proper welding procedures when welding customl arms to the sliding arm bases.

  • Page 34: Arm Bearings - Removal And Installation

    ERVICE Arm Bearings – WARNING: Make sure that a safety person 5.2-7 is at the truck controls at all times if this Removal and Installation maintenance procedure is done with the truck running. The following procedure can be performed with the arms in place and the Clamp mounted on the truck.

  • Page 35: Valve/Manifold

    ERVICE Valve/Manifold Valve-to- Manifold O-rings (3) Valve Removal and 5.3-1 Installation The following procedure can be performed with the Clamp mounted on the truck. Raise the Clamp so that the Valve is accessible from behind, through the mast. Remove the valve guard (if equipped). WARNING: Before removing hydraulic components, relieve pressure in the hydrau- lic system.

  • Page 36: Valve Service

    Valve Service 5.3-3 IMPORTANT: Service the Valve in a clean work area. E-Series Clamps use three different types of Valve assem- blies: non-sideshifting, sideshifting, and sideshifting with regeneration. Service procedures are the same for all. Remove the Valve from the Clamp as described in Section 5.3-1.
  • Page 37 ERVICE Valve Service (Continued) 5.3-3 (clamp) CL0363.ill Sideshifting Valve (Sideshift) CL0400.ill Sideshifting Valve with Regeneration 215204 Rev. 1...

  • Page 38: Relief Valve Cartridge Adjustment

    ERVICE Relief Valve Cartridge WARNING: Before removing hydraulic lines 5.3-4 or components, relieve pressure in the Adjustments hydraulic system. Turn the truck off and open the truck auxiliary control valves several times in both directions. NOTE: For optimum performance, the relief valve cartridges for both the CLAMP and SIDESHIFT functions should be adjusted to match the truck hydraulic flow rate.

  • Page 39: Cylinders

    ERVICE Cylinders Cylinder Service 5.4-1 The cylinders can be serviced with the Clamp mounted on the truck by using the following procedure. If preliminary inspection reveals external damage, replace the cylinder (see Section 5.4-5. Cylinder Disassembly 5.4-2 CL0310.ill NOTE: All four cylinders should be serviced if trouble- Front shooting reveals that one cylinder is faulty or leaking.

  • Page 40: Cylinder Inspection

    ERVICE Cylinder Disassembly 5.4-2 (Continued) Place a towel or drip pan under the cylinder retainer. Scribe a mark on the cylinder retainer and shell for alignment during reassembly. CL0312.ill Use a 6 mm Allen hex extension to remove the cap- screws fastening the cylinder retainer to the shell.

  • Page 41: Cylinder Reassembly

    ERVICE Cylinder Reassembly 5.4-4     Lubricate all new seals and O-rings with petroleum jelly. Note the direction of the U-cup seals. Pressure seals must be installed with the lip toward the high pres- sure side of the cylinder. Piston U-Cup Retainer U-Cup   ...
  • Page 42 ERVICE Cylinder Reassembly 5.4-4 (Continued) Inspect the rod end anchor parts for wear and replace if necessary. Reassemble the rod end, split rings and anchor bar to the arm. Apply Loctite No. 242 (Blue) to CL0320.ill the capscrew threads and tighten to: 20, 30E, 33E –...

  • Page 43: Cylinder Replacement

    ERVICE Cylinder Replacement 5.4-5 The following procedure requires that the Clamp be Remove the cylinder and bearings from the front of the removed from the truck. baseplate. Plug the ports in the manifold. Keep track of the two O-rings between the cylinder and Remove the arm attached to the cylinder to be replaced the hydraulic manifold.

  • Page 44: Base Unit

    ERVICE CAUTION: Replace only one baseplate half at a time. Base Unit DO NOT LOOSEN ALL THE BASEPLATE CAPSCREWS AT THE SAME TIME. Baseplate Replacement Remove the capscrews from the baseplate half to be 5.5-1 replaced. Remove the baseplate. Baseplate halves can be replaced without disassembling NOTE: Do not move the Clamp or arms once the the Clamp.

  • Page 45: Solenoid Valve

    ERVICE Solenoid Valve Coil Service 5.6-1 Remove the cover from the valve assembly. Disconnect the wires and diode from the coil terminals. Loosen the end cover capscrews. Remove the end cover and coil. Install the new coil and end cover. Assure that the terminals are positioned correctly.

  • Page 46: Specifications

    (28 L/min.) (38 L/min.) 40E, 45E Cascade E-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 is not recommended. If fire resistant hydraulic fluid is required, special seals must be used.
  • Page 47 PECIFICATIONS Torque Values 6.1-4 Fastener torque values for E-Series Clamps are shown in the table below in both U.S. and Metric units. All torque values are also called out in each specific service proce- dure section throughout the Manual. Ref.
  • Page 48 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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