Cascade E Series Service Manual
Revolving clamps
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- Operator's manual (50 pages) ,
- Service manual (48 pages) ,
- Installation instructions manual (14 pages)
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Summary of Contents for Cascade E Series
- Page 1 ERVICE MANUAL E-Series Revolving Clamps Manual Number 221093 cascade Cascade is a Registered Trademark of Cascade Corporation...
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Page 2: Table Of Contents
ONTENTS Page Page INTRODUCTION, Section 1 Drive Motor, 5.4 Introduction, 1.1 Drive Motor Removal and Installation, 5.4-1 Drive Motor Disassembly, 5.4-2 Special Definitions, 1.2 INSTALLATION, Section 2 Drive Motor Inspection, 5.4-3 Truck System Requirements, 2.1 Drive Motor Reassembly, 5.4-4 Recommended Hydraulic Supply Options, 2.2 Drive Check Valve, 5.5 Revolving Clamp Installation Procedure, 2.3 Check Valve Service, 5.5-1... -
Page 3: Introduction
NSTALLATION Introduction This Manual provides the Installation, Periodic Mainte- nance, Troubleshooting, Service and Specifications for Cascade E-Series Revolving Clamps. E-Series Clamps are designed for three-shift-a-day continuous-duty operations with minimal maintenance. They offer exceptional visibility for the lift truck driver and provide optimized clamp force and load handling. -
Page 4: Truck System Requirements
(19 L/min.) (28 L/min.) (38 L/min.) Cascade E-Series 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 5: Recommended Hydraulic Supply Options
E-Series Revolving 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: •... - Page 6 Follow the steps shown to install the Revolving 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 Department for assistance. Attach overhead hoist WARNING: Make sure overhead...
- Page 7 Step 3 above. Oil level must be up to fill plug hole. RC0139.ill Remove rubber vent cover. If necessary, fill gearbox with Cascade Gear Lube 656300 or equivalent SAE 90 wt. gear lube (AGMA 'mild' 6EP Gear Oil). 221093 Rev. 0...
- Page 8 NSTALLATION Mount Clamp on truck carriage Center truck behind Revolving Clamp. Tilt mast forward and raise carriage into position. Engage upper mounting hooks with carriage. Make sure locater tab on left hook engages closest notch on top carriage bar. Lift Revolving Clamp 2 in. (5 cm) off pallet. CL0335.ill Make sure lower index block (if equipped) engages fork slot on lower carriage bar.
- Page 9 NSTALLATION Install stop block kit Connect hoses prepared in Step 3 to hose terminals • Preheat each stop block and carriage bar weld area to 325° F (180° C). • Use AWS E7018 low hydrogen rod and weld a 1/4-in (6 mm) fillet around each stop block.
- Page 10 NSTALLATION Check Revolving Clamp functions WARNING: Make sure all personnel are clear of the Clamp during testing. • With no load, cycle CLAMP and ROTATE functions several times. • Check functions for operation in accordance with ITA (ISO) standards. • Clamp and rotate a maximum load, check for equal arm movement and normal rotation.
- Page 11 NSTALLATION Adjust 180-degree stop valve (if equipped) • The 180-degree stop valve requires readjustment of the Factory setting if the Clamp does not slowly stop rotation. See Section 5.9-1 for adjustment procedure. 180-Degree Stop Valve CL0739.ill Back (Driver's) View Adjust cross-over relief valve •...
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Page 12: 100-Hour Maintenance
Capscrews • Check that rotator drive gearcase lubricant level is at bottom of fill plug hole. If necessary, fill with Cascade Rotator Drive Lubricant, Part No. 656300 or SAE 90 wt. gear lube (AGMA 'mild' 6 EP Gear Oil). Replace plug. -
Page 13: General Procedures
• 20 GPM (75 L/min) inline flow meter. (2) No. 8-12 JIC/ O-Ring Flow Meter (Cascade Flow Meter Kit, Part No. 671477.) • 3000 psi (200 bar) pressure gauge. (Cascade Pressure Gauge Kit, Part No. 671212.) • Assorted fittings, lines, drain hoses and quick-couplers GA0013.ill... -
Page 14: Plumbing
ROUBLESHOOTING Plumbing Hosing Diagram 4.2-1 Rotator Drive SOLENOID ADAPTION Cylinders (4) Rotate CCW / Release Rotate CW / Clamp (TANK Port) (PRESSURE Port) Manifold Hose Reels (2) or CLAMP Internal Reeving Port Solenoid Valve Revolving CLAMP Connection Port Hose/Cable Reel or Internal Reeving OPEN Port... -
Page 15: Hydraulic Circuit
ROUBLESHOOTING Hydraulic Circuit 4.2-2 Cylinders (4) Revolving Connection TEST TEST Shaft Block Clamp Check Valves (2) Cross- over Relief Valve Flow Divider/Combiner OPEN CLAMP port port Rotator Drive 2-Port Solenoid Adaption Hose Reel 2-Port Rotator Motor, Hose Reel Relief Valve or Internal Solenoid Valve Reeving... -
Page 16: 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 17: Rotate 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 5.6). -
Page 18: Rotate Circuit Test
ROUBLESHOOTING Rotation Circuit Test 4.4-2 without Load Pressure gauges 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. Assure that the valve is not jammed (see Section 5.8). -
Page 19: 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 20: Revolving Clamp Removal
ERVICE Rotate Revolving Clamp Clamp Rotate Removal Open 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 move the truck auxiliary control valves several times in both directions. -
Page 21: Arms
ERVICE Arms Arm Assemblies – 5.2-1 Removal and Installation The following procedures can be performed with the Revolving Clamp mounted on the truck. Position the arms to frame width. Lower the Clamp to position the arms 1/2 in. (13 mm) above the floor. Remove the upper and lower cylinder rod anchor bars on the arm to be removed. -
Page 22: 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 Revolving 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. -
Page 23: Rigid Arm Pad Replacement/Rotation
ERVICE Rigid Arm Contact Pad – 5.2-3 Replacement or Rotation The following procedures can be performed with the Revolving 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 24: Clamps Without Arms
ERVICE Clamps without Arms 5.2-4 Customer-supplied arms can be welded to the vertical Sliding arm bases that connect the Revolving Clamp's parallel sliding bar assembly arm bars. Sliding arm assemblies must be removed from the Clamp to accomplish this procedure. WARNING: Use a certified welder and proper welding procedures when welding custom arms to the sliding arm bases. -
Page 25: Arm Bearings - Removal And Installation
ERVICE Arm Bearings – 5.2-5 WARNING: Make sure that a safety person 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 Revolving Clamp mounted on the truck. -
Page 26: Drive Group
Lubricant must be up to the bottom of the fill plug hole. If necessary, fill RC0171.ill with Cascade Gear Lube Part No. 656300, or SAE 90 wt. gear lube (AGMA 'mild' 6 EP Gear Lube). Drive Group Drive Group –... - Page 27 ERVICE Drive Group – 5.3-2 Disassembly and Service (Continued) Bearing outer race Tap the worm and bearing assembly out through the end-cover side of the housing. Remove the opposite outer bearing race through the motor side of the housing. RC0173.ill Worm Press the pinion gear, pinion bearings and worm gear Worm...
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Page 28: Drive Group Reassembly
ERVICE Drive Group Reassembly 5.3-3 Apply Loctite sealant 515 (Cascade Part No. 668184) to the pinion shaft seating area and shoulder for the housing/pinion bearing. Install the housing/pinion Pinion bearing. Remove excess sealant. gear RC0176.ill Install the key, worm gear, cover plate/pinion bearing and snap ring on the pinion. - Page 29 Remove excess sealant. With the gearcase laying flat, fill with 2-1/2 cups (600 ml) of Cascade Gear Lube Part No. 656300, or SAE 90 wt. gear lube (AGMA 'mild' 6EP Gear Lube). Install the cover plate and gasket. Install the four RC0181.ill...
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Page 30: Drive Motor
Tighten the capscrews to 55–65 ft.-lbs. (75–90 Nm). • Fill the drive group with 2-1/2 cups (600 ml) Cascade Gear Lube Part No. 656300, or SAE 90 wt.gear lube (AGMA 'mild' 6 EP Gear Lube). 221093 Rev. 0... -
Page 31: Drive Motor Disassembly
ERVICE Drive Motor Disassembly 5.4-2 Cascade provides service replacement parts for the unshaded parts only. 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 5.4-1. -
Page 32: Drive Motor Inspection
ERVICE Drive Motor Inspection 5.4-3 • Remove all Loctite residue from the threaded holes. • Clean all parts with solvent and blow dry. Do not use paper or cloth towels. • Inspect all parts for small nicks or burrs. Remove any small nicks or burrs with emery cloth. - Page 33 ERVICE Drive Motor Reassembly (Continued) 5.4-4 Install the seal and Gerotor set on the spacer plate. IMPORTANT: Make sure a lobe point on the geroler set matches up with the reference threaded capscrew Seal hole marked in Step 7. End Cap washers (7) Install the seal and end cap, seal washers and capscrews.
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Page 34: Drive Check Valve
ERVICE Drive Check Valve Check Valve Service 5.5-1 WARNING: Before removing hydraulic lines or components, relieve pressure in the hydraulic system. Turn the truck off and move the truck auxiliary control valves several times in both directions. Disconnect the hydraulic hoses to the drive group. Tag the hoses for reassembly Rotator Drive Check Valve... -
Page 35: Revolving Connection/Manifold
ERVICE Revolving Connection, Manifold Removal and Installation 5.6-1 WARNING: Before removing any hydraulic lines or components, relieve pressure in the NOTE: The revolving connection body can be serviced with Attachment hydraulic system. Turn the the Attachment mounted on the truck. If service is required truck off and move the auxiliary control on the end block or shaft, the Attachment must be removed valve several times in both directions. -
Page 36: Manifold Removal And Installation
ERVICE Manifold Removal and 5.6-2 Installation IMPORTANT: Removing the hydraulic manifolds requires WARNING: Before removing any hydraulic that the Attachment be removed from the truck and the lines or components, relieve pressure in the complete base unit be removed from the Attachment. hydraulic system. - Page 37 If severely worn, replace the shaft. tool (Cascade Part No. 674424). • Body – Check the seal grooves in the body for sharp NOTE: Do not scratch or damage the grooved sur- nicks or projections.
- Page 38 • Install the square rubber rings into the grooves in the revolving connection body. • Install the Teflon rings over the rubber rings. NOTE: Use seal installation tool (Cascade part number 599512) when installing internal seals. If seals are installed by hand, form into 'kidney' shape to avoid sharp bends that can cause permanent damage to seals.
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Page 39: Relief Valve Adjustment
ERVICE Cross-Over Relief Valve Pressure gauges 5.6-4 connected to both Adjustment TEST ports on revolving connection For Attachment over-pressure protection, the cross-over relief valve cartridge for the CLAMP function should be adjusted to match the truck hydraulic flow rate. MAXIMUM RELIEF VALVE SETTING = 2600 psi (180 bar). WARNING: Before removing hydraulic lines or components, relieve pressure in the Attachment hydraulic system. -
Page 40: Cylinders
ERVICE Cylinders Cylinder Service 5.7-1 The cylinders can be serviced with the Attachment mounted on the truck by using the following procedure. If preliminary inspection reveals external damage, replace the complete cylinder (see Section 5.7-5). Cylinder Disassembly 5.7-2 NOTE: All four cylinders should be serviced if trouble- CL0786.ill Front View shooting reveals that one cylinder is faulty or leaking. -
Page 41: Cylinder Inspection
ERVICE Cylinder Disassembly 5.7-2 (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 42: Cylinder Reassembly
ERVICE Cylinder Reassembly 5.7-4 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 43 ERVICE Cylinder Reassembly 5.7-4 (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: 30E, 33E –...
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Page 44: Cylinder Replacement
ERVICE Cylinder Replacement Remove the cylinder and bearings from the front of the 5.7-5 faceplate. Plug the ports in the manifold. The following procedure requires that the Attachment be Keep track of the two O-rings between the cyinder and removed from the truck, and that the baseplate and manifold section. -
Page 45: Base Unit
ERVICE Base Unit Rotation Bearing Assembly – 5.8-1 Removal and Installation Remove the Attachment from the truck as described in Section 5.1. Remove the drive group as described in Section 5.3-1. Remove the upper mounting hooks. For reassembly, tighten the capscrews to 125 ft.-lbs. (165 Nm). Remove the revolving connection retainer yoke. - Page 46 ERVICE Rotation Bearing Assembly – 5.8-1 Removal and Installation (Continued) Attach two eyebolts to the outer race on the bearing assembly. Attach an overhead hoist to the bearing and take up the slack in the chain. Remove the capscrews fastening the bearing assembly Faceplate to the faceplate.
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Page 47: 180-Degree Stop Group
ERVICE 180-Degree Stop Group Stop Valve Adjustment 5.9-1 Adjustment Screw and WARNING: Make sure all personnel are Jam Nut clear of the Clamp during adjustment. The stop valve slowly stops Clamp rotation as it ap- proaches the hard stops at the 180° positions. Operation is by cam-operated plungers that slowly shut off the rotator drive hydraulic supply. -
Page 48: Stop Valve Service
ERVICE Stop Valve Service 5.9-2 WARNING: Before removing hydraulic RC0339.ill lines, relieve pressure in the hydraulic system. Turn the truck off and open the truck auxiliary control valves several times in both directions. Disconnect the hydraulic tubing from the stop valve. Remove the capscrews and stop valve from the angle bracket on the baseplate. -
Page 49: Specifications
(19 L/min.) (28 L/min.) (38 L/min.) Cascade E-Series 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 50 PECIFICATIONS Torque Values 6.1-4 Fastener torque values for E-Series Revolving 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 procedure section throughout the Manual. NOTE: Torque values given are for lubricated threads.
- Page 51 PECIFICATIONS CL0682.ill 17 18 19 (Capscrews accessed through plug) CL0683.ill 221093 Rev. 0...
- Page 52 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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Questions and answers
what is the issue if only one of the arms moves very slow... the other one moves at the right speed
One possible cause is that the muscle on the slower-moving arm is generating less force or power, possibly due to fewer muscle fibers being activated. This could result from weaker neural signals, leading to fewer motor units being recruited, or from physiological limitations such as fatigue or reduced muscle efficiency. Differences in load or resistance on each arm could also affect the speed of movement due to the force–velocity relationship of muscles.
This answer is automatically generated