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Summary of Contents for Cascade 100KTH
- Page 1 Operator’s Manual Maintenance · Service · Operation · Spare Parts Dedicated Tyre Handler Model No. 100KTH Part No. 100K-THC-E-16858 Quick Hitch Mount to Suit CAT 988H PSM Coupler Serial No. AUS462049 cascade ® corporation Cascade Australia Pty Ltd Queensland Australia...
- Page 2 Due to Cascade’s policy of continuous improvement, product specifications are subject to change without notice. Hence, all spare part orders must include the machine details listed above to ensure the correct parts are supplied.
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Page 3: Table Of Contents
100K-THC-E-16858 Table of Contents MANUAL REVISIONS LIST ...................... 1.3 INTRODUCTION........................2.4 SPECIAL INSTRUCTION DEFINITIONS ..................2.4 SAFETY INFORMATION ........................2.5 INSTALLATION INSTRUCTIONS ..................... 3.6 TRUCK SYSTEM REQUIREMENTS ....................3.6 FITTING OF ATTACHMENT TO FORK TRUCK ................3.6 SPECIFICATIONS ........................4.7 SAFETY RULES ........................ - Page 4 100K-THC-E-16858 REVOLVING CONNECTION SEALS AND CARTRIDGES............9.25 CYLINDER SERVICE......................10.26 10.1 REMOVING AND INSTALLING THE CLAMP CYLINDERS............10.26 10.2 CYLINDER DISASSEMBLY......................10.26 10.3 CYLINDER INSPECTION......................10.27 10.4 CYLINDER REASSEMBLY ......................10.27 10.5 TILT CYLINDER ..........................10.27 10.6 ROTATE CYLINDER ........................
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Page 5: Manual Revisions List
100K-THC-E-16858 1 MANUAL REVISIONS LIST Date of Revision Location Description of Revision 06/09/18 Released 1.3 | P a g e... -
Page 6: Introduction
Cascade Tyre Handler. Note that all specifications are in metric units where applicable. The descriptions and specifications in this manual are subject to change without notice. Cascade Corporation reserves the right to improve equipment. Some product improvements may have taken place after this manual was published. -
Page 7: Safety Information
Ensure that all ground personnel remain out of the operating area of the machine. Follow safe practices when servicing attachments. Do not modify or weld on any area of this attachment without consulting Cascade or their service agent. Most structural components are manufactured from high tensile plate and require special procedures for any welding. -
Page 8: Installation Instructions
During and after installation, check to ensure that the Tyre Handler attachment CAUTION: will not interfere with any part of the fork truck at any stage of operation. If any interference is apparent or anticipated, contact Cascade Australia. 3.6 | P a g e... -
Page 9: Specifications
100K-THC-E-16858 4 SPECIFICATIONS MODEL NUMBER 100KTH PART NUMBER 100K-THC-E-16858 SWL CAPACITY 10,000 kg LOAD CENTRE / ARM LENGTH 2500 mm MAX. TYRE DIA 3600 mm (Max. opening between pads: 4310 mm) MIN. TYRE DIA 1600 mm (Min. opening between pads: 1260 mm) MAX. - Page 10 100K-THC-E-16858 OPENING RANGE ARM LENGTH VC of G HC of G 4.8 | P a g e...
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Page 11: Safety Rules
5.1 GENERAL Safety is a first priority when it comes to Cascade Tyre handlers. This Equipment is designed to handle tyres with ease and safety. It is also user’s responsibility to maintain and operate this tyre handler with caution, skill &... -
Page 12: Operator Instructions
6.5 PREPARATION BEFORE EACH SHIFT This procedure is for the daily pre-start check for a Cascade tyre handler Important: This attachment is a clamping attachment and the pre-start checks listed are important to ensure that each design function is operating as it was designed. - Page 13 100K-THC-E-16858 Ensure both arms move to the right when the sideshift right function is selected. Note: Do not sideshift arms until the cylinders bottom out. Conduct function test with arms approximately in the mid position. Ensure both arms move to the left when the sideshift left function is selected. Note: Do not sideshift arms until the cylinders bottom out.
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Page 14: Operating Controls
100K-THC-E-16858 6.6 OPERATING CONTROLS Typical joystick functions 6.12 | P a g e... -
Page 15: Operating Restrictions
100K-THC-E-16858 6.7 OPERATING RESTRICTIONS DANGER – failure to obey the following may result in death, serious injury, instability or equipment damage. This section should be placed in truck cabin & made visible to the operator at all times. NEVER handle tyre’s filled with ballast. If load limits NEVER transport tyre in vertical position. -
Page 16: Operator Training
Operations must be suspended until the work area is cleared. 6.8 OPERATOR TRAINING The Cascade Tyre Clamp is designed for operator simplicity. Prior to operating this unit, the operator must become thoroughly familiar with control functions, operating procedures, and safety precautions. - Page 17 100K-THC-E-16858 WARNING Apply clamp load only when arms are horizontal or near horizontal. Do not re-clamp load when arms are vertical. WARNING When Tyre stops are not in use they should be positioned facing backwards. If positioned forward, they may damage the cylinder guards. Tyre stop rotated backwards for storage.
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Page 18: Tyre Handler Operating Restrictions
100K-THC-E-16858 Fig 3 6.11 TYRE HANDLER OPERATING RESTRICTIONS The Tyre handler is intended to be a tyre lifting and positioning unit. There are possible misapplications of this machine that can cause serious damage. Use of a single arm for lifting or carrying a load will void the tyre handler warranty. Use of one arm of the tyre handler for bead breaking will void the warranty. -
Page 19: Maintenance Procedures
100K-THC-E-16858 7 MAINTENANCE PROCEDURES 7.1 IMPORTANT SAFETY INFORMATION WARNING Before servicing any hydraulic component, relieve pressure in the system. Turn the truck off and open the truck auxiliary control valves several times in both directions. After completing any service procedure, always test the function through five complete cycles. First test the attachment empty to bleed air trapped in the system to the truck system. - Page 20 100K-THC-E-16858 Never reuse the main slew bearing mounting fasteners. Always replace with new fasteners. If hardened washers are fitted, these must be used when fitting new fasteners. Lubricate slew ring bearing and gear with EP-2 grease. Rotate in 30 degree increments grease each...
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Page 21: Tyre Handler Lubrication Diagram
100K-THC-E-16858 7.3 TYRE HANDLER LUBRICATION DIAGRAM Apply multi-purpose extreme-pressure NLGI 2 grease all grease points Rotate cylinder spherical bearings There are 6 plugs spaced equally for access to the rotator Rotate whilst bolts. applying grease. 7.19 | P a g e... -
Page 22: Troubleshooting
100K-THC-E-16858 8 TROUBLESHOOTING IMPORTANT: It is important that you gather all the facts regarding the problem before you begin service procedures. The best way of doing this is to talk with the fork truck operator. 8.1 GUIDELINES The following guidelines will help you decide where to begin your troubleshooting procedures: Clamp drops load after it has been picked up. -
Page 23: Chart
100K-THC-E-16858 8.2 CHART Trouble Shooting Chart Problem Possible Cause Possible Solution Vibration and jerking Lock of oil in reservoir. Add hydraulic oil when first operating Low temperature of oil. Manoeuvre with no load to warm oil. unit Lack of oil in reservoir. Add hydraulic oil Vibrations with every function when oil is hot. -
Page 24: Clamp Circuit Test
100K-THC-E-16858 Trouble Shooting Chart Main arm travel is Flow divider is faulty. Clean or replace uneven Main body doesn’t Rotate relief valve faulty. Test and replace if required rotate. Unit will not sideshift Pressure trapped in clamp Remove plug from equaliser port. after clamping a load. - Page 25 100K-THC-E-16858 If Clamp will not sideshift or sideshifts slowly, adjust SS relief clockwise (CW) until Clamp sideshifts. Then adjust counter-clockwise (CCW) 1/4-turn increments until sideshift speed slows (relief opening). Finish by adjusting cartridge clockwise (CW)1/4-turn. If Clamp will not sideshift after attempted relief adjustment, go to Step 3. 3.
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Page 26: Control Valve Assembly Service
100K-THC-E-16858 9 CONTROL VALVE ASSEMBLY SERVICE 9.1 REVOLVING CONNECTION FEATURES All the main hydraulic valves and cartridges for the operation of the tyre handler are contained in the revolving connection. This valve also contains 3 test points for checking the hydraulic pressure of the sideshift, clamp and tilt functions. -
Page 27: Revolving Connection Seals And Cartridges
100K-THC-E-16858 9.3 REVOLVING CONNECTION SEALS AND CARTRIDGES. 9.3.1 Disassemble. To service the revolving connection, the valve support must be removed, all feed tubes removed and the unit moved to the rear of the tyre handler. Clean the revolving connection before disassembling. Carefully remove the main shaft from the valve body after checking for any burrs on the shaft. -
Page 28: Cylinder Service
100K-THC-E-16858 10 CYLINDER SERVICE. 10.1 REMOVING AND INSTALLING THE CLAMP CYLINDERS. The cylinders can be removed whilst the unit is mounted on the truck. Do not remove the hydraulic supply till the cylinder rod has been disconnected from the arm. Note that the cylinders are heavy and a crane will be required to lift then from the unit. -
Page 29: Cylinder Inspection
100K-THC-E-16858 10.3 CYLINDER INSPECTION. Inspect the rod, piston and retainer for any nicks or burrs. Minor imperfections can be removed with 400-grit emery cloth. Inspect the cylinder bore and remove any minor nicks with a butterfly hone. Inspect the outside of the barrel of any dents, etc. Inspect the feed tubes for any damage. -
Page 30: Rotate Cylinder
100K-THC-E-16858 Removal of the cylinder cover is required to remove the feed hoses. Check all welds at the attachment location for the bearing housings. Refer to the assembly drawing for assembly torques and replacement part numbers. 10.6 ROTATE CYLINDER The rotate cylinder is mounted on the upper area of the base and the rod is attached to the carraige or base plate. - Page 31 100K-THC-E-16858 10.6.2 Cylinder inspection The disassembly and reassembly process is similar to the clamp cylinder. Each end of the cylinder has a spherical bearing with can be replaced after removing a circlip. The cylinder is fitted with 2 counterbalance valves. Do not adjust these valves as they are factory-preset.
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Page 32: Main Slew Bearing
100K-THC-E-16858 11 MAIN SLEW BEARING The tyre handler rotates on a large diameter slew bearing with a large number of bolts to attach the bearing to the carriage and to the base weldment. The bearing is not adjustable for wear. The unit has a drain hole or drain slot at the bottom of the bearing to allow any water trapped inside the rotator to escape. -
Page 33: Shimming Clamp Arms
100K-THC-E-16858 12 SHIMMING CLAMP ARMS. 12.1 SHIM SLIDE ARM The sliding clamp arms are guided by a number of plastic bearings retained in the main body by bronze plugs. Under the upper and front bearings are steel shims used to adjust the arm clearance. -
Page 34: Fastener Torque Values
100K-THC-E-16858 13 FASTENER TORQUE VALUES Nm – non lubed Fastener Size Nm - lubed (As supplied) Baseplate to rotator bearing, M24 – 10.9 1000 Rotator bearing to base weldment, M24 – 12.9 1230 Baseplate to rotator bearing, M20 – 10.9 Rotator bearing to base weldment, M20 –... -
Page 35: Mechanical Assembly Drawings
100K-THC-E-16858 14 MECHANICAL ASSEMBLY DRAWINGS 14.1 INDEX OF DRAWINGS & DIAGRAMS Tyre Handler, Dedicated. Assembly, Carriage. Assembly, Rotate. Assembly, Arm, L.H. Assembly, Arm, R.H. Revolving connection. Bracket. Clamp cylinder. Tilt cylinder. Rotate Cylinder. Relief Valve. Hose Layout. Feed Tubes. Bearing Assembly. Bearing Assembly. -
Page 54: Hydraulic Circuit & Layout Diagrams
100K-THC-E-16858 15 HYDRAULIC CIRCUIT & LAYOUT DIAGRAMS 15.1 INDEX OF HYDRAULIC CIRCUIT & LAYOUT DIAGRAMS 1. Hydraulic Group , Drawing S- 52127 PRESSURE PRESSURE CIRCUIT PRESSURE PRESSURE PRESSURE BODY ROTATE BODY ROTATE REC. CLAMP SIDESHIFT PAD TILT (ROD END) (BASE END) FLOW S - 52127 16 MPa... -
Page 56: Electric Circuit & Layout Diagrams
100K-THC-E-16858 16 ELECTRIC CIRCUIT & LAYOUT DIAGRAMS 16.1 INDEX OF ELECTRIC CIRCUIT & LAYOUT DIAGRAMS NO ELECTRIC’S FITTED. 16.35 | P a g e... -
Page 57: Assembly Parts List
100K-THC-E-16858 17 ASSEMBLY PARTS LIST Included in this manual is a complete parts list for the Tyre handler. When ordering spare parts, please quote the part numbers as they appear in this parts list. All parts lists are as noted on drawings. 17.36 | P a g e... -
Page 58: Tyre Handler Weld & Structural Inspection
TYRE HANDLER ARMS – REFER ATTACHED SHEET BASE & REAR CARRIAGE ASSEMBLY – REFER ATTACHED SHEET If any Non-destructive tests are required to be carried out for further inspection Cascade recommends NATA accredited representative. If Magnetic flaw detection test is used it should be carried out as per AS1171-1998 If Ultrasonic Testing is used AWS D-14.1 Sections 10.13 through 10.15.11 is recommended. -
Page 59: Arm Inspection
100K-THC-E-16858 18.1 ARM INSPECTION RATING OF SEVERITY: 1- Advised Supervisor 2- Advised Supervisor - Plan for Repairs 3-Advised Supervisor - Repair Immediately DATE LOCATION OF CRACK LENGTH OF RATE OF COMMENTS ACTIONS TAKEN CRACK SEVERITY SUPERVISOR NAME: …………………………………………………. SUPERVISOR SIGNATURE: ………………………………………… DATE: ………………………….. -
Page 60: Base & Rear Carriage Inspection
100K-THC-E-16858 18.2 BASE & REAR CARRIAGE INSPECTION. RATING OF SEVERITY: 1- Advised Supervisor 2- Advised Supervisor - Plan for Repairs 3-Advised Supervisor - Repair Immediately DATE LOCATION OF CRACK LENGTH OF RATE OF COMMENTS ACTIONS TAKEN CRACK SEVERITY SUPERVISOR NAME: …………………………………………………. SUPERVISOR SIGNATURE: …………………………………………... -
Page 61: Warranty
CASCADE AUSTRALIA DOES NOT WARRANT PRODUCT DAMAGED OR ALTERED DURING FIELD REPAIR: Cascade Australia may request return of any part for which a claim is filed. Retain all parts including packing for return upon request. Do not return any part without an inwards goods authorisation (IGA). - Page 62 EXCLUSIONS: Cascade Australia does not warrant that its products will perform any particular task. Cascade Australia assumes no responsibility for loss, damage or injury to persons or property, or for consequential damages, resulting from the possession or use of its products. Cascade Australia’s warranty does not cover wear, tear, abnormal applications, normal or scheduled maintenance.
- Page 63 100K-THC-E-16858 Appendix 1 TYRE HANDLER INDUCTION LOG Induction Date: Mine: Operator Name: Company: Inducted By: Signature of Inductee: 19.42 | P a g e...
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