Related Manuals for Cascade 80D
Summarization of Contents
Introduction, Section 1
1.1 Introduction
Overview of the D-Series service manual scope and product identification.
1.2 Special Definitions
Explains the meaning of WARNING, CAUTION, IMPORTANT, and NOTE statements used in the manual.
Installation, Section 2
2.1 Truck Requirements
Details truck hydraulic pressure, flow volume, and carriage mount dimensions for compatibility.
2.2 Recommended Hydraulic Supply
Specifies hose and fitting requirements for different clamp configurations and functions.
2.3 Installation Procedure
Step-by-step guide for attaching the attachment to the lift truck, including hooks and hoses.
2.4 Custom Arm Installation
Instructions for fabricating and welding custom arms onto the attachment base.
2.5 Prior to Operation
Critical pre-operation checks for leaks, arm travel, and clamp function testing.
Periodic Maintenance, Section 3
3.1 100-Hour Maintenance
Routine inspection and tightening of cylinder anchor joints and arm capscrews.
3.2 500-Hour Maintenance
Checks for hook engagement clearance and tightening of lower hook capscrews.
3.3 1000-Hour Maintenance
Inspecting arm bearings for wear and potential replacement.
3.4 2000-Hour Maintenance
Inspecting arm bearings and tightening frame mounting plate capscrews.
Troubleshooting, Section 4
4.1 General Procedures
Outlines system requirements, tools, and general guidelines for diagnosing problems.
4.1-1 Truck System Requirements
Specifies truck hydraulic pressure, flow, and fluid requirements for attachment operation.
4.1-2 Tools Required
Lists essential tools for troubleshooting, including flow meters and pressure gauges.
4.1-3 Troubleshooting Chart
Provides a guide to common clamp and sideshift circuit problems and their solutions.
4.2 Plumbing – Top Mount Valve
Hosing diagrams and circuit schematics for top mount valve troubleshooting.
4.2-1 Hosing Diagram, Non-Sideshifting
Illustrates hydraulic hose routing for non-sideshifting clamp operations.
4.2-2 Circuit Schematic, Non-Sideshifting
Shows the hydraulic circuit schematic for non-sideshifting clamp operations.
4.2-3 Hosing Diagram, Sideshifting (including Turnafork)
Illustrates hydraulic hose routing for sideshifting clamp operations.
4.2-4 Circuit Schematic, Sideshifting (including Turnafork)
Shows the hydraulic circuit schematic for sideshifting clamp operations.
4.3 Plumbing – Center Mount Valve
Hosing diagrams and circuit schematics for center mount valve troubleshooting.
4.3-1 Hosing Diagram, Non-Sideshifting
Illustrates hydraulic hose routing for non-sideshifting clamp with center mount valve.
4.3-2 Circuit Schematic, Non-Sideshifting
Shows the hydraulic circuit schematic for non-sideshifting clamp with center mount valve.
4.3-3 Hosing Diagram, Sideshifting
Illustrates hydraulic hose routing for sideshifting clamp with center mount valve.
4.3-4 Circuit Schematic, Sideshifting
Shows the hydraulic circuit schematic for sideshifting clamp with center mount valve.
4.4 Attachment Troubleshooting
Specific problem areas and diagnostic procedures for attachment functions.
4.4-1 Clamp Circuit Pressure Test
Procedure to test hydraulic pressure in the clamp circuit.
4.4-2 Check Valve Pressure Test
Procedure to test check valve functionality by monitoring pressure drop.
4.4-3 Cylinder Test
Procedure to test cylinder performance by monitoring pressure drop.
4.4-4 Sideshift Circuit Pressure Test
Procedure to test sideshift circuit functionality and cartridge issues.
4.4 Electrical Circuit (Solenoid Equipped Attachments)
Troubleshooting steps for electrical circuits on solenoid-equipped attachments.
Service, Section 5
5.1 Attachment Removal
Step-by-step guide for safely removing the attachment from the lift truck.
5.2 Arms
Procedures for servicing the clamp arms, including removal, installation, and replacement.
5.2-1 Arm Assembly Removal and Installation
Procedures for removing and installing the arm assemblies, including torque values.
5.2-2 Bolt-On Arm Removal
Detailed steps for removing bolt-on arm assemblies, including torque specifications.
5.2-3 Multi-Purpose/Rigid and Drum Arm Contact Surface Replacement
Instructions for replacing contact surfaces on multi-purpose, rigid, and drum arms.
5.2-4 Rigid Arm Contact Pad Rotation and Replacement
Procedures for rotating or replacing rigid arm contact pads.
5.2-5 Arm Bearing Removal and Installation
Detailed steps for removing and installing arm bearings within the frame.
5.2-6 Turnafork Arm Service
Disassembly procedures for Turnafork arm assemblies.
5.2-7 Turnafork Arm Indexing
How to reposition Turnafork arms that are out of phase or not horizontal/vertical.
5.3 Cylinders
Procedures for removing, installing, and servicing the hydraulic cylinders.
5.3-1 Cylinder Removal and Installation
Procedures for removing and installing the cylinders from the clamp frame.
5.4 Cylinder Service
Detailed procedures for disassembling, inspecting, and reassembling hydraulic cylinders.
5.4-1 Cylinder Disassembly
Step-by-step guide for disassembling hydraulic cylinders.
5.4-2 Cylinder Inspection
How to inspect cylinder rods, pistons, retainers, and shells for wear or damage.
5.4-3 Cylinder Reassembly
Detailed instructions for reassembling hydraulic cylinders with torque values.
5.5 Restrictor Cartridges
Procedures for adjusting and servicing restrictor cartridges to ensure equal arm movement.
5.5-1 Restrictor Cartridge Adjustment
How to adjust restrictor cartridges for equal arm travel during opening and closing.
5.5-2 Restrictor Cartridge Service
Procedures for servicing and replacing restrictor cartridge components.
5.6 Check Valves
Procedures for removing and servicing check valves in top and center mount assemblies.
5.6-1 Check Valve Removal – Top Mount Valves
Steps to remove check valves from top mount valve assemblies.
5.6-2 Check Valve Removal – Center Mount Valves
Steps to remove check valves from center mount valve assemblies.
5.6-3 Check Valve Service – Top Mount Valves
Procedures for servicing check valve cartridges in top mount assemblies.
5.6-4 Check Valve Service – Center Mount Valves
Procedures for servicing check valve cartridges in center mount assemblies.
5.6-5 Eliminating the Arm Opening Regenerative Function
How to eliminate the regenerative function for equal arm opening and closing speed.
5.7 Base Unit
Procedures for disassembling and reassembling the base unit frame and mounting plates.
5.7-1 Frame and Mounting Plate Disassembly and Reassembly
Instructions for disassembling and reassembling the base unit frame and mounting plates.
5.8 Solenoid Valve
Procedures for servicing solenoid valve coils and the valve body.
5.8-1 Coil Service
Procedures for servicing the solenoid coil, including replacement.
5.8-2 Valve Service
How to service the solenoid valve body and plunger.
Specifications, Section 6
6.1 Specifications
Contains general technical specifications for the D-Series attachments.
6.1-1 Hydraulics
Details truck relief setting, flow volume, and hose/fittings specifications.
6.1-2 Auxiliary Valve Functions
Overview of auxiliary valve functions for various hydraulic controls.
6.1-3 Truck Carriage
Provides carriage mount dimension standards (ITA/ISO) for compatibility.
6.1-4 Torque Values
Lists torque values for various fasteners used on D-Series attachments.
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