Cascade G Series Manual de usuario
Cascade is a Registered Trademark of Cascade Corporation
cascade
corporation
ERVICE MANUAL
S
G-Series
Sliding Arm Paper
Roll Clamp
Manual No. 6851096
ONTENTS
C
i6851096
Page
INTRODUCTION, Section 1
Introduction 1
Special Definitions 1
PERIODIC MAINTENANCE, Section 2
100-Hour Maintenance 2
500-Hour Maintenance 2
1000-Hour Maintenance 2
4000-Hour Maintenance 2
TROUBLESHOOTING, Section 3
General Procedures 3
Truck System Requirements 3
Tools Required 3
Troubleshooting Chart 4
Plumbing 5
Hosing Diagram – Standard 5
Hydraulic Circuit – 30G Standard 6
Hydraulic Circuit – 41G-50G Standard 7
Hosing Diagram – Independent Arm Control 8
Hydraulic Circuit – Independent Arm Control 9
Clamp Function 10
Supply Circuit Test 10
Clamp Circuit Test 10
Sideshift Function 12
Supply Circuit Test 12
Sideshift Circuit Test 13
Electrical Circuit 14
SERVICE, Section 4
Attachment Removal 15
Arms 16
Arm Assemblies - Removal and Installation 16
Contact Pad - Removal and Installation 17
Arm Bearing Service 18
Articulating Arm Bushing Service 19
Articulating Arm Adjustment 20
Valve 21
Valve Removal and Installation 21
Standard Valve Service 22
Independent Arm Control Valve Service 25
Relief Adjustments - 30G Standard Valve 26
Relief Adjustments - 41G-50G Standard Valve 27
Clamp Cylinder 28
Removal and Installation 28
Cylinder Disassembly 29
Cylinder Inspection 29
Cylinder Reassembly 30
Solenoid Valve 31
Coil Service 31
Valve Service 31
SPECIFICATIONS, Section 5
Specifications 32
Hydraulics 32
Auxiliary Valve Functions 32
Truck Carriage 32
Torque Values – 30G 33
Torque Values – 41G-50G 34
NTRODUCTION
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50G-RSM-4A-0000
123456-01R0
50G-RSM-4A-0000
123456-01R0
RC5060.eps
1. 2 Special Definitions
The statements shown appear throughout this manual
where special emphasis is required. Read all WARNINGS
and CAUTIONS before proceeding with any work.
Statements labeled IMPORTANT and NOTE are provided
as additional information of special significance or to make
your job easier.
WARNING - A statement preceded by
WARNING is information that should be
acted upon to prevent bodily injury. A
WARNING is always inside a ruled box.
CAUTION - A statement preceded by CAUTION is
information that should be acted upon to prevent
machine damage.
IMPORTANT - A statement preceded by IMPORTANT is
information that possesses special significance.
NOTE - A statement preceded by NOTE is information that
is handy to know and may make your job easier.
Nameplate
1. 1 Introduction
This manual provides the Periodic Maintenance,
Troubleshooting, Service and Specifications for Cascade
G-Series Sliding Arm Roll Clamps.
In any communication about the attachment, refer to
the product catalog and serial numbers stamped on the
nameplate. If the nameplate is missing, the numbers
can be found stamped on the frame where the plate was
mounted.
IMPORTANT: Tubing connection and supply fitting types
vary depending on end-user. Specifications are shown in
US and (metric). All fasteners have a torque value range of
±10% of stated value.
ERIODIC MAINTENANCE
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RC4283.eps
WARNING: After completing any service
procedure, always test the attachment
through five complete cycles. First test
empty, then test with load to make sure
attachment operates correctly before
returning it to the job.
2.1 100-Hour Maintenance
Every time the lift truck is serviced or every 100 hours
of truck operation, whichever comes first, complete
the following maintenance procedure:
• Check for loose or missing bolts, worn or damaged
supply hoses and hydraulic leaks.
• Check decals and nameplate for legibility.
• Inspect the cylinder rod anchor joint for lubrication
and correct hold.
NOTE: Anchor joint operates with a loose
clearance. Lubricate with wheel bearing grease.
• Check for equal arm movement.
• Check the load holding hydraulic system for
proper function. Cascade Clamp Force Indicators
300G-CFI-812C and 300G-CFI-824C are available
for this test.
2.2 500-Hour Maintenance
After each 500 hours of truck operation, in addition
to the 100-hour maintenance, perform the following
procedures:
• Check the lower mounting hook engagement
clearance with the truck carriage bar:
Quick-Change Hooks – 3/32 in. (2.5 mm) min.
3/16 in. (5.0 mm) max.
Bolt-On Hooks – Tight against lower carriage
bar.
If adjustment is necessary, refer to Section 4.1,
Step 3. Tighten the lower hook capscrews to a
torque of:
CL III – 120 ft.-lbs. (165 Nm)
CL IV – 320 ft.-lbs. (435 Nm)
• Tighten the upper hook capscrews to a torque of
320 ft.-lbs. (435 Nm).
• Inspect all load-bearing structural welds on arms,
frame and cylinder anchor areas for visual cracks.
Replace components as required.
• Inspect contact pads, pivot pins, wear tiles and
arm tips for wear and damage. Replace or repair,
as needed.
2.3 1000-Hour Maintenance
After each 1000 hours to lift truck operation, in
addition to the 100 and 500-hour maintenance
procedures, perform the following procedures.
• Inspect the arm bearings for wear. If any bearing
is worn to less than 0.04 in. (1.0 mm) thickness,
replace all bearings.
Arm Bearings
Cylinder Anchor Joint
Hook Capscrews
Lower Hook Capscrews
Front View
Back (Driver's) View
2.4 4000-Hour Maintenance
After each 4000 hours of truck operation, in addition to
the 100, 500 and 2000-hour maintenance, perform the
following procedures:
• Due to normal mechanical wear and component
service life, cylinder seals should be replaced to
maintain performance and safe operation.
ROUBLESHOOTING
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3.1 General Procedures
3.1-1 Truck System Requirements
• Truck hydraulic pressure should be within the range
shown in Specifications, Section 5.1. PRESSURE TO
THE ATTACHMENT MUST NOT EXCEED:
Low Pressure Valve – 2245 psi (155 bar)
High Pressure Valve – 2755 psi (190 bar)
• Truck hydraulic flow should be within the range shown
in Specifications, Section 5.1.
• Hydraulic fluid supplied to the attachment must meet
the requirements shown in Specifications, Section 5.1.
WARNING: Before servicing any
hydraulic component, relieve pressure
in the system. Turn the truck off and
move the truck auxiliary control valves
several times in both directions.
After completing any service procedure, test the
attachment through several cycles. First test the
attachment empty to bleed any air trapped in the
system to the truck tank. Then test the attachment
with a load to be sure it operates correctly before
returning to the job.
Stay clear of the load while testing. Do not raise the
load more than 4 in. (10 cm) off the floor while testing.
GA0013.eps
GA0014.eps
AC0127.eps
Flow Meter Kits:
671476 – 10 gpm (37 L/min)
671477 – 20 gpm (75 L/min)
(2) No. 8
JIC/O-Ring Flow Meter
(2) No. 6-8
JIC Reducer
Pressure Gauge Kit:
671212
Pressure
Gauge ▲No. 6-6 Hose ▲
No. 6 and No. 8
JIC Swivel Tee
No. 6-8 JIC
Reducer
No. 4, No. 6 ▲
and No. 8
JIC/O-Ring
No. 4-6
Pipe/JIC ▲
▲NOTE: Diagnostics
Kit 394382 includes
items marked.
Male Straight Thread
O-Ring Coupler:
No. 4 (Part No. 212282) ▲
No. 5 (Part No. 210378)
No. 6 (Part No. 678592)
Female JIC Thread
Coupler:
No. 4 (Part No. 210385) ▲
No. 6 (Part No. 678591)
Quick-Disconnect Couplers
AC0037.eps
3.1-2 Tools Required
In addition to a normal selection of mechanic's hand tools,
the following are required:
• In-line Flow Meter Kit:
10 gpm (37 L/min) – Cascade Part No. 671476.
OR
20 gpm (75 L/min) – Cascade Part No. 671477.
• Pressure Gauge Kit:
5000 psi (345 bar) – Cascade Part No. 671212.
• Assorted fittings, hoses, and quick-disconnect couplers
as required.
• Optional – Clamp Force Indicator:
300G-CFI-812C – For solid arms,
Measures 5,000–25,000 lbf
(22.241–124.550 kN)
OR
300G-CFI-824C – For Split Arms,
Measures 5,000–25,000 lbf
(22.241–124.550 kN)
Clamp Force Indicator:
300G-CFI-812C (solid arms)
300G-CFI-824C (split arms)
ROUBLESHOOTING
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3.1-3 Troubleshooting Chart
Determine All The Facts – It is important that all the
facts regarding the problem are gathered before
beginning service procedures. The first step is to
talk to the equipment operator. Ask for a complete
description of the malfunction. Guidelines below and
on the following pages can then be used as a starting
point to begin troubleshooting.
Clamp Circuit
• Attachment drops load after it has been picked up.
• Attachment will not carry load up to its rated
capacity.
• Attachment arms have uneven travel.
• Attachment arms travel slowly.
• Attachment arms will not move.
To correct these problems, see Section 3.3-1 and
3.3-2.
Sideshift Circuit
• Attachment drops load while sideshifting.
• Attachment drops load at end of sideshift stroke.
• Attachment sideshifts left and right at different
speeds.
• Attachment will not sideshift.
To correct these problems, see Section 3.4-1, 3.4-2.
ROUBLESHOOTING
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CL4994.eps
CL4995.eps
3.2 Plumbing
3.2-1 Hosing Diagram –Standard
CLAMP
PRESSURE
RETURN
NOTE: For OPEN ARMS,
reverse the colors shown.
SIDESHIFT LEFT
PRESSURE
RETURN
SLAVE
NOTE: For SIDESHIFT RIGHT,
reverse the pressure and return
colors shown.
SIDESHIFT CIRCUIT
OPEN/CLAMP CIRCUIT
SSR Port
OP OPEN Port
Cylinders
Cylinders
Hose Reel
or Internal
Reeving
Hose Reel
or Internal
Reeving
Truck Auxiliary
Valve SIDESHIFT
Truck Auxiliary
Valve CLAMP
SSL Port
CL CLAMP
Port
Attachment
Valve
Attachment
Valve
ROUBLESHOOTING
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CL5822.eps
3.2-2 Hydraulic Circuit –30G Standard
Cylinders
GA
OR
CLCLOP
CLSSR
OP
OPEN
Check
Valves
OPEN
Check
Valves
CL line
Equalization
Orifice
CLOSE
Check
Valve
Flow Divider/
Combiner
Equalizer
Relief Valve
OPSSL
Hose Reel or
Internal Reeving
Hose Reel or
Internal Reeving
Truck Auxiliary Valve
(CLAMP/OPEN)
Truck Auxiliary
Valve (SIDESHIFT)
Truck Relief
Valve
Truck Tank
Truck
Pump
SIDESHIFT
Relief
CLAMP
Relief
Attachment
Valve
ROUBLESHOOTING
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CL4996.eps
3.2-3 Hydraulic Circuit –41G-50G Standard
GA CLCL OP
CL SSR
OP
OPEN
Check
Valves
CLOSE
Check
Valve
Flow Divider/
Combiner
CLAMP
Relief
OPEN
Relief
Equalizer
Relief Valve
Sideshift
Relief Valve
OP SSL
Hose Reel or
Internal Reeving
Hose Reel or
Internal Reeving
Truck Auxiliary Valve
(CLAMP/OPEN)
Truck Auxiliary Valve
(SIDESHIFT)
Truck Relief
Valve
Truck Tank
Truck
Pump
Attachment
Valve
Cylinders
ROUBLESHOOTING
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3.2-4 Hosing Diagram –
Independent Arm Control
CL5600.eps
CLOSE LEFT ARM
PRESSURE
RETURN
NOTE: For OPEN LEFT ARM,
reverse the colors shown.
CLOSE RIGHT ARM
PRESSURE
RETURN
NOTE: For OPEN RIGHT ARM,
reverse the colors shown.
CL
(Clamp Port)
CL
(Clamp Port)
OP
(Open Port)
OP
(Open Port)
Cylinders
Cylinders
Hose Reel
or Internal
Reeving
Hose Reel
or Internal
Reeving
Truck
Auxiliary
Valves
Truck
Auxiliary
Valves
Attachment
Valve
Attachment
Valve
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