Transcript
I
NSTALLATION INSTRUCTIONS and PERIODIC MAINTENANCE
80G–170G Non-Revolving Clamps
Manual Number 6526543-R2
cascade corporation
Cascade is a Registered Trademark of Cascade Corporation
BLANK
C
ONTENTS
Recommended Hydraulic Supply
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Truck Requirements
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Installation 2 Periodic Maintenance 9
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This manual provides instructions for installing Cascade 80G–170G Non-Revolving Clamps. Follow the suggested installation procedures for best results. If you have any questions or need more information, contact your nearest Cascade Service Department for assistance. Refer to back cover. Read the WARNING Statements placed throughout this manual to emphasize safety during attachment installation. IMPORTANT: Field alterations may impair performance or capability and could result in loss of warranty. Consult Cascade for any required modifications.
ECOMMENDED HYDRAULIC SUPPLY OPTIONS
80G–170G Non-Revolving Clamps provide the best performance with one 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: • All hoses and fittings for CLAMP and SIDESHIFT functions should be at least No. 6 (M8) with a minimum internal diameter of 9/32 in. (7 mm)
Non-Sideshifting A or B
RH or LH THINLINETM 2-port hose reel group.
A
B C
OR C Mast single internal hose reeving group. Sideshifting A or B
RH or LH THINLINETM 2-port hose reel group.
OR C Mast double internal hose reeving group.
GA0033.eps
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RUCK REQUIREMENTS WARNING: Rated capacity of the truck/attachment combination is a responsibility of the original truck manufacturer and may be less than that shown on the attachment nameplate. Consult the truck nameplate.
Truck Relief Setting Low Pressure
High Pressure
80G-140G 1455 psi (100 bar) 2250 psi (155 bar) - Minimum 1455 psi (100 bar) 2760 psi (190 bar) - Maximum 170G
— —
2250 psi (155 bar) - Minimum 2465 psi (170 bar) - Maximum
NOTE: The attachment valve has separate pressure relief control, see Installation Step 9 for adjustment.
Truck Flow Volume ➀ Min. ➁
Recommended
Max. ➂
80G–100G
10 GPM (38 L/Min.)
15 GPM (57 L/Min.)
20 GPM (76 L/Min.)
120G–170G
10 GPM (38 L/Min.)
15 GPM (57 L/Min.)
24 GPM (90 L/Min.)
➀ Cascade 80G–170G Non-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. Contact Cascade. ➁ Flow less than recommended will result in reduced system performance. ➂ Flow greater than maximum can result in excessive heating, reduced system performance and short hydraulic system life.
GA0444.eps
Carriage Mount Dimension (A) ITA (ISO) A Class III Class IV
Minimum
Maximum
18.68 in. (474.5 mm) 23.44 in. (595.5 mm)
18.74 in. (476.0 mm) 23.50 in. (597.0 mm)
Carriage – Clean carriage bars and inspect carriage bars. Make sure the bars are parallel and that ends are flush. Repair any damaged notches.
GA0028.eps
Auxiliary Valve Functions Check for compliance with ANSI (ISO) standards
Tilt Forward
WARNING: Truck control handle and attachment function activation shown here conforms to ANSI/ITSDF B56.1 (ISO 3691) recommended practices. Failure to follow these practices may lead to serious bodily injury or property damage. End user, dealer and OEMs should review any deviation from the practices for safe operation.
Hoist Down
Sideshift Left
Release
GA0082.eps
Hoist Up
Clamp Tilt Back
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Sideshift Right
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NSTALLATION
Follow the steps shown to install the attachment on the truck. Read and understand all WARNING and CAUTION statements. If a procedure is not understood, ask your supervisor or call the nearest Cascade Service Department for assistance.
1
Attach overhead hoist A Remove banding, use multiple chains
WARNING: Check the attachment weight (located on the nameplate) to make sure the overhead hoist and chains or straps are at least the rated capacity of the attachment.
to stabilize the attachment while lifting. Set the attachment upright on pallet.
B
Remove bolt-on lower mounting hooks (if equipped).
A Clamp A Lifting Eye
B
Lower Hooks
CL4296.eps
2
Prepare Hoses A Determine hose lengths required for hydraulic supply configuration of truck.
B
Cut hoses to length and install end fittings or use hose kits supplied. Sideshift Left Sideshift Right
Clamp
Sideshift Right
CL4297.eps
Sideshifting Clamp – Double Hose Reels
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Clamp
Sideshift Left
Open
Open
CL4298.eps
Sideshifting Clamp – Double Internal Hose Reeving
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3
NSTALLATION
Flush hydraulic supply hoses A Install hoses using union fittings. B Operate auxiliary valves for 30 sec. C Remove union fittings
GA0092.eps
4
Mount attachment on truck carriage A Center truck behind attachment. B Tilt forward and raise carriage into position. C Engage upper mounting hooks with upper
B
carriage bar. Make sure a centering tab engages a notch on the carriage bar, as shown.
D
A
Lift the clamp 2 in. (5 cm) off the pallet.
CL4353.eps
OR
LH Upper Hook Tab (shown)
Center Tab (all models) CL4779.eps
ITA Class III – 0.72–0.78 in. (18–20 mm) ITA Class IV – 0.72-0.78 in. (18-20 mm)
Engage Notch
ITA Class III – 0.39–0.43 in. (10–11 mm) ITA Class IV – 0.48-0.51 in. (12-13 mm) Truck Carriage
3
CL4354.eps CL0242.eps
170G shown
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5
NSTALLATION
Install and engage lower hooks
BOLT-ON TYPE
Tap tight into position
6
Connect hoses prepared in Step 2 to attachment
Lower Carriage Bar
ST
JU
AD
CL4355.eps
Hose Reels Hydraulic Supply Shown
Tighten capscrews to: Class III – 165 ft.-lbs. (225 Nm) Class IV – 190 ft.-lbs. (260 Nm)
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SD0066.eps
Install Stop Block Kit (for attachments with centering tab) • Locate a stop block on the outside of each upper hook. Preheat stop block and carriage bar weld area to 325° F (180° C).
Upper Mounting Hook
• Use AWS E7018 lower hydrogen rod and weld a 0.25 in. (6 mm) filler fill length on three sides of each stop block. NOTE: Do not weld stop block on inside 1/16 in. (1.6 mm)
Steel Stop Block
Truck Upper Carriage Bar 0.25 in. (6 mm) fillet weld on three sides
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CL4780.eps
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8
NSTALLATION Cycle attachment functions
WARNING: Truck control handle and attachment function activation shown here conforms to ANSI/ITSDF B56.1 (ISO 3691) recommended practices. Failure to follow these practices may lead to serious bodily injury or property damage. End user, dealer and OEMs should review any deviation from the practices for safe operation.
• With no load, cycle attachment function and sideshift function several times. • Clamp and lift a maximum load. Sideshift left and right. • Check fir operation in accordance with ANSI (ISO) standards. IMPORTANT: If necessary, adjust relief valve cartridges and/or open internal CL line equalization orifice. Refer to Step 9.
WARNING: Make sure all personnel are clear of the clamp during testing.
• Check for leaks at fittings, valve, manifold and cylinders.
Tilt Forward Hoist Down
A C
B D GA0005.eps
Hoist Up
Tilt Back
NON-SIDESHIFTING CLAMPS
SIDESHIFTING CLAMPS
A Release Arms B Clamp Arms C (not used) D (not used)
C D
5
CL2478.eps
C
A Sideshift Left B Sideshift Right C Release Arms D Clamp Arms
B
C D
A
CL2478.eps
C
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9
NSTALLATION Adjust Relief Cartridges To avoid over clamping or slow sideshifting speed, relief cartridges should be adjusted to maintain correct settings. Check the nameplate and decal on the valve for correct circuit hydraulic pressure settings.
Relief Cartridge Adjustment: Clockwise (CW) = increase pressure Counterclockwise (CCW) = lower pressure
NOTE: Attachments used for fork positioning requires no CLAMP relief adjustment. Contact Cascade before making any adjustments.
CLAMP Circuit
SIDESHIFT Circuit
A Confirm that TRUCK pressure delivered to the
Arm Synchronization
attachment valve is within the range shown on the attachment nameplate. Refer to page 1.
A Open arms to half way and sideshift the attachment. B Open and close the arms until one arm bottoms or is
B Install a 5000 psi (345 bar) pressure gauge (with a
No. 4 O-ring fitting) to the valve CLAMP gauge port.
C Fully open and close arms at normal speed to
Arm Speed
D Adjust the valve CLAMP relief cartridge to show a
A Clamp a maximum load and sideshift LEFT and
maximum setting (refer to valve decal). Tighten the jam nut.
RIGHT observing sideshifting movement.
B If the attachment will not sideshift or sideshifts
loosen jam nut on the relief cartridge. Adjust the relief cartridge to no higher than 1450 psi (100 bar), recommended. Clamp and release a load. If the arms do not open, increase the pressure. Tighten jam nut.
NOTE: If equipped with OPEN gauge port, a pressure gauge can be installed into the port to aid with OPEN relief adjustment.
C Adjust the flow divider relief cartridge in 1/4 turn
increments until the desirable synchronization is met. Tighten jam nut.
clamp a rigid load (or clamp force indicator). Release truck handle and read pressure gauge.
E Repeat steps C and D to confirm setting. F If OPEN (or backhand) circuit requires adjustment,
fully open.
slowly, adjust sideshift relief clockwise (CW) until the attachment sideshifts. Then adjust the relief cartridge counterclockwise (CCW) 1/4 turn increments until sideshift speed slows (relief opening). Finish by adjusting cartridge clockwise (CW) 1/4 turn. Tighten jam nut.
C If the attachment will not sideshift after relief
adjustment (Step B), remove the setscrew plug from the equalization orifice located in a port on top of the valve. Both plug and orifice are 5/32 in. (4 mm) Allen hex socket. Repeat SS relief adjustment in Step A.
120G/140G/170G (Current)
80G/100G Sideshift Relief Cartridge, "SS RLF" CLAMP Gauge OPEN Gauge Port, Port, "CL GAGE" "OPEN GAGE" Flow Divider Relief Cartridge, "FD ADJUST"
Flow Divider Relief Cartridge
Backhand Relief Cartridge, "BH REL"
Sideshift Relief Cartridge, "SS RLF" CLAMP Gauge Port, "GA" Socket Head Cap Plug CLAMP Relief Cartridge, "CL REL"
Socket Head Cap Plug, "SS ORIFICE"
CL6089.eps
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CLAMP Relief Cartridge, "C REL"
RH CLAMP Ports, LH SIDESHIFT Ports Valves shown
OPEN Relief Cartridge, "OR REL"
CL6088.eps
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NSTALLATION
Adjust Relief Cartridges (continued) 170G Valve (Early Units) To avoid overclamping or slow sideshifting speed, relief cartridges should be adjusted . Check nameplate and decal on the valve for correct CLAMP hydraulic pressure settings.
A B
Install pressure gauge into CL (clamp) test port.
C
Loosen jam nut on open relief cartridge (CL–>OP). Adjust the relief cartridge inward (CW) to increase pressure or outward (CCW) to lower pressure. Clamp and release a load. If the arms do not open, increase the pressure. Tighten jam nut.
D
Clamp the heaviest load. Raise the load and sideshift. If the load does not sideshift, loosen the jam nut and turn the equalization cartridge screw out until the load will sideshift. Tighten jam nut.
E
Loosen jam nut on sideshift left relief cartridge (SSR–>SSL). Adjust the relief cartridge inward (CW) to increase pressure or outward (CCW) to lower pressure. Clamp the heaviest load. Raise the load and sideshift left. Turn the relief cartridge outward (CCW) until the load does not sideshift. Turn inward (CW) 1/2 turn increments until the load can be sideshifted fully left. Tighten jam nut.
F
Loosen jam nut on sideshift right relief cartridge (SSL–>SSR). Adjust the relief cartridge inward (CW) to increase pressure or outward (CCW) to lower pressure. Clamp the heaviest load. Raise the load and sideshift right. Turn the relief cartridge outward (CCW) until the load does not sideshift. Turn inward (CW) 1/2 turn increments until the load can be sideshifted fully right. Tighten jam nut.
G
If the arm movement is unequal or stalled during clamping, loosen the jam nut on the adjust compensation relief valve. Adjust relief cartridge inward (CW) to increase pressure or outward (CCW) to lower pressure. Clamp the heaviest load. Raise the load and sideshift. Increase (CW) for inaccurate arm movement or decrease (CCW) for a stalled arm. Tighten jam nut.
Loosen jam nut on clamp relief cartridge (OP–>CL). Adjust the relief cartridge inward (CW) to increase pressure or outward (CCW) to lower pressure. Clamp a load and check gauge pressure. Readjust as required. Tighten jam nut. Remove pressure gauge and plug port.
Clamp Gauge Port
C
G D
E
CL4366.eps
B
F 7
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NSTALLATION ATTACHMENTS WITHOUT ARMS – 80G & 100G
Attachments without arms are supplied with two arm bases. Special forks can be welded directly to the arm bases or they can be used as a base to fabricate custom built arms.
WARNING: Rated capacity of the truck/ attachment combination is a responsibility of the original truck manufacturer and may be less than that shown on the attachment nameplate. Consult the truck nameplate.
WARNING: Cascade requires that a qualified or certified welder experienced in this type of fabrication be used for best quality.
Drive Adapter
CAUTION: Weld fabricated arms to the arm bases only. Do not weld or bolt special built arms or forks directly to the arm bars. The arm base material is ANSI C-1020 HR with the following specifications: • TENSILE STRENGTH – 61,000 PSI (420 mPa min.) • YIELD STRENGTH – 43,000 PSI (300 mPa min.)
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• CARBON CONTENT – 23% max.
Arm Bar
CAUTION: The surface flatness of the arm base must remain within 0.010 in. (0.25 mm) in capscrew area and arm must slide manually.
1
Fasten the arm bases to the arm bars. Use drive extension tool 676218 (0.75 in., 19 mm) to clear arm bars and tighten the capscrews to a torque of 682 ft.-lbs. (924 Nm).
IMPORTANT: Be careful not to damage the arm bar. Premature bearing failure will occur.
Drive extension tool dimensions are provided to make the tool from an Allen wrench. Do not use mild steel hex stock.
2
Lubricate the cylinder rod threads, nut threads and spherical portion of the nut with wheel bearing grease.
3
Install the hex washer on the rod end with the beveled side facing the lug.
4 5
Engage the rod end into the lug. Engage the rod end nut to a torque of 250 ft.-lbs. (340 Nm).
Prevent rod turning by using wrench on hex washer.
NOTE: The rod nut is being tightened against the hex washer. The nut will not be tight against the arm base lug. This looseness allows for cylinder alignment during clamping.
6
Install the locking cap and cotter pin.
Arm Base
A Hex
CL2532.eps
B
C
63
D Model 80G, 100G
6
A 0.75 in. (19 mm)
B 0.50 in. (13 mm)
CL0456.eps
C D 0.75 in. 5.00 in. (19 mm) (127 mm)
Arm Base Lug
3 1 5 Capscrew Tightening Sequence
CL5382.eps
6 2 4 6526543-R2
CL1520.eps
5
Hex washers beveled side facing lug
3 8
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ERIODIC MAINTENANCE 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.
100-Hour Maintenance Every time the lift truck is serviced or every 100 hours of truck operation, whichever comes first, complete the following maintenance procedures. • Check for loose or missing bolts, worn or damaged supply hoses and hydraulic leaks. • Inspect cylinder anchor joint for lubrication and correct hold. NOTE: Anchor joint operates with a loose clearance. Lubricate with wheel bearing grease.
CL4364.eps
• Check for equal arm movement.
Bolt-On Lower Hook
• Check decals and nameplate for legibility. Cylinder Anchor Joint
Upper Arm Bearings
500-Hour Maintenance
Arm Pivot Joint
After each 500 hours of truck operation, in addition to the 100-hour maintenance, perform the following procedures. • Inspect arm bearings for wear and damage. If bearings are worn in any area to less than 1.5 mm thickness, replace bearings. • Check lower mounting hooks for engagement clearance. Hook should be tight against lower carriage. If adjustment is necessary, refer to installation Step 6.
Lower Arm Bearings
CL4908.eps
• Tighten lower hook capscrews to: Class III – 165 ft.-lbs. (225 Nm) Class IV – 190 ft.-lbs. (260 Nm)
Lube and inspect wear plugs Retainer Adjust
• Bolt-On Upper Hooks – Tighten upper hook capscrews to 320 ft.-lbs. (435 Nm). • Articulating Arms – Lubricate arm pivot joint zerk fittings with chassis grease. • Articulating Arms – Inspect the arm pivot wear plugs. If either plug is worn to less than 0.13 in. (3.0 mm), replace both wear plugs. • Articulating Arms – Loosen retainer capscrews, adjust retainer to wear pad clearance to 0.5 mm. Tighten retainer capscrews to 320 ft.-lbs. (435 Nm).
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0.015 in. (0.5 mm) CL4907.eps
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ERIODIC MAINTENANCE
1000-Hour Maintenance
After each 1000 hours of truck operation, in addition to the 100 and 500-hour maintenance, perform the following procedures:
Bolt-On Fork Arms
Bolt-On Upper Hook
• Bolt-On Arms – Tighten bolt-on arm capscrews to a torque of 680 ft.-lbs. (924 Nm).
4000-Hour Maintenance
After each 4000 hours of truck operation, in addition to the 100, 500 and 1000-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.
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CL5924.eps
Cylinder Anchor Joint
Bolt-On Lower Hook Attachments with Bolt-On Forks Back (Drive's) View
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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 U.S. Headquarters 2201 NE 201st Fairview, OR 97024-9718 Tel: 800-CASCADE (227-2233) Fax: 888-329-8207
Cascade do Brasil Praça Salvador Rosa, 131/141-Jordanópolis, São Bernardo do Campo - SP CEP 09891-430 Tel: 55-13-2105-8800 Fax: 55-13-2105-8899
Cascade Canada Inc. 5570 Timberlea Blvd. Mississauga, Ontario Canada L4W-4M6 Tel: 905-629-7777 Fax: 905-629-7785
EUROPE-AFRICA Cascade Italia S.R.L. European Headquarters Via Dell’Artigianato 1 37030 Vago di Lavagno (VR) Italy Tel: 39-045-8989111 Fax: 39-045-8989160
Cascade (Africa) Pty. Ltd. PO Box 625, Isando 1600 60A Steel Road Sparton, Kempton Park South Africa Tel: 27-11-975-9240 Fax: 27-11-394-1147
ASIA-PACIFIC Cascade Japan Ltd. 2-23, 2-Chome, Kukuchi Nishimachi Amagasaki, Hyogo Japan, 661-0978 Tel: 81-6-6420-9771 Fax: 81-6-6420-9777
Cascade Korea 121B 9L Namdong Ind. Complex, 691-8 Gojan-Dong Namdong-Ku Inchon, Korea Tel: +82-32-821-2051 Fax: +82-32-821-2055
Cascade-Xiamen No. 668 Yangguang Rd. Xinyang Industrial Zone Haicang, Xiamen City Fujian Province P.R. China 361026 Tel: 86-592-651-2500 Fax: 86-592-651-2571
Cascade Australia Pty. Ltd. 1445 Ipswich Road Rocklea, QLD 4107 Australia Tel: 1-800-227-223 Fax: +61 7 3373-7333
Cascade New Zealand 15 Ra Ora Drive East Tamaki, Auckland New Zealand Tel: +64-9-273-9136 Fax: +64-9-273-9137
Sunstream Industries Pte. Ltd. 18 Tuas South Street 5 Singapore 637796 Tel: +65-6795-7555 Fax: +65-6863-1368
Cascade India Material Handling Private Limited No 34, Global Trade Centre 1/1 Rambaugh Colony Lal Bahadur Shastri Road, Navi Peth, Pune 411 030 (Maharashtra) India Phone: +91 020 2432 5490 Fax: +91 020 2433 0881
c © Cascade Corporation 2015
10-2015
Part Number 6526543-R2
