Cascade 22E Assembly Instructions

Type
Assembly Instructions

This manual is also suitable for

Cascade is a registered Trade Mark of Cascade Corporation
®
Nº 214603
Installation Instructions
Instructions de Montage
Montageanweisungen
Installatie Instructies
Istruzioni di Installazione
Instrucciones de Montaje
E-SERIE/SERIE-E
Sideshifting and Non-Sideshifting Clamps
Turnaforkâ„¢ Clamps
Pinces avec et sans Déplacement Latéral
Fourches-Pinces Turnaforkâ„¢
Klammern mit und ohne Seitenschub
Turnaforkâ„¢ Drehgabelklammern
Klemmen met en zonder Sideshift
Turnaforkâ„¢ Draaivorkklem
Pinze Traslanti e Non-Traslanti
Pinze Turnaforkâ„¢
Pinzas con y sin Desplazamiento Lateral
Pinzas de Horquillas Pivotantes Turnaforkâ„¢
c
cascade
GB
F
D
NL
I
E
GB
F
D
NL
I
E
2
ONTENTS
C
ECOMMENDED HYDRAULIC SUPPLY OPTIONS
R
Recommended Hydraulic Supply 2
Truck Requirements 3
Installation 4
Periodic Maintenance 10
Non-Sideshifting
A or B
RH or LH THINLINEâ„¢ 2-port hose reel group.
OR
C Mast single internal hose reeving group.
Sideshifting
A and B
RH and LH THINLINE
â„¢
2-port cable hose reel groups.
OR
C Mast double internal hose reeving group.
Sideshifting with Solenoid
A 6-N-1 cable/hose reel group.
OR
A and C
Cable reel and single internal hose reeving group.
B
A
E-Series Clamps provide the best performance with the
hydraulic supply arrangements shown below. Refer to
Cascade Hose and Cable Reel Selection Guide, Part No.
212119, to select the correct hose reel for the mast and
truck. The hose and fitting requirements are:
• All hoses for clamp and sideshift functions should be at
least No. 6 hose with 9/32 in. (7 mm) minimum I.D.
• All fittings should have a minimum internal diameter of
9/32 in. (7 mm).
This Manual provides instructions for installing Cascade
E-Series Non-sideshifting and Sideshifting Clamps and
Turnafork
â„¢
. 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 (see back cover).
Read the WARNING Statements placed throughout this
Manual to emphasize safety during Clamp installation.
IMPORTANT: Field alterations may impair performance or
capability and could result in loss of warranty. Consult
Cascade for any required modifications.
GA0033.ill
C
3
GA0080.ill
GA0082.ill
RUCK REQUIREMENTS
Clamp
Sideshift
Right
Tilt
forward
Hoist up
Auxiliary Valve Functions
Check for compliance with ANSI standards:
WARNING: Rated capacity of the truck/attach-
ment combination is a responsibility of the
original truck manufacturer and may be less than
that shown on the attachment nameplate.
Consult the truck nameplate.
Carriage
Clean carriage bars and inspect for
damaged notches
T
Tilt
back
Hoist down
Release
Sideshift
Left
GA0028.eps
A
Carriage Mount Dimension (A) (ISO)
Minimum Maximum
Class 2 380.0 mm 381.0 mm
Class 3 474.5 mm 476.0 mm
Truck Relief Setting
2300 psi (160 bar) Recommended
2600 psi (180 bar) Maximum
Truck Flow Volume
¿
Min.
¡
Recommended Max.
¬
22E, 33E,
19 L/min. 28 L/min. 38 L/min.
45E
¿ Cascade E-Series 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.
¡ Flow less than recommended will result in reduced system
performance.
¬ Flow greater than maximum can result in excessive heating,
reduced system performance and short hydraulic system life.
4
I
Follow the steps shown to install the Clamp on the truck.
Read and understand all WARNING and CAUTION state-
ments. If you don't understand a procedure, ask your
supervisor, or call the nearest Cascade Service Depart-
ment for assistance.
NSTALLATION
2
Unlock quick-change lower
mounting hooks
A Remove pin and drop hooks into unlocked
position.
B Re-install pin in lower hole.
1
Attach overhead hoist
A Remove banding, set Clamp upright on
pallet with hooks overhanging end.
B Remove bolt-on lower mounting hooks
(if equipped).
WARNING: Make sure overhead
hoist has rated capacity of at least
1600 kg.
Tighten Capscrews:
Class 2/3 Mounting – 225 Nm.
cascade
®
C-675514-1
CL0097.ill
A
Pin
LH lower
Hook
NOTE: Guides can be reversed to
reduce hook-to-carriage clearance
(See lower hook installation, Step 6).
CL0096.ill
B
Guide
16 mm offset
on top pro-
vides max.
clearance.
B
A
5
Prepare Hoses
A Determine hose lengths required for hydraulic
supply configuration of truck.
B Cut hoses to length, install end fittings or
quick-disconnect kits.
NSTALLATION
I
3`
CL0245.ill
CL0246.ill
Sideshifting – Double Hose Reels
Sideshifting – Double Internal Hose Reeving
Sideshifting with Solenoid – IHR and Cable Reel
Sideshifting with Solenoid – 6-N-1 Cable/Hose Reel
Open
Sideshift Left
Sideshift Right
Clamp
CL0104.ill
CL0107.ill
SSL / Open
SSR / Clamp
Flush hydraulic supply hoses
A Install hoses using union fittings.
B Operate auxiliary valves for 30 sec.
C Remove union
fittings.
4
GA0092.ill
Non-Sideshifting – Single Hose Reel
CL0295.ill
Clamp
Open
Solenoid
Cable
6
Centering Tab
Positions
CL0243.ill
4
1
2
3
5
Mount Clamp on truck carriage
A Center truck behind Clamp.
B Tilt forward and raise carriage into position.
C Engage top mounting hooks with carriage.
Make sure centering tab engages a notch on
the top carriage bar. NOTE: Centering tab
can be oriented in 4 different positions to
center the Clamp (see illustration).
D Lift Clamp 2 in. (5 cm) off pallet.
I
NSTALLATION
C
ITA Class 2 – 15-17 mm
ITA Class 3 – 18-20 mm
ITA Class II – 0.32–0.36 in. (8–9 mm)
ITA Class III – 0.39–0.43 in. (10–11 mm)
CL0098.ill
A
B
CL0242.ill
Truck
Carriage
Engage Tab
ADJUST
SD0066.ill
Tighten Capscrews:
Class 2/3 Mounting – 225 Nm.
Lower
Carriage
Bar
6
Install and engage lower hooks
Tap tight into position.
Inspect hooks for
excessive clearance.
(Reverse guides to reduce
clearance – See Step 2.)
cascade
®
C-675514-1
SD0065.ill
5 mm.
max.
Lower
Carriage
Bar
BOLT-ON TYPE
QUICK-CHANGE TYPE
Slide hook up
to engage
bar, install
pin in locked
position.
(upper hole.)
7
I
NSTALLATION
Connect hoses as shown in
Step 3
7
CL0247.ill
9
Install wiring –
(Solenoid equipped units)
c
PRESS BUTTON
TO POSITION
ARMS
SIDESHIFT
CL0240.eps
Button
toward
driver
Truck control
valve handle
Adapter
8
Install solenoid control knob –
(Solenoid equipped units)
CL0258.ill
CL0257.ill
Solenoid Coil
User-supplied wire
7.5-Amp
Fuse
White
Black
7.5-Amp Fuse
White Black
Solenoid Coil
Diode
Diode
Knob
Button
CL0104.ill
Double Hose Reels Hydraulic Supply
Internal Hose Reeving Hydraulic Supply
8
10
Cycle Clamp functions
• With no load, cycle each Clamp function
several times.
• Check for operation in accordance with
ITA (ISO) standards.
• Lift a maximum load, check for smooth
arm movement.
• Check for leaks at fittings, valve, manifold
and cylinders.
Auxiliary Valve
Functions
Tilt Forward
Hoist Up
Tilt Back
I
NSTALLATION
WARNING: Make sure all personnel are
clear of the Clamp during testing.
GA0005.eps
AC
B
D
Hoist Down
NON-SIDESHIFTING CLAMPS
A Release Arms
B Clamp Arms
C (not used)
D (not used)
CL0023.ill
A
B
A
CL0022.ill
B
C
C
D
CL0274.ill
B
A
A
B
A
SIDESHIFTING CLAMPS
A Sideshift Left
B Sideshift Right
C Release Arms
D Clamp Arms
SIDESHIFTING CLAMPS WITH
SOLENOID VALVE
A Sideshift Left
A Release Arms
(press knob button)
B Sideshift Right
B Clamp Arms
(press knob button)
CL0024.ill
TURNAFORK
â„¢
Same as above,
close arms to
change function.
A
9
CL0622.ill
CL0623.ill
11
Adjust relief cartridges
For over-pressure protection, the relief valve
cartridges for both the CLAMP and SIDE-
SHIFT functions should be adjusted to match
the truck hydraulic flow rate.
Clamp relief adjustment:
A Confirm that the truck pressure is be-
tween 160 - 180 bar at the carriage
hose terminal.
B Install a 200 bar pressure gauge on the
main valve TEST port.
(Nº 4 O-ring fitting required).
C Cycle arms to full open. Slowly close
arms while clamping a maximum rigid
load (or clamp force indicator). Hold
lever in the CLAMP position and acce-
lerate engine to develop full pressure.
D Adjust the CLAMP relief cartridge for an
indicated 160 bar. Turn clockwise to
increase pressure, counterclockwise to
decrease pressure. Tighten jam nut and
replace cap.
I
NSTALLATION
Sideshift relief adjustment:
E With a maximum load clamped, sideshift
full left and full right while checking for an
arm speed of 20-25 cm /sec.
F Adjust the SIDESHIFT relief cartridge
counterclockwise (CCW) 1/4 turn.
Repeat steps E and F until sideshift
speed slows. (relief opening)
G Readjust cartridge clockwise (CW)
1/4 turn.
Tighten jam nut and replace cap.
WARNING: Before removing hydraulic
lines or components, relieve pressure in
the hydraulic system. Turn the truck off
and open the truck auxiliary control valves
several times in both directions.
CL0435.ill
C
C
B
E
D
F
Relief valve
cartridge
3/4 in (19 mm)
jam nut
Adjustment
screw
Cap
Decrease
pressure (CCW)
5/16 in. (8 mm)
Allen wrench
Increase
pressure
(CW)
Clamp Relief Cartridge
Sideshift Relief Cartridge
Front
NON SIDESHIFTING VALVE SIDESHIFTING VALVE SIDESHIFTING VALVE
WITH REGENERATION
10
WARNING: After completing any service
procedure, always test the Clamp through
five complete cycles. First test the Clamp
empty, then test with a load to make sure
the Clamp operates correctly before
returning it to the job.
P
ERIODIC MAINTENANCE
IMPORTANT: E-Series Clamps are prelubed at the
factory. Lubrication is not necessary for installation.
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 on the Clamp:
• Check for loose or missing bolts, worn or damaged
supply hoses and hydraulic leaks.
• Inspect the cylinder rod retainer blocks and split-ring
keepers for damage. Retainers operate with a loose
clearance and require no lubrication.
• Check for equal movement of the arms.
500-Hour Maintenance
After each 500 hours of truck operation, in addition to the
100-hour maintenance, perform the following procedures:
• Inspect the arm bearing surfaces for wear or damage.
If lubrication is required, silicon spray or light grease is
recommended.
• Check the clearance between the lower mounting hooks
and the truck carriage bar:
Quick-Change Hooks – 3/16 in. (5 mm) max.
Bolt-on Hooks – Tight against lower carriage bar.
If adjustment is necessary, refer to Installation Step 5.
Tighten lower hook capscrews to 165 ft.-lbs. (225 Nm).
1000-Hour Maintenance
After each 1000 hours of truck operation, in addition to the
100 and 500-hour maintenance, perform the following
procedures:
• Tighten frame capscrews (see Table).
• Tighten cylinder rod retainer bar capscrews (see Table).
Back (driver's) view
CL0293.ill
Frame
Capscrews
CL0291.ill
Cylinder Rod
Retainers
Bolt-On Lower
Mounting Hook
Arm
Bearings
Cylinder Rod
Retainer Bar
Capscrews (8)
Right Side
Torque Values
Model Frame Retainer Bar
22E 100 Nm. 65 Nm.
33E 100 Nm. 65 Nm.
45E 265 Nm. 105 Nm.
Quick-Change
Lower Mounting
Hook
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Cascade 22E Assembly Instructions

Type
Assembly Instructions
This manual is also suitable for

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