Carton | CN Series | D-Series Carton Clamps

I
NSTALLATION INSTRUCTIONS
and PERIODIC MAINTENANCE
D-Series
Carton Clamps
Manual Number 670488-R5
cascade
corportion
Cascade is a Registered Trademark of Cascade Corporation
C
ONTENTS
Introduction
i
Special Definitions
1
Recommended Hydraulic Supply
1
Truck Requirements
2
Installation
3
Periodic Maintenance
8
Troubleshooting
9
I
NTRODUCTION
This Manual provides the Installation, Periodic Maintenance
and Troubleshooting for Cascade D-Series Carton Clamps.
In any communication about the Carton Clamp, refer to the
product I.D. number stamped on the nameplate as shown.
If the nameplate is missing, the numbers can be found
stamped on the back of the baseplate.
IMPORTANT: All hoses, tubes and fittings on D-Series
Clamps are JIC.
NOTE: Specifications are shown in both U.S. and (Metric)
units.
c
SERIAL
NUMBER
CATALOG
NUMBER
cascade
ATTACHMENT CAPACITY
LIFT TRUCK ATTACHMENT
208910-P-2
15D-CC-01A
POUNDS
INCH LOAD
AT
CENTER
CAPACITY OF TRUCK AND ATTACHMENT COMBINATION
MAY BE LESS THAN ATTACHMENT CAPACITY SHOWN
ABOVE. CONSULT TRUCK NAMEPLATE.
WEIGHT
LBS.
RECOMMENDED SYSTEM PRESSURE – 2000 PSI
MAXIMUM SYSTEM PRESSURE – 2300 PSI
ADDITIONAL
EQUIPMENT
cascade
ADDITIONAL
EQUIPMENT
FOR TECHNICAL
ASSISTANCE, CONTACT
800-227–2233
PORTLAND, OREGON USA
ADDITIONAL
EQUIPMENT
2
-P0
1
9
CL1118.eps
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FOR PARTS AND SERVICE
MANUALS, CONTACT
800-227–2233
SPRINGFIELD, OHIO USA
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Nameplate
2
S/N
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670488 Rev. 5
S
PECIAL 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 the 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 the job easier.
R
ECOMMENDED HYDRAULIC SUPPLY
D-Series Clamps provide the best performance with one of
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:
• CLAMP Function – No. 8 with a minimum internal diameter of 13/32 in. (10 mm).
• SIDESHIFT Function – No. 6 with a minimum internal
diameter of 9/32 in. (7 mm).
Non-Sideshifting
A Hose reel group.
OR
C Single internal hose reeving group.
A
B
Sideshifting
A and B RH and LH Hose reel groups.
OR
C Double internal hose reeving group.
Sideshifting with Solenoid
A 6-N-1 Cable/Hose reel group.
OR
A and C
C
GA0033.eps
Cable Reel and Single internal hose reeving group.
670488 Rev. 5
T
RUCK REQUIREMENTS
D-Series Clamps will provide maximum operating capability
when the following requirements are met.
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
2000 psi (140 bar) Recommended
2300 psi (160 bar) Maximum
Truck Flow Volume 1
15D, 25D, 35D, 50D
Min. 2
Recommended
Max. 3
5 GPM
(19 L/min.)
7 GPM
(26 L/min.)
8 GPM
(30 L/min.)
1 Cascade D-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.
2 Flow less than recommended will result in reduced system
performance.
3 Flow greater than maximum can result in excessive heating,
reduced system performance and reduced hydraulic system life.
GA0080.eps
Carriage Mount Dimension (A) ITA (ISO)
A
Minimum
Class II 14.96 in. (380.0 mm)
Class III 18.68 in. (474.5 mm)
Maximum
Carriage
15.00 in. (381.0 mm)
18.74 in. (476.0 mm)
Clean and inspect carriage bars for
damage and smoothness. Repair any
protruding welds or damaged notches.
GA0028.ill
Auxiliary Valve Functions
Check for compliance with ITA (ISO) standards:
Tilt Forward
Hoist Down
GA0082.eps
Hoist Up
Tilt
Back
Release
Sideshift
Left
Sideshift
Right
Clamp
670488 Rev. 5
I
NSTALLATION
Follow the steps shown to install the Clamp on the truck.
Read and understand all WARNING and CAUTION
statements. If you don't understand a procedure, ask your
supervisor, or call the nearest Cascade Service Department
for assistance.
Prepare Attachment
ARemove banding.
BRemove bolt-on lower
A
mounting hooks (if equipped).
B
Bolt-On Lower
Hooks
CL1120.eps
Unlock Quick-Change lower mounting hooks
A Remove pin and drop hooks into unlocked position.
B Re-install pin in lower hole.
A
Locking Pin
Guide
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B
-1
14
55
67
C-
Locking Pin
LH Lower
Hook
CL1310.eps
NOTE: Guides can be reversed to
change hook to carriage clearance (See
lower hook installation, Step 6).
5/8 in. (16 mm) offset
on top provides max.
clearance.
670488 Rev. 5
Tighten Capscrews to
110 ft.-lbs. (150 Nm)
CL1293.eps
3
I
3
NSTALLATION
Prepare Hoses
A Determine hose lengths required for hydraulic
supply configuration of truck.
B
Cut hoses to length, install end fittings or QuickDisconnect coupling kits.
Sideshift
Left
Sideshift
Right
Open
WARNING: Do not remove the special
fitting from the valve CLAMP (CL) port. Use
a 6-8 reducer for No. 6 hose connection.
Clamp
CL0901.eps
CL1287.eps
Sideshifting – Double Hose Reels
Sideshifting – Double Internal Hose Reeving
SSR / Clamp
SSL / Open
Solenoid
Cable
CL0902.eps
Sideshifting with Solenoid – IHR and Cable Reel
4
CL1288.eps
Sideshifting with Solenoid – 6-N- Cable/Hose Reel
Flush hydraulic supply hoses
A Install hoses using union fittings.
B Operate auxiliary valves for 30 seconds.
C Remove union fittings.
GA0092.eps
4
670488 Rev. 5
I
5
NSTALLATION
Mount Clamp on truck carriage
A Center truck behind Carton Clamp.
B Tilt forward and raise carriage into position.
C Engage upper mounting hooks with carriage.
B
A
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.
CL0899.eps
ITA Class II – 0.60–0.66 in. (15–17 mm)
ITA Class III – 0.72–0.78 in. (18–20 mm)
Notch
Engage Tab
C
C
C
Centering Tab
Positions
ITA Class II – 0.32–0.36 in. (8–9 mm)
ITA Class III – 0.39–0.43 in. (10–11 mm)
2
3
4
CL1097.eps
Truck Carriage
6
1
GA0079.eps
Install and engage lower hooks
BOLT-ON TYPE
QUICK-DISCONNECT TYPE
Rotate hooks
up to engage
bar, install
pin in holes
(locked.)
CAUTION: Inspect QD hooks for
excessive clearance:
New Type – Reverse guides to
reduce clearance (See Step 2).
Early Type – Replace hooks.
Slide hook
up to engage
bar, install pin
in upper hole
(locked.)
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AD
e
ST
JU
1
4-
51
75
6
C-
Lower
Carriage
Bar
3/32 in.
(2.5 mm)
Min.
3/16 in.
(5 mm)
Max.
CL1291.eps
Tap tight into
position.
CL1309.eps
Tighten Capscrews: 110 ft.-lbs. (150 Nm)
670488 Rev. 5
5
I
NSTALLATION
7
Connect hoses prepared in
Step 3 to Attachment
CL1100.eps
CL1287.eps
Double Hose Reels Hydraulic Supply
8
Internal Hose Reeving Hydraulic Supply
Install solenoid control knob or
pushbutton switch – (Solenoid-equipped units)
Pushbutton
Switch
Snap Ring
Indicator
Plate
PRESS
BUTTON
TO CLAMP
Cable
Ties
SIDESHIFT
Button
toward
driver
NOTE: Shrink tubing may
be removed around button
as desired.
3 in. (60 mm)
Typical
Tape
Nut
Heat-Shrink
Tubing
Adapter
AC0898.eps
AC0897.eps
Install wiring –
(Solenoid-equipped units)
Diode
7.5-Amp Fuse
White
Knob
Button
Control Lever Knob
with Pushbutton
Diode
Solenoid Coil
7.5-Amp
Fuse
Black
CL0258.eps
White Black
CL0257.eps
User-supplied wire
Solenoid Coil
Solenoid Coil
6
670488 Rev. 5
I
NSTALLATION
0
Cycle Clamp functions
• With no load, cycle each Carton Clamp func•
Check for operation in accordance with ITA
(ISO) standards.
•
Clamp and lift a maximum load. Sideshift
left and right. Check for proper clamp force,
equal arm movement and adequate speed.
•
Check for leaks at fittings, valve, and cylinders.
SIDESHIFTING CLAMPS
NON-SIDESHIFTING CLAMPS
A
B
WARNING: Make sure all personnel are
clear of the Clamp during testing.
tion several times.
A
B
C
D
Release Arms
Clamp Arms
SIDESHIFTING CLAMPS WITH
SOLENOID VALVE
Sideshift Left
Sideshift Right
Release Arms
Clamp Arms
A
A
B
B
Sideshift Left
Release Arms
(press knob button)
Sideshift Right
Clamp Arms
(press knob button)
B
C
A
B
A
D
CL1300.eps
B
A
C
A
CL1295.eps
A
CL1300.eps
B
A
AUXILIARY VALVE
FUNCTIONS
Hoist Down
Tilt Forward
A C
B D
GA0005.eps
670488 Rev. 5
Hoist Up Tilt Back
7
P
ERIODIC MAINTENANCE
100-Hour Maintenance
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.
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 anchor nuts for proper connection
and tightness. Lubricate with chassis grease.
Application
• Lubricate the four arm bars (see Table).
General Products
Chassis Grease w/Moly
• Check contact pads for wear, nicks, distortion.
Food Industry
Chassis Grease
(DuBois FGG-2)
Dry Lube Conditions
Slip Plate No. 3
(Superior Graphite)
• Check decals and nameplate for legibility.
500-Hour Maintenance
Lubrication
Cylinder Rod End Anchors
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 mm) max.
Bolt-On Hooks – Tight against lower carriage bar.
If adjustment is necessary, refer to Installation Step 6.
Tighten lower hook capscrews to 110 ft.-lbs. (150 Nm).
• Check Clamp force (Cascade Clamp Force Indicators
680072, 6003391, 831887 are available for this test).
• Perform Clamp Circuit Pressure Test (see Service Manual
670487).
CL1101.eps
1000-Hour Maintenance
After each 1000 hours of truck operation, in addition to
the 100 and 500-hour maintenance, perform the following
procedures:
Frame Capscrews (from
frontside)
Bolt-On Lower
Mounting Hook
Quick-Change
Lower Mounting
Hook
Upper
Mounting
Hook
Back (Driver's) View
• Tighten contact pad mounting bolts to 50 ft.-lbs. (65 Nm).
Arm Bar Bearings
• Inspect arm bearings for wear. If any bearing is worn to
less than .040 in. (1 mm) thickness, replace all bearings
(see Service Manual 670487).
• Inspect and replace wear tiles if worn (see Service
Manual 670487).
• Inspect pad pivot pins and bushings and replace if worn
(see Service Manual 670487).
2000-Hour Maintenance
After each 2000 hours of truck operation, in addition to
the 100, 500 and 1000-hour maintenance, perform the
following:
• Tighten frame capscrews to 75 ft.-lbs. (100 Nm).
• Replace all arm bar bearings (see Service Manual
670487).
CL1121.eps
Contact Pad
Mounting Bolts
8
Cylinder Head End
Anchor Nuts
Cylinder Rod End
Anchor Nuts
670488 Rev. 5
T
ROUBLESHOOTING
Carton Clamp Loads
IMPORTANT: Before adjusting contact pad camber to
solve handling problems, make sure the Clamp is being
used correctly and is not damaged. Use the Troubleshooting procedure shown and, if necessary, adjust the contact
pad camber using a Cascade Shim Service Kit.
IF FRONT STACK OF
LOAD TILTS OUT:
1
4
Re-clamp
load against
backrest
Check for bent
stabilizers;
straighten or
replace
2
Check for bent
pads; straighten
or replace
CL1301.eps
IF LOWER TIER OF LOAD BRIDGES
DOWN OR SLIDES OUT:
Check
hydraulics
for low
supply
pressure
Check for bent
pads; straighten
or replace
CL1302.eps
3
670488 Rev. 5
Assure center of
load is between
pad pivot and
backrest
2
4
Check for worn
lower surfaces;
rotate pads 180°
and exchange
sides or replace
3
1
Re-clamp load
so bottom edge
is even with
bottom of pads
Add or increase
positive camber
5
T
ROUBLESHOOTING
Carton Clamp Loads (Continued)
IF LOWER TIER OF LOAD
IS CREASED:
Re-clamp
load squarely
between pads
3
4
Check
hydraulics
for high
supply
pressure
Check for bent
pads; straighten
or replace
CL1303.eps
Add or increase
negative camber
Re-clamp load
so bottom edge
is even with
bottom of pads
5
TYPICAL PAD CAMBER FOR HANDLING CASE LOADS
LOAD
CAMBER
CANNED / BOTTLED / DENSE CASE GOODS
Neutral-to-Positive
SOFT CASE GOODS
Neutral-to-Negative
APPLIANCE & LARGE CASE GOODS
Neutral-to-Negative
UNKNOWN LOADS
Pads–Front View
Start with neutral, look
for creases and adjust
camber as required.
CL0093.eps
0
670488 Rev. 5
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
Rua João Guerra, 134
Macuco, Santos - SP
Brasil 11015-130
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
37050 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
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Cascade Corporation 2005
12-2005
Part Number 670488-R5
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