S ERVICE MANUAL

F-Series
Fixed & Swing
Frame Paper Roll
Clamps

Manual Number 674512-R4

cascade
corporation
Cascade is a Registered Trademark of Cascade Corporation
 C ONTENTS
Page Page
INTRODUCTION, Section 1 Revolving Connection, 5.6 50
Introduction 1 Removal and Installation 50
Special Definitions 1 Shaft Only Service 51
INSTALLATION, Section 2 Seals-in-Shaft Service 52
Truck System Requirements 2 Seals-in-Body Service 53
Installation – Fixed Frame Clamps 3 Two-Piece Seals-in-Body Service 54
Recommended Hydraulic Supply 3 Split Long Arm Service 55
Clamp Installation 4 Counterbalance Valve Adjustment 55
Installation – Swing Frame Clamps 9 Cylinders, 5.7 56
Recommended Hydraulic Supply 9 Servicing Cylinders on Clamp 56
Control Valve Group 10 Cylinder Removal – Long or Short Arm 56
Control Valve Group (77F Model) 15 Cylinder Removal – Swing Frame 57
Clamp Installation 19 Cylinder Check Valve Service 57
PERIODIC MAINTENANCE, Section 3 Cylinder Bushing Service 58
100-Hour Inspection 24 Cylinder Service, 5.8 59
500-Hour Inspection 24 Cylinder Disassembly 59
2000-Hour Inspection 24 Cylinder Inspection 59
TROUBLESHOOTING, Section 4 Cylinder Reassembly 60
General Procedures 25 Base Unit, 5.9 61
Truck System Requirements 25 Swing Frame Service 61
Tools Required 25 Frame Bushing Service 61
Troubleshooting Chart 25 Rotation Bearing Torque Inspection 62
Plumbing, 4.2 26 Rotation Bearing Removal and Installation 63
Hosing Diagram – Fixed Frame 26 Adjustable Bumper Service 65
Hosing Diagram – Swing Frame 27 180-Degree Hydraulic Stop Group, 5.10 67
Schematic – Fixed Frame 29 Stop Valve Service 67
Schematic – Split Long Arm 30 Stop Position Adjustment 67
Schematic – Swing Frame 31 Electronic Rotational Control Group, 5.11 68
Schematic – Split Long Arm ERC Stop Valve Service 68
Clamp Function, 4.3 33 Stop Position Adjustment 69
Supply Circuit Test 33 Stop Troubleshooting 69
Clamp Circuit Test 33 Solenoid Valve Service, 5.12 71
Swing Circuit Test 34 SPECIFICATIONS, Section 6
Rotation Function, 4.4 35 Specifications, 6.1 72
Supply Circuit Test 35 Hydraulics 72
Rotation without Load 35 Auxiliary Valve Functions 73
Rotation with Load 35 Truck Carriage 73
Electrical Circuit, 4.5 36 Torque Values 74
SERVICE, Section 5
Clamp Removal, 5.1 37
Arms, 5.2 38
Arm Assembly 38
Contact Pad 39
Arm Tip Repair 39
Drive Group, 5.3 41
Removal and Installation 41
Disassembly and Service 42
Reassembly 43
Drive Motor, 5.4 45
Removal and Installation 45
Disassembly 46
Inspection 47
Reassembly 47
Rotator Drive Check Valve, 5.5 49
Check Valve Service 49

i 674512-R4
 I NTRODUCTION

1.1 Introduction
This Manual provides installation instructions, periodic
maintenance requirements, troubleshooting procedures
and service procedures for the Cascade F-Series Paper
Roll Clamps.
In any communication about the Roll Clamp refer to the
product I.D. number stamped on the nameplate. If the
nameplate is missing, the numbers can be found stamped
on the front of the faceplate top or side.
IMPORTANT: All hoses, tubes and fittings on F-Series Roll
Clamps are JIC.
NOTE: Specifications are shown in both U.S. and (Metric)
units.

Nameplate Locations

c
�
ATTACHMENT CAPACITY
LIFT TRUCK ATTACHMENT POUNDS INCH LOAD
AT CENTER
SERIAL
NUMBER 674870 CAPACITY OF TRUCK AND ATTACHMENT COMBINATION
MAY BE LESS THAN ATTACHMENT CAPACITY SHOWN
CATALOG
NUMBER 60F-RCP-459 WEIGHT
LBS.
ABOVE. CONSULT TRUCK NAMEPLATE.
RECOMMENDED SYSTEM PRESSURE – 2000 PSI
ADDITIONAL MAXIMUM SYSTEM PRESSURE – 2300 PSI
EQUIPMENT
ADDITIONAL
�
EQUIPMENT FOR TECHNICAL ASSISTANCE, PARTS AND SERVICE
CONTACT:
ADDITIONAL 1-800-227–2233
EQUIPMENT PORTLAND, OREGON USA

70
7 48R 9
RC0720.eps 6 O 45
C P -
0 F-R
6

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 special
information that is useful when servicing the attachment.

WARNING - A statement preceded by a

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.

674512-R4 
 I NSTALLATION

2.1 Truck System WARNING: Rated capacity of the truck/

attachment combination is a responsibility
Requirements of the original truck manufacturer and may
be less than that shown on the attachment
nameplate. Consult the truck nameplate.
To achieve maximum operating capability for the F-Series
Paper Roll Clamp, the following requirements must be met.

Truck Relief Setting

45F–160F Clamp & Rotate Circuits, 38F Rotate Circuit
2000 psi (140 bar) Recommended
2300 psi (160 bar) Maximum
38F Clamp Circuit
2300 psi (160 bar) Recommended
2600 psi (180 bar) Maximum

Truck Flow Volume

➀

Min. ➁ Recommended Max. ➂

38F Clamp 5 GPM 10 GPM 12 GPM

(19 L/min.) (38 L/min.) (45L/min.)
Rotate 5 GPM 10 GPM 15 GPM
(19 L/min.) (38 L/min.) (57 L/min.)

45F, 60F, 5 GPM 10 GPM 15 GPM

66F (19 L/min.) (38 L/min.) (57 L/min.)

77F, 90F, 100F 10 GPM 15 GPM 20 GPM

120F (38 L/min.) (57 L/min.) (76 L/min.)

130F, 150F, 15 GPM 20 GPM 25 GPM

GA0356.eps
160F (57 L/min.) (76 L/min.) (95 L/min.)

➀ Cascade Roll 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 minimum will result in a rotate speed less
than 2 RPM.
➂ Flow greater than maximum can result in excessive heating,
reduced system performance and short hydraulic system life.
Carriage
Clean and inspect carriage
bars for damage and smooth-
ness. Repair any protruding
welds or damaged notches.
Carriage Mount Dimension (A) ITA (ISO)

Minimum Maximum
A Tilt
Class II 14.94 in. (380.0 mm) 15.00 in. (381.0 mm) Forward Rotate Release
Class III 18.68 in. (474.5 mm) 18.74 in. (476.0 mm) CCW
Class IV 23.44 in. (595.5 mm) 23.50 in. (597.0 mm) (Swing
Extend)
GA0028.eps Hoist Down

Auxiliary Valve Functions

Check for compliance with
ITA (ISO) standards:
GA0082.eps
Hoist Up Rotate
CW
Tilt (Swing Clamp
Back Retract)

 674512-R4
 I NSTALLATION

2.2 Installation –
Fixed Frame Clamps
2.2-1 Recommended
Hydraulic Supply
F-Series Fixed Frame Paper Roll Clamps provide the best
performance with the hydraulic supply arrangement A
and B. Refer to Cascade Hose and Cable Reel Selection
Guide, Part No. 212199, to select the correct hose reel for
the mast and truck. The hose and fitting requirements are:
• ROTATE Function – Hoses and fittings should be No. 8
with 13/32 in. (10 mm) minimum I.D.
• CLAMP Function – Hoses and fittings should be No. 8
with 13/32 in. (10 mm) minimum I.D., except for internal
reeving arrangements where hoses and fittings may be
No. 6 minimum with 9/32 in. (7 mm) minimum I.D.

A and B
RH and LH THINLINE™ 2-Port Hose Reel Groups.

OR (optional)
A and C
RH THINLINE™ 2-Port Hose Reel Group and Mast
Single Internal Hose Reeving Group.
A B

GA0033.eps

674512-R4 
 I NSTALLATION

2.2-2 Clamp Installation

Follow the steps shown to install the Clamp on the truck.
Read and understand all WARNING statements. If you
don't understand a procedure, ask your supervisor or call
the nearest Cascade Service Department for assistance.

1 Attach overhead hoist

A Remove banding, set Roll Clamp

upright on pallet.
WARNING: Check weight on name-
plate of Roll Clamp and make sure
overhead hoist is rated appropriately .

B Remove bolt-on lower mounting

hooks (if equipped).

A A

RC0967.ill

2 Unlock Quick-Change lower

mounting hooks (if equipped)
A Move hooks into unlocked position
(pin in lower hole).

NOTE: Guides can be reversed to

Guide
A change hook-to-carriage clearance
(See Step 7).

®
CL0097.eps
d e
s ca
ca

-1
14
55
67
C-
5/8-in. (16 mm)
LH lower offset on top
Hook provides
maximum
Pin clearance.
Tighten Capscrews:
CL II, III 38F, 45F, 60F, 66F – 110 ft.-lbs. (150 Nm)
CL IV 60F, 66F, 77F – 195 ft.-lbs. (265 Nm)
CL IV 90F, 100F – 260 ft.-lbs. (360 Nm)
 674512-R4
 I NSTALLATION

3 Prepare Hoses
A Position truck carriage behind Roll Clamp.
B Determine hose lengths required.
CAUTION: Hoses should be 2600-psi working-
C Cut hoses to length, install end fittings. pressure rated for all Attachment functions.

INSTALLATION USING RH & LH 2-PORT INSTALLATION USING RH 2-PORT HOSE

THINLINE™ HOSE REELS: REEL AND INTERNAL HOSE REEVING:

38F–100F Rotate CCW Rotate CW Rotate CCW

Rotate CW

Clamp Clamp

Open
RC0441.ill RC0442.ill
Open

INSTALLATION USING RH & LH 2-PORT INSTALLATION USING RH 2-PORT HOSE

THINLINE™ HOSE REELS: REEL AND INTERNAL HOSE REEVING:

Rotate CW Rotate CCW Rotate CW Rotate CCW

120F–160F

Clamp

Clamp
RC1816.eps RC1815.eps

Open Open

674512-R4 
 I NSTALLATION

4 Flush hydraulic supply hoses

A Install hoses as shown below.
B Operate auxiliary valves for 30 sec. 5 Check oil level and remove
rubber vent cover

C Remove union fittings.

D Install hoses to Roll Clamp fittings as shown in
Step 3 above.
Oil level must
be up to
fill plug hole.

RC0139.eps

Remove rubber
vent cover.

If necessary, fill gearbox with Cascade Gear Lube 656300 or

equivalent SAE 90 wt. gear lube (AGMA 'mild' 6EP Gear Oil).
GA0081.eps

6 Mount Clamp on truck carriage

A Center truck behind Roll Clamp.
B Tilt forward and raise carriage into position.
C Engage top mounting hooks with carriage.
Make sure left hook engages closest notch on
top carriage bar.
D Lift Clamp 2 in. (5 cm) off pallet.
RC0757.ill

Class II carriage bars

and upper mounting
ITA Class II – 0.60–0.66 in. (15–17 mm) hooks shown.
ITA Class III – 0.72–0.78 in. (18–20 mm)
ITA Class IV – 0.72–0.78 in. (18–20 mm)

C C
Notch
Engage locator
tab in notch

Connect hoses to
end block before
Clamp installation.

ITA Class II – 0.32–0.36 in. (8–9 mm)

ITA Class III – 0.39–0.43 in. (10–11 mm)
ITA Class IV – 0.47–0.51 in. (12–13 mm)
RC0723.eps
Center Spacer
Upper Carriage
Bar GA0079.eps Back (Driver's) View

 674512-R4
 I NSTALLATION

7 Install and engage lower hooks

BOLT-ON TYPE QUICK-CHANGE TYPE (OPTIONAL)

Inspect hooks for

Lower excessive clearance.
Carriage (Reverse guides to
Lower
Bar change clearance
Carriage
Bar – See Step 2.)

Install hooks,
ST
tap tight AD
JU
e
®

into position. c ad
cas

Slide hook 14
-1
55
up to engage C-
67

bar, install
pin in locked
position 3/16 in.
(upper hole). (5 mm)
Max.

RC1130.eps RC1131.eps

Tighten Capscrews:
CL II & III 38F, 45F, 60F, 66F – 110 ft.-lbs. (150 Nm)
CL IV 60F, 66F, 77F – 195 ft.-lbs. (265 Nm)
CL IV 90F, 100F and larger – 260 ft.-lbs. (350 Nm)

8 Connect hoses to hose terminal

fittings as shown in Step 3

RC0440.ill RC0765.eps

674512-R4 
 I NSTALLATION

9 Install stop block kit

• Assure Clamp is centered on carriage.
• Locate one(1) stop block on outside of
RH Upper
Mounting Hook

each upper hook.
(NOTE: Do not
NOTE: Stop blocks may be located weld stop block
vertically on each end of carriage bar if on inside)
insufficient room exists outside of upper 1/16 in. Steel Stop
hooks. (1.5 mm) Blocks
• Preheat stop block and carriage bar
weld area to 325° F (180° C).
• Use AWS E-7018 low hydrogen rod and Truck Upper
weld a 6 mm (1/4 in.) fillet full length on Carriage Bar
three (3) sides of each stop block.
1/4-in. (6 mm)
fillet weld on RC0224.eps
three (3) sides.

Back (Driver's) View

10 Cycle Clamp functions

WARNING: Make sure all

personnel are clear of the Clamp
AUXILIARY VALVE FUNCTIONS

during testing.
Tilt Forward
Hoist Down
• With no load, cycle all functions several
times. A C
• Check functions for operation in accordance
with ITA (ISO) standards.
• Clamp and rotate a maximum load, check
for smoothness and normal rotation. B D
• Check for leaks at fittings, revolving GA0005.eps
connection and cylinder rod ends. Hoist Up Tilt Back

LONG ARM ROTATE

(vertical & horizontal (Driver's view)
positions only)
A Counterclockwise (CCW)
C Release
D Clamp
B B Clockwise (CW)

A
D SHORT ARM
(45-degree position only)
C D C Open
C D Close

RC0030.eps RC0031.eps

 674512-R4
 I NSTALLATION

2.3 Installation –
Swing Frame Clamps
2.3-1 Recommended
Hydraulic Supply
F-Series Swing Frame Paper Roll Clamps provide the best
performance with the hydraulic supply arrangement A and
B. Refer to Cascade Hose and Cable Reel Selection Guide,
Part No. 212199, to select the correct hose reel for the mast
and truck. The hose and fitting requirements are:
• ROTATE Function – Hoses and fittings should be No. 8
with 13/32 in. (10 mm) minimum I.D.
• CLAMP & SWING Functions – Hoses and fittings should
be No. 8 with 13/32 in. (10 mm) minimum I.D., except for
internal reeving arrangements where hoses and fittings
may be No. 6 minimum with 9/32 in. (7 mm) minimum I.D.
A and B
RH THINLINE ™ 2-Port Hose Reel Group and
LH THINLINE™ 4-Port Hose Reel Group.

OR (optional)
A, B and C
RH and LH THINLINE™ 2-Port Hose Reel Groups and
Mast Single Internal Hose Reeving Group.

OR (optional)
A and C
RH THINLINE™ 2-Port Hose Reel Group and Mast
Double Internal Hose Reeving Group.

A
B

GA0033.eps

674512-R4 
 I NSTALLATION

2.3-2 Control Valve Group

Installation
(All Models except 77F Serial Numbers 675414–675467)

NOTE: Swing Frame Clamps require a solenoid-operated

control valve group to convert a two (2) function auxiliary
control valve to three (3) function operation.

This Section describes installation procedures for all Swing

Frame Clamps except 77F Models (see Section 2.3-3 for
Control Valve Group
77F Models). For hose reel information, refer to Installation
Part Number Truck Voltage
Instructions 673835 for THINLINE™ 2-Port Hose Reels,
and Installation Instructions 675395 for THINLINE™ 4-Port 674924 12V
Hose Reels (needed for masts without internal reeving). 674925 24V
Control valve groups for different voltages are listed in the 674926 36V
Table opposite. 674927 48V

Follow the Steps shown. Read and understand all WARN-

ING statements. If you don't understand a procedure,
ask your supervisor or call the nearest Cascade Service
Department for asistance.

1
Determine an appropriate mounting location for the HORIZONTAL MOUNT
control valve on the truck cowl. The valve can be
mounted horizontally or vertically. The valve must Check for
not extend outside the width of the cowl or interfere interference
with the truck mast when tilted back. with mast
tilted back.

Valve must not

extend outside width
of cowl.

2
Assemble the solenoid valve, fittings, cover and
subplate. Position the assembly on the truck cowl RC0725.eps

noting any clearance problems. VERTICAL MOUNT

HORIZONTAL MOUNT

To RH 2-Port Hose VERTICAL MOUNT

Reel (No. 8 SAE)

To RH 2-Port Hose
Reel (No. 8 SAE)

To LH 4-Port or
2-Port Hose Reel
(No. 6 SAE)
NOTE: Solenoid coil
must be rotated 90 To LH 4-Port or
degrees to clear cover 2-Port Hose Reel
when assembled. (No. 6 SAE)

RC0726.eps

To truck auxiliary To truck auxiliary valve

valve ports (No. 8) ports (No. 8 SAE)

10 674512-R4
 I NSTALLATION

2.3-2 Control Valve

Group Tack weld subplate to

Installation (Continued) truck cowl.

(All Models except 77F Serial Nos. 675414–675467)

3
Mark the mounting location on the truck cowl. Grind
and clean the area in preparation for welding. Tack
weld the subplate to the cowl and mount the valve
to the subplate with the capscrews supplied in the
kit.

NOTE: Horizontal
mount only shown

RC0727.eps
Capscrews, 5/16-18
UNC x 3.5 in. long

4
Measure and assemble two hoses (user-supplied)
to run from the solenoid valve P and T ports to the
truck valve ports. Install the hoses.

IMPORTANT: Proceed to Step 7 if lift truck is

equipped with mast internal hose reeving.

Port P Port T

Truck auxiliary RC0728.eps

valve ports

Installation with RH 2-Port and LH 4-Port
Hose Reels
LH 4-Port

5
Hose Reel
Rotate Function – Measure and assemble two RH 2-Port
hoses (user-supplied) to run from the control valve Hose Reel
4
C1 and C4 ports to the RH hose reel. Install hoses.
3
Swing Function – Measure and assemble two
hoses (user-supplied) to run from the control valve ROTATE
C2 and C3 ports to the LH 4-port hose reel 3 and 4 function
ports. Install hoses.
Ports 1 and
2 for CLAMP/
OPEN circuit
C4 only

SWING
C1
function
C3
C2
RC0729.eps

674512-R4 11
 I NSTALLATION

2.3-2 Control Valve

Group
Installation (Continued)
(All Models except 77F Serial Numbers 675414–675467)

6
Clamp Function – Measure and assemble two LH 4-Port
hoses (user-supplied) to run from the truck valve Hose Reel
ports to the LH 4-port hose reel 1 and 2 ports.
Install hoses.

WARNING: The hose operating the

OPEN function must connect to
Port 1 on the 4-port hose reel.

CLAMP
function
(Port 2) OPEN
function
(Port 1)

RC0730.eps
Truck auxiliary
valve ports
LH 4-Port
4
Hose Reel

1 2

Carriage Hose
Terminal

RH 2-Port
Hose Reel
SWING
Function
C3
C2 Solenoid-operated
CLAMP/OPEN Control Valve
Function
C1
C4
ROTATE Carriage Hose
Function Terminal

Truck Auxiliary
Valve with push- P
button (ROTATE T
and SWING)
RC0731.eps
Truck Auxiliary
Valve (CLAMP)

12 674512-R4
 I NSTALLATION

2.3-2 Control Valve

Group RH 2-Port

Installation (Continued)
Hose Reel

(All Models except 77F Serial Numbers 675414–675467)

Installation with RH and LH 2-Port Hose

Reels and Internal Hose Reeving ROTATE
Function

7
Internal
Rotate Function – Measure and assemble two Reeving
hoses (user-supplied) to run from the control valve Hoses
C1 and C4 ports to the RH hose reel. Install hoses.
C4
Swing Function – Measure and assemble two
hoses (user supplied) to run from the control valve
C2 and C3 ports to the internal hose reeving SWING
hoses. Install hoses. C1 Function
C3
C2
RC0732.eps

8
Clamp Function – Measure and assemble two LH 2-Port
hoses (user supplied) to run from the truck valve Hose Reel
ports to the LH 2-Port hose reel. Install hoses.

LH 2-Port
Hose Reel

Truck Auxiliary CLAMP

Valve Ports Function

Carriage Hose RC0733.eps

Terminal

SWING Carriage Hose

Function Terminal RH 2-Port
Hose Reel

CLAMP/OPEN
Function

C1
C4
Carriage Hose
C2 ROTATE Terminal
Function

P
Truck Auxiliary C3 T
Valve with Push-
button (ROTATE Solenoi
and SWING) Operated RC0734.eps
Truck Auxiliary Control Valve
Valve (CLAMP)

674512-R4 13
 I NSTALLATION

2.3-2 Control Valve

Group
Installation (Continued)
(All Models except 77F Serial Numbers 675414–675467)

9
Locate the auxiliary valve lever that operates the
hydraulic hoses connected to the solenoid control
valve P and T ports. Install a new knob with
pushbutton, or shrink-wrap the alternate pushbutton
switch onto the control lever.
IMPORTANT: Lever should control the ROTATE
function per ITA (ISO) standards. When the
pushbutton is depressed, the lever should activate
the SWING function.
CAUTION: Secure cable with cable ties to avoid
pinching at truck cowl during handle movement.

PUSHBUTTON SWITCH ON CONTROL LEVER SOLENOID KNOB WITH PUSHBUTTON

New knob with pushbutton
(ROTATE Control Lever)
Pushbutton switch
shrink wrapped to
Cable Ties control lever

3 in. (75 mm)

AC0402.eps typical
NOTE: Remove
tubing around
button as desired
Foam Tape

Heat Shrink Tubing

Cable Ties

ROTATE Control Lever

AC0234.eps

10
Connect the wiring from the pushbutton and control
valve terminals to the truck electrical system as shown.
IMPORTANT: Fuse must be connected to an
unswitched positive terminal – control valve must be
able to energize with truck key in off position.
Control Knob
Control
Pushbutton with Pushbutton
Solenoid Coil Valve
shrink wrapped
to control lever

OR
Pushbutton RC0736.eps

7.5-Amp Fuse White Diode

IMPORTANT: Banded
7.5-Amp Fuse end must connect to
Diode Truck positive (+) side of
Power Source circuit.
(unswitched)
Cable
Black

14 674512-R4
 I NSTALLATION

2.3-3 Control Valve Group Control Valve Group

Installation Part Number Truck Voltage

(77F Model Serial Numbers 675414–675467) 675125 12V

675115 24V
675126 36V
This Section describes procedures for installation of 675127 48V
Solenoid Control Valve Groups on early 77F Model 675128 72V
Swing Frame Clamps. For hose reel information, refer to
Installation Instructions 673835 for THINLINE™ 2-Port Hose
Reels, and Installation Instructions 675395 for THINLINE™
4-Port Hose Reels (for masts without internal reeving).
Control valves groups for different truck voltages are listed
in the Table opposite.
Check for
interference

1
Determine an approximate mounting location for the with mast
control valve on the truck cowl. The valve must not tilted back.
extend outside the width of the cowl or interfere with
the truck mast when tilted back.
Valve must not
extend outside
width of cowl.

RC0737.eps

To LH 2-Port or 4-Port Hose Reel, or

2
Assemble the control valve, fittings, cover and Internal Hose Reeving (No. 6 SAE)
subplate. Position the assembly on the truck cowl
noting any clearance problems.

Tack-weld
subplate to
truck cowl.

3
Mark the mounting location on the truck cowl. Grind
and clean the area in preparation for welding. Tack
weld the subplate to the cowl and mount the valve
RC0738.eps
to the subplate with the capscrews supplied in the
kit.

To RH 2-Port Hose
To truck auxiliary valve Reel (No. 8 SAE)
ports (No. 8 SAE)

4
Measure and assemble two hoses (user-supplied)
to run from the solenoid valve IN ports to the truck
valve ports. Install the hoses.

IN

Truck Auxiliary
Valve Ports
RC0739.eps

674512-R4 15
 I NSTALLATION

2.3-3 Control Valve Group RH 2-Port LH 4-Port

Installation (Continued)
Hose Reel Hose Reel

(77F Model Serial Numbers 675414–675467) 4

3
IMPORTANT: Proceed to Step 7 if lift truck is equipped ROTATE
with mast internal hose reeving. function

Installation with RH 2-Port and LH 4-Port Ports 1 and

Hose Reels 2 for CLAMP/
OPEN circuit
only

5
Rotate Function – Measure and assemble two
hoses (user-supplied) to run from the control valve SWING
ROTATE ports to the RH 2-port hose reel. Install function
hoses. SWING
ROTATE
Swing Function – Measure and assemble two RC0740.eps
hoses (user-supplied) to run from the control valve
SWING ports to the LH 4-port hose reel 3 and 4 LH 4-Port
ports. Install hoses. Hose Reel

6
Clamp Function – Measure and assemble two
hoses (user-supplied) to run from the truck valve
ports to the LH 4-port hose reel 1 and 2 ports.
Install hoses.

WARNING: The hose operating the

OPEN function must connect to
Port 1 on the 4-port hose reel.

CLAMP OPEN
LH 4-Port 4 function function
Hose Reel (Port 2) (Port 1)

Truck auxiliary
valve ports
1 2

Carriage Hose RC0741.eps

Terminal

RH 2-Port
Hose Reel

SWING
Function
CLAMP/OPEN
Function
ROTATE Carriage Hose
IN Function Terminal

Truck Auxiliary
Valve with push- IN
button (ROTATE Solenoid
and SWING) Operated
Control Valve RC0742.eps

Truck Auxiliary
Valve (CLAMP)

16 674512-R4
 I NSTALLATION

2.3-3 Control Valve Group RH 2-Port

Hose Reel
Installation (Continued)
(77F Model Serial Numbers 675414–675467)

Installation with RH and LH 2-Port Hose

Reels and Internal Hose Reeving ROTATE
Function

7
Internal
Rotate Function – Measure and assemble two
Reeving
hoses (user-supplied) to run from the control valve Hoses
ROTATE ports to the RH 2-Port hose reel. Install
hoses.
SWING
Function
Swing Function – Measure and assemble two
hoses (user supplied) to run from the control valve SWING
SWING ports to the internal hose reeving hoses.
ROTATE
Install hoses.
RC0743.eps

LH 2-Port
Hose Reel

8
Clamp Function – Measure and assemble two
hoses (user supplied) to run from the truck valve
ports to the LH 2-Port hose reel. Install hoses.

LH 2-Port
Hose Reel

CLAMP
Truck Auxiliary Function
Valve Ports
Carriage Hose
Terminal
RC0744.eps

IHR
SWING Carriage RH 2-Port
Function Terminal Hose Reel

CLAMP/OPEN
Function

Carriage Hose
ROTATE Terminal
Function

Truck Auxiliary
Valve with Push- Solenoid
button (ROTATE Operated RC0745.eps
and SWING) Control Valve
Truck Auxiliary
Valve (CLAMP)

674512-R4 17
 I NSTALLATION

2.3-3 Control Valve Group

Installation (Continued)
(77F Model Serial Numbers 675414–675467)

9
Locate the auxiliary lever that operates the hydraulic
hoses connected to the solenoid control valve
IN ports. Install a new knob with pushbutton, or
shrink-wrap the alternate pushbutton switch onto the
control lever.
IMPORTANT: Lever should control the ROTATE
function per ITA (ISO) standards. When the
pushbutton is depressed, the lever should activate
the SWING function.
CAUTION: Secure cable with cable ties to avoid
pinching at truck cowl during handle movement.

PUSHBUTTON SWITCH ON CONTROL LEVER SOLENOID KNOB WITH PUSHBUTTON

Knob with pushbutton
Pushbutton switch
shrink-wrapped to (ROTATE Control Lever)
control lever
Cable Ties

3 in. (75 mm)

AC0402.eps
Typical
NOTE: Remove
tubing around but-
ton as desired
Foam Tape

Heat-Shrink Tubing

Cable Ties

ROTATE Control Lever

AC0234.eps

10
Connect the wiring from the pushbutton and control valve
coil terminals to the truck electrical system as shown.
IMPORTANT: Fuse must be connected to an unswitched
positive terminal and control valve must be able to
energize with truck key in off position.

Pushbutton Control Knob

shrink-wrapped with Pushbutton
to control lever
Diode IMPORTANT:
White Banded end must
connect to positive (+) Solenoid Coils
side of circuit.
Diode OR

7.5-Amp
Pushbutton
Fuse

7.5-Amp Fuse

Truck Control
Cable
Power Valve
Source
(unswitched) RC0747.eps
Black
18 674512-R4
 I NSTALLATION

2.3-4 Clamp Installation

1 Attach overhead hoist

A Remove banding, set the clamp
upright on pallet.
WARNING: Check weight on name-
plate of Roll Clamp and make sure
overhead hoist is rated appropriately .

B Remove bolt-on lower mounting

hooks (if equipped).

A A

RC0839.eps

2 Unlock Quick-Change lower mounting

hooks (if equipped)
A Move hooks into unlocked position
(pin in lower hole).

NOTE: Guides can be reversed to

Guide
A change hook clearance (See Step 7).

®
CL0097.eps
d e
s ca
ca

-1
14
55
67
C-
5/8 in. (16 mm)
LH lower offset on top
Hook provides
maximum
Pin clearance.

Tighten Capscrews:
CL II, III 38F, 45F, 60F, 66F – 110 ft.-lbs. (150 Nm)
CL IV 60F, 66F, 77F – 195 ft.-lbs. (265 Nm)
CL IV 90F, 100F, 120F – 260 ft.-lbs. (360 Nm)

674512-R4 19
 I NSTALLATION

3 Prepare Hoses
A Position truck carriage behind Roll Clamp.
B Determine hose lengths required.
C Cut hoses to length, install end fittings. CAUTION: Hoses should be 2300 psi working
pressure rated for all Attachment functions.

INSTALLATION USING RH & LH 2-PORT INSTALLATION USING RH 2-PORT HOSE

THINLINE™ HOSE REELS, SINGLE IHR: REEL and LH 4-PORT HOSE REEL:

Rotate CW Rotate CCW Rotate CW Rotate CCW

Swing Swing
Clamp Clamp Swing Extend
Retract Extend

RC0769.ill RC0768.eps

Outer Hose Open Swing Retract

Open
(See WARNING)

WARNING: Hose connecting revolving

connection OPEN port to 4-port hose reel must
be connected to outer-most hose on reel only.

4
Flush hydraulic supply hoses
A Install hoses as shown below.
B Operate auxiliary valves for 30 sec.
5 Check oil level and remove
rubber vent cover

C Remove union fittings.

D Install hoses to revolving connection fittings as
shown in Step 3 above. Oil level must
be up to
fill plug hole.

RC0139.eps

Remove rubber
vent cover.

If necessary, fill gearbox with Cascade Gear

RC0748.eps
Lube 656300 or equivalent SAE 90 wt. gear lube
(AGMA 'mild' 6EP Gear Oil).

20 674512-R4
 I NSTALLATION

6 Mount Clamp on truck carriage

A Center truck behind Roll Clamp.
B Tilt forward and raise carriage into position.
B

C Engage top mounting hooks with carriage. A

Make sure left hook engages closest notch on
top carriage bar.
D Lift Clamp 2 in. (5 cm) off pallet.

RC0757.ill

Class II carriage bars

and upper mounting
ITA Class II – 0.60–0.66 in. (15–17 mm) hooks shown.
ITA Class III – 0.72–0.78 in. (18–20 mm)
ITA Class IV – 0.72–0.78 in. (18–20 mm)

Notch
C C
Engage locator
tab in notch

Connect hoses to
end block before
clamp installation.
ITA Class II – 0.32–0.36 in. (8–9 mm)
ITA Class III – 0.39–0.43 in. (10–11 mm)
ITA Class IV – 0.47–0.51 in. (12–13 mm) RC0843.eps

Center Spacer
Upper
Carriage Bar GA0079.eps Back (Driver's) View

7 Install and engage lower hooks

BOLT-ON TYPE QUICK-CHANGE TYPE (OPTIONAL)

Inspect hooks for

Lower excessive clearance.
Lower Carriage (Reverse guides to
Carriage Bar change clearance
Bar – See Step 2.)

Install hooks,
ST
tap tight AD
JU ®

de
into position. sc
a
ca

Slide hook 67
55
14
-1

up to engage C-

bar, install
pin in locked
position. 3/16 in.
(upper hole.) (5 mm)
Max.

RC1130.eps RC1131.eps

Tighten Capscrews:
CL II & III 38F, 45F, 60F, 66F – 110 ft.-lbs. (150 Nm)
CL IV 60F, 66F, 77F – 195 ft.-lbs. (265 Nm)
CL IV 90F, 100F, 120F and larger – 260 ft.-lbs. (350 Nm)

674512-R4 21
 I NSTALLATION

8 Connect hoses to hose terminal

fittings as shown in Step 3

RC0771.eps RC0772.eps

9 Install stop block kit

• Assure Clamp is centered on carriage.
• Locate one stop block on the outside of each
RH Upper
Mounting
Hook
upper hook.
NOTE: Stop blocks may be located vertically
(NOTE: Do not
on each end of carriage bar if insufficient room weld stop block
exists outside of upper hooks. on inside)
1/16 in.
• Preheat stop block and carriage bar weld area Steel
(1.5 mm)
to 325° F (180° C). Stop
Blocks
• Use AWS E-7018 low hydrogen rod and weld a
1/4 in. (6 mm) fillet full length on three sides of
each stop block. Truck Upper
Carriage Bar

1/4 in. (6 mm)

fillet weld on RC0224.eps
three (3) sides.

22 674512-R4
 I NSTALLATION

10 Cycle Clamp functions

WARNING: Make sure all personnel

are clear of the clamp during LONG ARM
testing. (vertical & horizontal
positions only)

• With no load, cycle all functions several times. C Release

• Check functions for operation in accordance D Clamp

with ITA (ISO) standards.
• Clamp and rotate a maximum load, check for
smoothness and normal rotation.
• Check for leaks at fittings, revolving connection
and cylinder rod ends.
C D

RC0030.eps

SWING ROTATE
(Bilge handling shown) (Driver's view)
A (Push Button) Extend A Counterclockwise (CCW)
B (Push Button) Retract B Clockwise (CW)

B
A
A
D SHORT ARM
B (45-degree position only)
C Open
C D Close
RC0773.eps
RC0031.eps

AUXILIARY VALVE FUNCTIONS

Tilt Forward
Hoist Down

A C

B D
GA0005.eps
Hoist Up Tilt Back

674512-R4 23
 P ERIODIC MAINTENANCE

3.1 100-Hour Maintenance

Every time the lift truck is serviced or every 100 hours
WARNING: After completing any service
procedure, always test the clamp through
of truck operation, whichever comes first, complete the five complete cycles. First test the clamp
following maintenance procedures: empty, then test with a load to make sure the
clamp operates correctly before returning it
• Check for loose or missing bolts, worn or damaged to the job.
hoses, and hydraulic leaks.
• Check the edges of the contact pads for wear or sharp Contact Pad Contact Pad Rotator Bearing
nicks that could damage or tear paper rolls. Grind the Edges Pivot Joints Assembly Grease
edges smooth. Fitting Rotator
• Check the contact pad pivot joints for wear and replace Drive
or repair as necessary (see Section 5.2). Fill Plug

• Lubricate plungers on 180 degree stop valve (if fitted).

• Check that load-holding hydraulic system is functioning
properly. Clamp Force Indicators 830141, 832442 and
200645 for paper roll clamps are available for this test.
• Check decals and nameplate for legibility.

3.2

500-Hour Maintenance
After each 500 hours of truck operation, in addition to the
100-hour maintenance, perform the following procedures:
• Check sample of baseplate capscrews for proper torque
value. See Sections 5.9-3 and 5.9-4 for checking and
replacement procedures.
• Check sample of faceplate capscrews for proper torque
value. See Sections 5.9-3 and 5.9-4 for checking and RC0749.eps
replacement procedures.
Arm, Cylinder
• Tighten mounting hook capscrews. See Section 6.1-4 Left Side and Swing Frame
for specific Roll Clamp Model torque specifications. Pivot Joints
• Tighten rotator drive assembly capscrews to 75 ft.-lbs.
(105 Nm). WARNING: Faceplate and baseplate bear-
• Lubricate rotator bearing assembly with multi-purpose ing assembly capscrew torque must be
extreme-pressure NLGI 2 grease (Whitmore 'Omnitask' checked initially at 500 hours and then every
or equivalent). Rotate Clamp one full turn during 2000 additional hours. Failure to keep the
procedure. capscrews tightened can result in attachment
• Check rotator drive gearcase lubricant level. Lubricant damage and serious injury.
should be up to bottom of fill plug hole. If necessary, fill
with Cascade Rotator Drive Lubricant, Part No. 656300,
or SAE 90 wt. gear lube (AGMA 'mild' 6 EP Gear Oil). Bearing Assembly-to- Rotator Drive
Faceplate Capscrews Capscrews
Replace plug. Baseplate-to-Bearing
(Access all through hole
Assembly Capscrews
• Inspect all arm, frame and cylinder pivot bushings for in baseplate)
wear and replace if necessary (see Sections 5.7-5 and
5.9-2 for wear limits).
• Inspect all load-bearing structural welds on arms, swing
frame pivots, arm pivots and cylinder pivot areas for
visual cracks. Replace components as required. Rotator
Drive
Fill Plug
3.3

2000-Hour Maintenance
After each 2000 hours of truck operation, in addition to
the 100 and 500-hour maintenance, perform the following
procedures:
• Check all rotation bearing capscrews for proper torque
value. See Section 5.9-3 and 5.9-4 for checking and
replacement procedures.
• Inspect all arm and cylinder pivot pins for wear and
replace if necessary (see Section 5.9).
RC0750.eps
• Perform CLAMP circuit hydraulic pressure check (see
Section 4.3-2). Back (Driver's) View Mounting Hook Capscrews

24 674512-R4
 T ROUBLESHOOTING

4.1 General Procedures WARNING: Before servicing any hydrau-

4.1-1 Truck Requirements lic component, relieve pressure in the
system. Turn the truck off and move the
• Truck hydraulic pressure should be within the range truck auxiliary control valves several times
shown in Specifications, Section 6.1. Pressure to the in both directions.
Clamp must not exceed the following: After completing any service procedure, test the Clamp
45F–160F, 2300 psi (160 bar) through several cycles. First test the Clamp empty to
38F, 2600 psi (180 bar) bleed any air trapped in the system to the truck tank.
Then test the Clamp with a load to be sure it operates
• Truck hydraulic flow should be within the range shown in correctly before returning to the job.
Specifications, Section 6.1.
Stay clear of the load while testing. Do not raise the
• Hydraulic fluid supplied to the Clamp must meet the load more than 4 in. (10 cm) off the floor while testing.
requirements shown in Specifications, Section 6.1.

4.1-2 Tools Required

In addition to a normal selection of mechanic's hand tools,
the following are required: Flow Meter Kits: 671476 (10 GPM – 37 L/min)
• In-line Flow Meter Kits: 671477 (20 GPM – 75 L/min)
10 GPM (37 L/min) – Cascade Part No. 671476.
(2) No. 8-12 JIC/
OR O-Ring Flow Meter
20 GPM (75 L/min) – Cascade Part No. 671477.
• Pressure Gauge Kit (2 kits required):
5000 psi (345 bar) – Cascade Part No. 671212.
GA0013.eps
• Assorted fittings, hoses, and quick-disconnect couplers
as required. (2) No. 6-8 JIC Reducer

4.1-3 Troubleshooting Chart

Pressure Gauge Kit: 671212
Determine All The Facts – It is important that all the
facts regarding the problem are gathered before be- Pressure No. 6 and No. 8
ginning service procedures. The first step is to talk to Gauge* No. 6-6 Hose* JIC Swivel Tee
the equipment operator. Ask for a complete descrip-
tion of the malfunction. The following guidelines can
then be used as a starting point to begin troubleshoot-
ing procedures: GA0014.eps

Clamp Circuit No. 4-6 Pipe/JIC* No. 6-8 JIC No. 4, No.
Reducer
• Clamp drops roll after it has been picked up. 6* and No. 8
JIC/O-Ring
• Clamp will not pick up rolls to its rated capacity.
• Clamp arms will not function properly.
To correct one of these problems, see Section 4.3. Quick-Disconnect Couplers
Rotate Circuit Male Straight Thread
O-Ring Coupler:
• Clamp will not rotate.
No. 4 (Part No. 212282)*
• Clamp will not rotate rolls up to its rated capacity. No. 5 (Part No. 210378)
No. 6 (Part No. 678592)
• Clamp rotates in one direction only.
To correct one of these problems, see Section 4.4. Female JIC Thread
Coupler:
• Clamp will not stop smoothly with 180° stop valve or No. 4 (Part No. 210385)* AC0127.eps
rotational control. No. 6 (Part No. 678591)
To correct this problem, see Section 5.10 or 5.11.
* NOTE: Diagnostics Kit 394382
Swing Circuit includes items marked.
• Clamp swings slowly or not at all.
To correct this problem, see Section 4.3-3.

674512-R4 25
 T ROUBLESHOOTING

4.2 Plumbing
4.2-1 Fixed Frame Clamp –
Hosing Diagram

Rotator
Drive CCW
CW

Long Arm
Cylinders Short Arm
Cylinders
(if equipped)

2-Port
Hose Reel
CLAMP NOTE: Short arm
cylinders operate
only when Clamp is
rotated to the
45-degree position.

OPEN

Revolving
Connection

2-Port
Truck Auxiliary
Hose Reel
Valve (ROTATE)
or Internal
Hose
Reeving

Truck Auxiliary
Valve (CLAMP)

RC0680.ill

ARMS CLOSING, ARMS OPENING,

ROTATE CW ROTATE CCW
Pressure:
Return:

26 674512-R4
 T ROUBLESHOOTING

4.2-2 Swing Frame Clamp –

Hosing Diagram

Rotator
Drive CCW
Revolving CW
Connection

Long Arm
Cylinders Short Arm
Cylinders
(if equipped)

4-Port
Hose Reel
CLAMP
NOTE: Short arm
cylinders operate
1 Swing only when Clamp is
Cylinder rotated to the
45-degree position.
2
OPEN
1
2

2-Port
Hose Reel
or Internal
Hose
Reeving
ROTATE

Truck Auxiliary
Valve (ROTATE IN
and SWING)

IN

77F Solenoid
Valve RC0682.eps

Truck Auxiliary
Valve (CLAMP)
C4

45F, 60F C1
Solenoid Valve

ARMS CLOSING, ARMS OPENING,

ROTATE CW ROTATE CCW P
Pressure: T
Return:

674512-R4 27
 T ROUBLESHOOTING

4.2-2 Swing Frame Clamp –

Hosing Diagram (Continued)

Rotator
Drive
Revolving
Connection

Long Arm
Cylinders Short Arm
Cylinders
(if equipped)

4-Port
Hose Reel
NOTE: Short arm
cylinders operate
Port 3 only when Clamp is
Swing rotated to the
Port 4 Cylinder 45-degree position.

Port 3 SWING
EXTEND
Port 4

SWING
RETRACT

2-Port
Hose Reel
or Internal
Hose
Reeving
SWING

Truck Auxiliary
Valve (ROTATE IN
and SWING)

IN

77F Solenoid
Valve RC0681.eps

Truck Auxiliary
Valve (CLAMP)

C2 C3
45F, 60F
Solenoid Valve
SWING EXTEND SWING RETRACT
Pressure:
P
Return:
T

28 674512-R4
 T ROUBLESHOOTING

4.2-3 Fixed Frame Clamp –

Hydraulic Schematic

(Typical All Cylinders)

Test Port Check Valve

G
G

Long Arm Short Arm

Cylinders Cylinders
(if equipped)

G
G

CL CL
Revolving
Connection
OP OP
OP OP

CL CL

Clamp Relief
CLAMP (if equipped)

OPEN Rotator
Drive Motor

Motor
Check
Valve

CCW CW

2-Port
Hose Reel 2-Port
or Internal Hose Reel
Reeving

Truck Auxiliary Truck Auxiliary

Valve (CLAMP) Valve (ROTATE)

Truck Pump
Truck Relief Truck Tank

RC2477.eps

674512-R4 29
 T ROUBLESHOOTING

4.2-4 Fixed Frame Clamp, Split Long Arm –

Hydraulic Schematic
(Typical All Cylinders)
Various split long arm hydraulic circuits/revolving connections used.
Test Port Check Valve

G
G

Long Arm Short Arm

Cylinders Cylinders
(if equipped)

G
G

CL CL
Split Long Arm Circuit Components
(variations shown below )

Revolving Shuttle
Connection OP Spool Valve
CL
OP Sequence
OP Valve
CL OP
Flow Divider
RC2454.eps

29
79
22

CLAMP
Rotator
Drive Motor
OPEN Shuttle Check Valve
Cross-Over Check
Relief (if Valve
equipped)

NOTE: Truck CCW CW

components
not shown. Adjustable
Relief Valve
Flow
CL
Divider

65
17
21

CL
Closing Free Arm
Orifice (if equipped) Adjustable
Relief Valve

Flow Divider

CL Sequence
Valve

CL
08
88
20

OP Shuttle
Valve

30 674512-R4
 T ROUBLESHOOTING

4.2-5 Swing Frame Clamp –

Hydraulic Schematic
(Typical All Cylinders)

Test Port Check Valve

G
G

Short Arm
Long Arm Cylinders
Cylinders (if equipped)

G
G
Revolving Connection

CL SWR
CL Swing
OP OP Cylinder

OP OP
CL
CL
SWE
Counterbalance
Valves
OPEN SWR
CAUTION: Outer most
hose on 4-port hose reel Rotator
CLAMP SWE Drive Motor
must connect to OPEN
port on attachment.
Check
Valve

CCW CW
Solenoid-Operated 4-Port Solenoid-Operated
Control Valve Hose Reel Control Valve
or Internal
77F Serial Numbers Reeving All Models 2-Port
675414–675467 (except as shown) Hose Reel

1 2 3 4

C C CC
1 2 3 4

P T

Truck Auxiliary Truck Auxiliary Valve

Valve (CLAMP) (ROTATE and SWING)

Truck Truck Relief Truck

Pump Tank

RC2466.eps

674512-R4 31
 T ROUBLESHOOTING

4.2-6 Swing Frame Clamp, Split Long Arm –

Hydraulic Schematic (Typical All Cylinders)
Various split long arm hydraulic circuits/revolving connections used. Test Port Check Valve

G
G

Short Arm
Long Arm Cylinders
Cylinders (if equipped)

G
G Revolving Connection

CL OP
OP

SWR
Split Long Arm
Circuit Components Swing
(variations shown Cylinder
below) CL
CL Counterbalance
SWE Valves (2)
OP
OP
CL
Flow Divider
OPEN SWR

CLAMP SWE Rotator

Adjustable Drive Motor
Relief Valve
Check
Valve

CCW CW
21
23
95
RC2457.eps
NOTE: Truck components not shown.

Adjustable Counterbalance
Relief Valve Valves

Shuttle Valve

CL
Sequence
Valve

73
87
20

CL
OP
Flow
Divider
Counterbalance
Valves

32 674512-R4
 T ROUBLESHOOTING

4.3 Clamp Function

There are five potential problem areas that can affect the • If one of the gauge pressures drops more than 150
CLAMP function: psi (10 bar) initially, and additional drop exceeds
25 psi (2 bar) per minute, the cylinder check valve
• Clamping roll improperly, or handling rolls that exceed cartridge or piston seals may be faulty. Continue
capacity of Clamp. Refer to Operator’s Guide for troubleshooting.
suggested procedures.

• If both gauge pressures do not drop more than 150

• Low hydraulic pressure or flow from lift truck. psi (10 bar) initially, and additional drop does not
• External leaks. exceed 25 psi (2 bar) per minute, the problem is not
hydraulic (see Section 4.3).
• Defective solenoid coil or valve (if equipped).
• Worn/defective revolving connection shaft seals or 3 Position both arms at midstroke to relieve cylinder
cartridge valves, cylinder seals or check valves. pressure. Remove, swap and reinstall the cylinder
check valve cartridges.

4.3-1 Supply Circuit Test 4 Long Arm Cylinders – Close the long arm fully and
hold the handle in the CLAMP position a few seconds

to develop full truck system pressure. Watch the gauge
WARNING: Before removing hydraulic lines,
relieve pressure in the Attachment hydraulic pressure readings.
system. Turn the truck off and move the Short Arm Cylinders – Rotate the Roll Clamp to the 45-
truck auxiliary control valves several times degree position. Close the short arm fully and hold the
in both directions. handle in the CLAMP position a few seconds to develop
full truck system pressure. Watch the gauge pressure
1 Check the pressure delivered by the truck. Refer to the readings.
truck Service Manual. The pressure must be within 100
psi (7 bar) of specified truck pressure. Pressure to the • If the gauge pressure on the cylinder continues to
Clamp must not exceed the following: drop more than 150 psi (10 bar) initially, and ad-
45F–160F, 2300 psi (160 bar) ditional drop exceeds 25 psi (2 bar) per minute, the
38F, 2600 psi (180 bar)
cylinder piston seals are faulty (see Section 5.7).
2 Check the flow volume at the carriage hose terminal. • If the gauge pressure on the cylinder does not drop
See Section 6.1-1 for recommended flow volumes. If the more than 150 psi (10 bar) initially, and additional
truck pressure and flow are correct, proceed with the drop does not exceed 25 psi (2 bar) per minute, the
Clamp circuit pressure test. check valve (now in the other cylinder) is faulty and
requires replacement (see Section 5.7-4).
4.3-2 Clamp Circuit Test
WARNING: Before removing hydraulic 45F–160F
lines, position both arms at midstroke to
relieve cylinder pressure. Turn the truck
off and move the truck auxiliary control
valves several times in both directions.

1 Check for external leaks at the cylinders and revolving

connection.
2 Long Arm Cylinders – Install a pressure gauge to each
long arm cylinder's test port. Close the long arm fully
Long Arm
and hold the handle in the CLAMP position a few sec-
Cylinder Test

2
onds to develop full truck system pressure. Watch the Port
gauge pressure readings. Pressure
Gauge
Short Arm Cylinders – Install a pressure gauge to each
short arm cylinder's gauge port. Rotate the Clamp to
the 45-degree position. Close the short arm fully and
hold the handle in the CLAMP position a few seconds
to develop full truck system pressure. Watch the gauge
pressure readings.
• If the initial gauge pressures are not within 100 psi
(7 bar) of system pressure measured at the hose
terminal, the revolving connection may be faulty and RC2005.eps
requires service. Refer to Section 5.6.

38F

674512-R4 33
 T ROUBLESHOOTING

4.3-3 Swing Circuit Test

(Swing-Frame Clamp Only)
1 Clamp a vertical roll of the approximate weight capacity
of the Clamp. Rotate 90 degrees to position the short
arm down. Extend the swing cylinder fully to swing the
frame upward. Swing Up

• If the roll drifts downward, the revolving connection

counterbalance valve may require service (see Section
5.6-4.).
• If the roll does not drift down, continue troubleshooting.
2 Retract the swing cylinder to lower the roll:

1
• If the roll drops suddenly, the counterbalance valve
requires adjustment (see Section 5.6-2.). Swing
Cylinder Short Arm
3 Raise the roll and rotate 180° to position the long arm
down. Retract the swing cylinder fully to swing the frame
upward.
• If the roll drifts downward, the revolving connection
Swing
counterbalance valve may require service (see Section Cylinder
5.6-4.).
• If the roll does not drift down, continue trouble
shooting.
4 Extend the swing cylinder to lower the roll: Swing Up
• If the roll drops suddenly, the counterbalance valve
requires adjustment (see Section 5.6-2.).

RC0790.ill

Long Arm
3

34 674512-R4
 T ROUBLESHOOTING

4.4 Rotation Function • If the higher gauge reading is close to truck pres-
sure as measured at the carriage hose terminal and
no rotation occurs, the rotator motor output shaft or
There are four potential problem areas that can affect the drive box may need repair. Continue troubleshoot-
rotation function: ing.
• Operator may be handling roll incorrectly. Loads may
be too heavy or rotated off-center, exceeding capacity
2 Remove the motor from the drive box assembly as
described in Section 5.4.
of Clamp. Refer to Operator’s Guide for suggested
handling procedures. 3 Reinstall the hoses to the rotator motor fittings. Actuate
• Low hydraulic pressure or flow from lift truck. the rotate circuit.

• Worn or defective hydraulic rotator motor or check valve • If the rotator motor shows rotational output, the drive
assembly. box may require service (see Section 5.3).
• Worn or defective drive assembly or rotator frame • If the rotator motor shows little or no rotational out-
bearing assembly. put, the rotator motor requires service (see Section
5.4).
Flowmeter
4.4-1 Supply Circuit Test

WARNING: Before removing hydraulic
lines, relieve pressure in the Attachment
hydraulic system. Turn the truck off and
move the truck auxiliary control valves
several times in both directions.

1 Check the pressure delivered by the truck. Refer to the

truck Service Manual. The pressure must be within 100
psi (7 bar) of specified truck pressure. Pressure to the
Clamp must not exceed the following:
45F–160F, 2300 psi (160 bar) RC1132.ill
Pressure Gauges
38F, 2600 psi (180 bar)
2 Check the flow volume at the carriage hose terminal.
See Section 6.1-1 for recommended flow volumes. If the Check Valve
truck pressure and flow are correct, proceed with the
Rotation circuit pressure test.
3 Check for external leaks.

4.4-2 Rotation without Load

1 Install pressure gauges to the rotator motor fittings.
2 Rotate the Clamp without a load and note pressure
readings of both gauges. RC0303.ill

• If the Clamp rotates faster in one direction than the Hydraulic

Motor
other, or rotates in one direction only, the check valve
assembly may need service (see Section
Section 5.5). Drive Box

• If the lower gauge reading exceeds 500 psi (35 bar),
there is excessive back pressure in the supply circuit. Model Max. Torque Capacity
Check for restrictions such as numerous fittings, 90- 38F* – 64,000 in.-lbs.@ 2000 psi
degree fittings, or hose sizes less
(7230 Nm @ 140 bar)
than No. 8.
45F*, 60F*, – 72,000 in.-lbs. @ 2000 psi
4.4-3 Rotation with Load 66F*

(8135 Nm @ 140 bar)
77F‡ – 85,000 in.-lbs @ 2000 psi
1 Rotate a load requiring approximately 3/4 of the Clamp's (9600 Nm @ 140 bar)
maximum torque capacity as shown in the Table
90F‡, 100F‡ – 112,000 in.-lbs. @ 2000 psi
opposite and note gauge readings.
(12600 Nm @ 140 bar)
• If the higher gauge reading is substantially less than
the truck pressure as measured at the carriage hose * Rated at 10 GPM (37 L/min.) flow
‡
Rated at 15 GPM (56 L/min.) flow
terminal, the rotator motor geroter set may need repair
SS Reference: 1116, 347, 353, 456, 351, 385.
(see Section 5.4).
674512-R4 35
 T ROUBLESHOOTING

4.5 Electrical Circuit 4 Disconnect the electrical leads from the solenoid coil ter-
minals. Use a voltmeter to determine if there is voltage
(Solenoid-equipped attachments) at the electrical lead terminals when the control knob
button is depressed.
Use the schematics shown and follow the steps below.
• If there is no current to the solenoid, troubleshoot the
electrical circuit for opens or shorts.
1 Check the control knob circuit fuse. Replace if neces-
sary. • If there is current to the solenoid, test for coil continu-
ity and proper rating.
2 Check for loose electrical connections at the truck igni-
tion switch, control knob button, solenoid coil terminals 5 Test for coil continuity and rating by placing an ohmme-
and diode. ter test lead on each solenoid coil terminal (ohmmeter
on Rx1 scale):
3 Remove the diode from the solenoid coil terminal. Test • If there is a reading, the coil is good. Check for proper
with an ohmmeter for high resistance in one direction ohm value for the truck.
and no resistance in the other direction. If there is no
resistance in both directions, replace the diode. • If the coil is good, but the solenoid does not 'click'
when the control knob button is depressed, the sole-
NOTE: When replacing the diode, the banded end must
noid cartridge may be jammed (see Section 5.12).
be connected to the coil and wiring as shown.
• If there is no ohmmeter reading, the coil is defective
and should be replaced (see Section 5.12).

ALL CLAMPS
(Except 77F swing frame early model) Pushbutton attached Control Knob
to control lever with with Pushbutton Solenoid Solenoid
heat shrink tubing Coil Valve
12V: 2.4–2.8 Ohm
24V: 9.5–11 Ohm
Coil 36V: 24–28 Ohm
48V: 40–46 Ohm

Pushbutton RC0736.eps

7.5-Amp
Fuse White Diode IMPORTANT:
7.5-Amp Fuse Banded end must con-
nect to positive (+) side
Diode of circuit.

Cable
Black

Pushbutton attached Control Knob

77F SWING FRAME EARLY MODEL to control lever with with Pushbutton
heat shrink tubing
Diode IMPORTANT:
White Banded end must con- Solenoid
nect to positive (+) side Coils
of circuit.

Diode

7.5-Amp
Pushbutton
Fuse

7.5-Amp Fuse

Control
Cable
Valve

Black RC0747.eps

36 674512-R4
 S ERVICE

5.1 Clamp Removal

1
1 Rotate the clamp to the vertical roll handling position.
Extend the arms outside the width of the frame.

WARNING: Before removing hydraulic

lines, relieve pressure in the Attachment
hydraulic system. Turn the truck off and

4
move the auxiliary control valves several
times in both directions.

2 Disconnect and plug the hydraulic supply hoses to the

Clamp. Tag hoses for reassembly.
Rotate CCW
Rotate CW

3
RC0758.ill

Lower Hooks

2
Clamp
Rotate CCW
Rotate CW

RC0441.ill
Open
3 Disconnect the lower hooks:
Bolt-On Hooks – Remove the lower mounting hooks.
For reassembly, tap hooks tight against lower carriage
bar and tighten the capscrews to: Clamp Swing
Extend
CL II, III 38F, 45F, 60F, 66F – 110 ft.-lbs. (150 Nm)
CL IV 60F, 66F, 77F – 195 ft.-lbs. (265 Nm)
CL IV 90F, 100F, 120F – 260 ft.-lbs. (350 Nm)
Quick-Change Hooks – Pull out the locking pins and RC0446.ill
drop the lower hooks to the unlocked position. Reinstall Outer
the pins in the lower holes. For reassembly, slide the Hose Swing
hooks up to the locked position and install the locking Open Retract
pins in the top holes.
WARNING: Hose connected to
4 Set the Clamp on a pallet. Tilt the mast forward and
OPEN port must use outer-most
lower the carriage to remove the Clamp from the truck.
hose on 4-port hose reel.
5 For installation, reverse the above procedures with the
following exceptions:
• Refer to Section 2, Installation, for complete
installation procedures.

3 BOLT-ON HOOKS
Carriage Bar
RC0368.eps
QUICK-CHANGE HOOKS
Guide

RC0367.eps
®

ST de
U a
ADJ LH lower sc
ca
Hook
-1
14
55
67
C-

LH lower Hook in
unlocked position
Locking Pin

674512-R4 37
 S ERVICE

5.2 Arms Cylinder Rod

Anchor Pins
Arm Assembly –
5.2-1
Removal and Installation
Spacers
2
1 Open the arm to be removed to mid-range position.
Rotate the Clamp to the vertical roll handling position.
3 Shims
(each
2 Remove the cylinder rod anchor pins from both cylinder joint)
rods. Retract the cylinders. For reassembly, tighten the
anchor capscrews to 35 ft.-lbs. (45 Nm).
3 Swing the arm being removed inward to contact the

3
other arm. Rotate the Clamp 90 degrees to position the
arm being removed on top.

2
RC0332.ill

4 Attach an overhead hoist to the arm and take up slack

in the chain.
WARNING: Make sure the hoist used to
5 Remove the arm pivot pins and spacers (if equipped). remove the arm has a rated capacity of at
Note location of shims. Lift away arm assembly. For least 2000 lbs. (900 kg).
reassembly, tighten the arm pivot pin capscrews to 35
ft.-lbs. (45 Nm).
NOTE: Clamps built after 6/87 are equipped with

4
spacers at the arm pivot points. It is recommended that
all Clamps be equipped with these spacers. Kits listed

5
below include spacers for the swing frames, arms, and
cylinder base pivots.
Clamp Model Spacer Kit
45F 681774
60F, 66F 681775
77F, 90F, 100F 681776
and larger
6 For reassembly, reverse the above procedures.

RC0333.ill

38 674512-R4
 S ERVICE

5.2-2 Contact Pad –

Removal and Installation
Pad Link
4 Contact
Pad

2
Link
Clevis
1 Rotate the Clamp to the vertical roll handling position. Pin
Lower the unit until the contact pads lightly touch the
ground.
NOTE: If bolt-on pad surfaces are to be replaced,
remove and replace at this point. Tighten capscrews to
15 ft.-lbs. (20 Nm).
2 Remove the clevis pins fastening the links to the contact
pad.
3 Remove the pipe plug retainers or drive pin retainer
3
Pad Pivot
Pin, Plugs
from the contact pad pivot points and drive out the pivot
pins.
4 Remove the contact pad. Pad links can be removed
from the arm by rotating 90 degrees and pulling out.
Long arms links are held in by a spring. 45F–120F PADS
5 38F – Assure pad opener springs are installed as RC0334.ill

shown. Replace as required.

6 For reassembly, reverse the above procedures with the

5
following exceptions: Pad Opener
• Inspect the arm tips and pivot pins for wear and Springs
repair/replace as necessary (see Section 5.2-3).
• 38F – Install drive pin-type retainer 2 mm below
outside surface of contact pad. Assure pin is an
interference fit. (Pin .312 in. dia. x 1.250 in long).

5.2-3 Arm Tip Repair

Pad Link
Spring
Link
Clevis Pin Plug
3
The following procedure describes tip removal and Retainers
replacement using Service Kit 683065 (25F), 6047539

4
(38F), 674928 (45F, 60F, 66F) and 676810 (77F, 90F and Pivot
larger). Each kit includes four (4) replacement arm tips to OR
Pin
repair one (1) arm.
Drive Pin
WARNING: Cascade Corporation recom- Retainer
mends that a qualified welder experienced in 38F PADS
this type of repair be used for best quality. RC1987.eps

1 Remove the contact pad as described in Section 5.2-2.

3
2 Scribe a cut line using dimension A, back from the inner Remove tips of
surface of the existing pivot pin hole on both sides of arm casting
the arm tip.
3 Remove the worn tip portion of the arm casting at
the cut line by grinding, sawing, or flame cutting.
Remove any contaminants from around the repair area. A

Model Dimension A in. (mm)

25F 0.26 ± .03 (6.6 ± 0.7)
A
38F, 45F 0.15 ± .03 (3.8 ± 0.7)
60F, 66F 0.15 ± .03 (3.8 ± 0.7)
77F, 90F, 100F 0.26 ± .03 (6.6 ± 0.7)
and larger
RC0762.ill

674512-R4
Cut line
2 39
 S ERVICE

5.2-3 Arm Tip Repair (Continued) Dimensions

4 Position the new tubes on the arm tips using dimensions Model B in. (cm) C in. (cm) D in. (mm)
B and C as shown. Place a rod of diameter D through
all tubes for alignment. 38F 7.18 ± .06 24.89 ± .12 0.50
(18.2 ± .15) (63.23 ± .30) (12.7)
5 Preheat the arm tip base metal to 70° F (21° C)
minimum and tack-weld the new tubes to the arm tips. 45F 9.06 ± .06 27.12 ± .12 0.50
Use the recommended weld procedures listed below. (23.0 ± .15) (68.8 ± .30) (12.7)
6 Install the contact pad and pivot pins on the arms. 60F, 9.06 ± .06 28.46 ± .12 0.50
Check the tube alignment and realign as required. 66F (23.0 ± .15) (72.2 ± .30) (12.7)
Remove the contact pad and pins.
7 Finish-weld the tubes to the arm tips using the following 77F, 10.60 ± .06 32.20 ± .12 0.56
weld procedures: 90F, (26.9 ± .15) (81.8 ± .30) (14.2)
100F and larger
• Protect threaded end of tubes from weld spatter.
• Preheat arm tip base metal as follows:
38F – 90F: 150° F (66° C) Start weld this side
100F: 400°F (205° C).
Monitor and maintain arm tip heat at locations shown
using suitable temperature-indicating devices.
• Weld sequence - Start weld on side indicated. 0.40 in. (10 mm)
Terminate each weld at center of tube.
• WELD METHOD A – FCAW (Flux Core Arc Weld).
Attach ground wire to arm. Weld using AWS E70T-1 2 in.
1/16 in. (1.6 mm) or 5/64 in. (2 mm) diameter wire (50 mm)
with 100% CO2 shielding gas at 35–50 CFH. Set
welding amps per manufacturer's recommendations.
Apply weld holding a close arc. Do not oscillate or
Temperature
use a wash bead pattern. Align new tubes
Measurement
Areas flush with inner
• WELD METHOD B – SMAW (Stick Welding).
edge of casting.
Attach ground wire to arm. Weld using E-7018
low hydrogen 1/8 in. (3.2 mm) or 5/32 in. (4 mm)
electrodes. Set welding amps per manufacturer's
recommendations. Do not use electrodes exposed
to moisture without first re-drying them at 200° F
7 B

4
(75° C) for 2 hours. Apply weld holding a close arc.
Do not oscillate or use a wash bead pattern.
• Cool arm tip base metal as follows:
38F – 90F: normal air-cool.
100F: slow cool with insulating blanket cover.
8 Remove slag after each weld and inspect for defects. C
NOTE: Arc craters, undercut, overlap and porosity are
not permitted. Repair any weld defect as required.
9 Grind all welds to smooth transitions between parts. START

STOP

START

7 Weld Sequence:

START
B

STOP

START

RC0306.eps

40 674512-R4
 S ERVICE

5.3 Drive Group

5.3-1 Drive Group Removal

and Installation
1 Remove the Clamp from the truck as described in
2
3
Section 5.1.
2 Remove the four capscrews fastening the drive group to
the baseplate. For reassembly, tighten the capscrews
to 75 ft.-lbs. (100 Nm).
3 For reassembly, reverse the above procedures with the
following exceptions:
• After the drive group has been reinstalled, check the
gearcase lubricant level. Lubricant must be up to
the bottom of the fill plug hole. If necessary, fill with
Cascade Gear Lube Part No. 656300, or SAE 90 wt.
gear lube (AGMA 'mild' 6 EP Gear Lube). RC0171.eps

Drive
Group

5.3-2 Drive Group Disassembly

and Service
1 Remove the drive group from the baseplate as Cover
43
described in Section 5.3-1.

7
Plate
2 Lay the drive group, pinion down, on two 4 x 4 in. (10 x
10 mm) wood blocks placed on both sides of the pinion.
3 Remove the four capscrews fastening the cover plate to
the housing.
4 Remove the center capscrew plug from the cover plate
and install a (early) 3/8 in. NC or (later) M10 capscrew Housing

5
with a minimum thread length of 2 in. (50 mm). Remove
the cover plate by turning the capscrew clockwise while
lightly tapping around the sides of the cover plate.
5 Drain the lubricant from the housing.
6 Remove the three capscrews fastening the end cover to
the housing.
7 Remove the drive motor as described in Section 5.4-1.

2 RC0172.eps
6
674512-R4 41
 S ERVICE

5.3-2 Drive Group Disassembly Bearing

outer race
and Service (Continued)
8 Tap the worm and bearing assembly out through the
end-cover side of the housing. Remove the opposite
outer bearing race through the motor side of the
housing.

8
RC0173.eps
Worm

9
Worm
Gear
9 Press the pinion gear, seal, pinion bearings and worm
gear out of the housing as an assembly.

RC0174.eps

Housing
Pinion Bearing

Worm Gear Key

10 Remove the snap ring from the pinion gear shaft. Press
the pinion gear bearing from the worm ring gear and
cover plate pinion bearing. Remove the pinion shaft
key.
Pinion Gear
10
IMPORTANT: Heavy Duty Pinion uses two bearings with
the first bearing retained by an additional snap ring (see Seal (if equipped)
illustration next page).

11 Press the pinion gear out of the housing pinion bearing.

Remove seal.
12 Clean and inspect all components. Remove all dried
11
sealant or threadlocker residue. Replace all worn items.
Remove any burrs or sharp edges with emery cloth. RC2111.eps

NOTE: Two types of large pinion bearing used: Sealed

bearing, and bearing with separate seal (shown)

42 674512-R4
 S ERVICE

Drive Group Reassembly

1
5.3-3 PINION AND BEARING WITH EXTERNAL SEAL

Build up the pinion/worm gear assembly vertically with the Housing

Seal Pinion
pinion gear down. Bearing
1 Standard Pinion – Position the seal against the pinion (Non-sealed)
gear, spring-side facing housing. Apply Loctite 271
Pinion
(red) to clean and dry bearing seating area as shown. gear
Press a non-sealed housing bearing onto the pinion
shaft. IMPORTANT: Earlier design uses a sealed Seal Bearing
bearing. Pry out bearing seals when using an external Seating Seating
seal. Remove excess Loctite. Area Area
RC2118.eps
Heavy Duty Pinion – No external seal is used. Position
PINION WITH SEALED BEARING
the first bearing and snap ring on the pinion shaft.
Apply Loctite 271 (red) to the second bearing seating Housing
area as shown. Press the second bearing onto the Pinion
pinion shaft. Remove excess Loctite. Bearing
(Sealed)
CAUTION: Assure Loctite does not squeeze into the
seal or bearings.
2 Install the key, worm gear, cover plate pinion bearing
and snap ring on the pinion.
RC2648.eps
3 Apply Loctite 271 (red) to clean and dry housing seating
area and shoulder for the housing pinion bearing and HEAVY DUTY PINION WITH SEALED BEARINGS
seal. Install the complete pinion assembly into the
housing. Remove excess Loctite. Baseplate
Pinion
CAUTION: Assure Loctite does not squeeze into the Bearing
seal or bearings. Housing
Pinion
4 Install the worm's outer bearing race in the drive motor Pinion Bearing
side of the housing. Make sure the race taper is inward Gear
as shown.
First
5 Install the drive motor as described in Section 5.4-1. Bearing
Second
Bearing
6 Install the worm and bearings in the housing. Fully Seating Seating
engage the worm with the drive motor shaft. Install the Area Area Additional
remaining outer bearing race. Make sure the race taper Snap Ring
RC2124.eps

is inward as shown.

Key
Worm Gear,
Bearing, Snap Ring

4
2 RC2125.eps

3 Housing

RC0179.eps

6 5 RC0178.eps

674512-R4 43
 S ERVICE

5.3-3 Drive Group Reassembly

(Continued)
7 Temporarily install the end cover without shims.
Tighten the capscrews sequentialy in 10 ft.-lb. (15 Nm)
increments to 20 ft.-lbs. (30 Nm).
8 Measure the gap between the end cover and housing
in three places with a feeler gauge or 'Pastigage'
thread and determine the minimum gap.
7
9 Choose a combination of end cover shims equal to the
minimum gap measured plus the next higher .005 in.
(0.12 mm) increment. See examples below:
(For .025–.029 in. measured gap, use .030 in. total
shim thickness.)

(For .010–.014 in. measured gap, use .015 in. total
shim thickness.)
(For .009 or less, use one (1) .010 in. shim, since a RC0180.eps
Housing 8 End cover

minumum of one .010 in. shim is required for proper

seal.

NOTE: Shim Service kit 670578 contains the shims

listed. A minumum of one (1) .010 shim is required to
seal against leakage:

Qty Part No. Color Thickness

11
9
2 671758 Clear/Yellow .020 in. (.50 mm)
2 671757 Pink .015 in. (.39 mm)
1 670574 Brown .010 in. (.25 mm)

10 Remove the end cover. Apply Loctite 515 sealant
(Cascade Part No. 668184) to both surfaces of the
shims and the capscrews. Install the shim pack and
end cover. Tighten the capscrews to a torque of 65
ft.-lbs. (90 Nm). Remove excess sealant.
11 With the gearcase laying flat, fill with 56 fluid ounces

10
(540 ml) of Cascade Gear Lube Part No. 656300, or
SAE 90 wt. gear lube (AGMA 'mild' 6EP Gear Lube). RC0181.eps

12 Install the cover plate and gasket. Install the four cover
plate capscrews and tighten to 15 ft.-lbs.
(20 Nm). Install the center hole plug.
13 Reinstall the drive group on the rotator baseplate as
described in Section 5.3-1. 12
Cover plate

RC0182.eps

44 674512-R4
 S ERVICE

5.4 Drive Motor

5.4-1 Drive Motor Removal and
Installation
1 Remove the Clamp from the lift truck as described
in Section 5.1. WARNING: Before removing hydraulic
lines, relieve pressure in the hydraulic
2 Remove the drive group from the Clamp as described system. Turn the truck off and open the
in Section 5.3-1. truck auxiliary control valves several times
in both directions.
3 Remove the fill plug and drain the lubricant from the
drive group.
4 Lay the drive group, pinion down, on two 4 x 4 (10 x 10
cm) wood blocks placed on both sides of the pinion
gear.
5 Remove the four capscrews and special lockwashers
fastening the check valve assembly to the drive motor.
Keep track of the two O-rings between the check valve Drive Motor

8
assembly and drive motor. For reassembly, tighten the

7
O-Rings
capscrews to 15 ft.-lbs. (20 Nm).

Adapter
Plate
Check Valve

5 6
6 Remove the three capscrews fastening the adapter
plate to the gearcase housing. Tap on the drive motor
with a rubber mallet to separate the drive motor/

3
adapter plate assembly from the gearcase housing.
7 Remove the four capscrews fastening the adapter plate

4
RC0778.eps
to the drive motor and separate the motor from the
adapter plate. Fill Plug
(two locations)
8 For reassembly, reverse the above procedures except
as follows:
• Apply Loctite 515 sealant (Cascade Part No.
668184) to both sides of the drive motor/adapter
plate gasket. Apply sealant to the threads of the
four drive motor capscrews. Install the gasket and
adapter plate to the drive motor. Tighten capscrews
to 30–40 ft.-lbs. (50–55 Nm).
• Apply sealant to both sides of the adapter plate/
gearcase housing gasket. Apply sealant to the
threads of the three adapter plate capscrews. Install
the drive motor/adapter plate assembly and gasket
to the gearcase housing. Tighten the capscrews to
55–65 ft.-lbs. (75–90 Nm).
• Fill the drive group with fill with 56 fluid ounces (540
ml) Cascade Gear Lube Part No. 656300, or SAE 90
wt. gear lube (AGMA 'mild' 6 EP Gear Lube).

674512-R4 45
 S ERVICE

5.4-2 Drive Motor Disassembly

Cascade provides service replacement parts for the
unshaded parts only. Due to cost, if other parts need
replacement, the complete drive motor assembly should
3
be replaced.
1 Remove the drive motor from the drive group as
described in Section 5.4-1.
IMPORTANT: Clean the outside of the drive motor and
service in a clean, dust-free work area. Use a soft-
jawed vise for all service procedures.
2 Drain the hydraulic fluid from the drive motor by rotating RC0184.eps
the shaft. Plug the ports.
3 Clamp the drive motor in a vise across the flange with
Capscrews
the shaft downward.
Seal
4 Remove the capscrews/seal washers, end cap/seal,
washers
Geroler set/seal, spacer plate/seal, splined drive, shaft,

4
needle thrust bearing and bearing race.
5 Turn the drive motor over, clamping the housing across
End
the port area with the flange upward.
Cap
6 Remove the four Loctited capscrews from the flange.
Do not use an impact wrench (see CAUTION below).
RR0092.ill

7 Flange
9 Spacer
Plate
Gerotor
Set

Splined
Drive
Shaft
Exclusion Thrust
Seal Bearing

5
Bearing
Race
Housing
O-ring

Pressure Seal

Capscrews 8 RC0186.eps

6 RC0187.eps

CAUTION: Thread-locker used on the capscrews may

9
Allen wrench
require that a small amount of heat be applied to the
housing (400° F / 200° C), to remove the capscrews.
Use a temperature indicator to prevent overheating the
housing.
7 Remove the flange from the housing.
8 Remove the exclusion seal and pressure seal from the
flange using a seal removal tool or modified screwdriver

as shown.
RC0188.eps
CAUTION: Do not scratch either of the seal cavities.
9 Using an Allen wrench, remove the metal plug and seal
from the housing.
46 674512-R4
 S ERVICE

Drive Motor Inspection

3
5.4-3
• Remove all Loctite residue from the threaded holes.
• Clean all parts with solvent and blow dry. Do not use 2
1
paper or cloth towels.
• Inspect all parts for small nicks or burrs. Remove any
small nicks or burrs with emery cloth. Replace parts
with scratches or burrs that could cause leakage.
• Inspect the flange seal seats for scratches. Check for
cracks in the flange area that could cause leakage.

RC0189.eps

Capscrews
5.4-4 Drive Motor Reassembly Seal
Washers
Gerotor
1 Clamp the housing with the flange side upward. Set
Spacer
2 Install the plug and seal into housing if it was removed. Plate
Push plug into housing until flush with housing surface. End
Do not damage the seal. Cap
3 Install the flange without the exclusion seal and pres-
sure seal. Use two capscrews only.
RC0190.eps

Plug
Flange
Splined

5
Drive
Shaft
Exclusion
Thrust
5
Seal
Bearing
Bearing
Race

Pressure Seal
O-Ring
Housing
4 4

Capscrews

4 Turn the housing over and clamp across the flange.

5 Lubricate the needle thrust bearing, bearing race and
shaft with hydraulic fluid. Install the needle thrust bear-
ing and bearing race on the shaft. Install the shaft into
the housing. The bearing race must rotate freely in

position. RC0209.eps

IMPORTANT: Do not allow hydraulic fluid to get into the

7
housing threaded holes.
6 Install the splined drive into the shaft with the longer
splined end (if applicable) down.
7 Install the seal and spacer plate to the housing.

IMPORTANT: Line up the timing mark on the shaft

with a threaded capscrew hole. Mark the hole. Make
sure the slots in the spacer plate provide passage for Timing Marks
hydraulic fluid. If the spacer plate is flipped, the motor
will not operate.
RC0210.eps

674512-R4 47
 S ERVICE

5.4-4 Drive Motor Reassembly (Continued)

8 Install the seal and Geroler set on the spacer plate.
IMPORTANT: Make sure a star point on the gerotor set

9
matches up with the timing marks on the spline drive.
Seal
9 Install the seal and end cap, seal washers and Washers
capscrews. Pre-tighten the capscrews to a torque of
15–40 in.-lbs. (2–5 Nm). Make sure the housing and End Cap
gerotor seals are properly seated. Final-tighten the
capscrews using a criss-cross tightening pattern to 200
in.-lbs. (22 Nm).
10 Turn the housing over and clamp across the port area
with the shaft upward. Seal
11 Remove the flange from the housing.
12 Lubricate the exclusion seal with petroleum jelly and
press into the flange.
13 Place the pressure seal on the shaft, flush against the
bearing race. Lubricate the outer surface of the seal
8
Gerotor Set
with O-ring lube or petroleum jelly.
14 Place the flange on the shaft flush against the pressure
seal. Install the four capscrews and tighten each Seal
capscrew one rotation at a time. The pressure seal Star Point,
must enter the flange seat evenly. Alternately tighten Timing
until the flange is tight against the housing. Marks

Wear Plate

12 Exclusion
seal
Flange

14
13Pressure seal
Flange
RR0094.eps

seal
Bearing race

Housing RC0213.eps

11
15 Remove the flange from the housing and inspect the
pressure seal for proper seating into the flange.
16 Clean the four capscrews and their corresponding
threaded holes in the housing. Use a non-petroleum

10
based solvent and blow dry. Apply Loctite Primer 'NF'
to the holes and allow to dry 1 minute minimum.
17 Apply 4 drops of Loctite 601 sealant to the threads of
each of the four housing holes. Wipe away any excess
sealant. Do not let the sealant dry more than 15 minutes
before installing the capscrews.
18 Apply a liberal amount of petroleum jelly to the exclusion
seal, pressure seal and shaft.
19 Install the flange seal into the flange, and install the
flange to the housing. Install the four capscrews and RC0212.eps

tighten in a criss-cross pattern to 250­ in.-lbs. (28 Nm).
IMPORTANT: The capscrews must be clean and dry.

48 674512-R4
 S ERVICE

5.5 Rotator Drive Check Valve

5.5-1 Check Valve Service
1
2
WARNING: Before removing hydraulic
lines, relieve pressure in the hydraulic
system. Turn the truck off and open the
truck auxiliary control valves several times
in both directions.
Valve
1 Disconnect the hydraulic hoses to the drive group valve.
Tag hoses for reassembly.
2 Remove the four capscrews fastening the check valve to
the drive group. Keep track of the two O-rings between
the check valve and drive motor. For reassemably,
tighten the capscrews to 18–24 ft.-lbs. (25–30 Nm).
3 Remove the plug fittings, check valve internal parts
(early) or cartridges (later).
4 Clean all parts with clean solvent or kerosene. Remove
any burrs or sharp edges with emery cloth. O-Rings

5 Inspect the internal ball seats for imperfections that

would keep the balls from seating fully.
6 For reassembly, reverse the above procedures except
as follows:
• Note the correct direction of the internal conical RC0214.eps
springs (Spring Type).
• Install new O-Rings and Back-up Rings on the check
valve cartridges as shown (Cartridge Type).

SPRING TYPE CARTRIDGE TYPE

Body
C

W
Check Valve
C

3
CC
W

Cartridges
C

6
CW
W

RC0197.eps
RC2522.eps

5 6 Check Cartridge O-Rings

6038929
CKCB-XCN
Sun

RC2519.eps

Back-Up Rings

674512-R4 49
 S ERVICE

5.6 Revolving Connection TYPICAL MOUNTINGS

5.6-1 Removal and Installation Front Views

WARNING: Before removing any hydraulic FLANGE Tighten to

40 ft.-lbs.
lines, relieve pressure in the attachment (55 Nm)
hydraulic system. Turn the truck off and
move the auxiliary control valves several
times in both directions.

CL OP CL OP
LONG ARM
CL OP CL OP
SHORT ARM
RC0805.eps

Tighten to
8 ft.-lbs.
BRACKETS
(10 Nm)

Revolving
Connection

RC0785.eps

NOTE: Revolving Connections vary in mounting style and

configuration. See typical examples opposite. RC0804.eps
Tighten to
1 Remove the Clamp from the lift truck as described in 8 ft.-lbs. (10 Nm)
Section 5.1. EYE PIN

2 Disconnect the hoses and tubes from the front and rear
of the revolving connection. Tag for reassembly.
3 Remove the capscrews fastening the revolving
connection to the faceplate. For reassembly, tighten
capscrews as noted in the illustration opposite.
4 Remove the revolving connection from the faceplate.
5 For reassembly, reverse the above procedures with the RC0926.eps
following exceptions:
• Service revolving connection in a clean work area
(see Sections 5.6-2 through 5.6-6).
• Position shaft/end block so that CLAMP/OPEN
fittings are on the left side (driver's view), or the BRACKET PIN
'TOP' stamping (if marked) is upward.

'TOP' stamping
L
C

Clamp Swing
P
O
L
C

Tighten to
Extend
P
O

8 ft.-lbs. (10 Nm)

LONG ARM
SHORT ARM

RC1972.eps

RC2479.eps
Open Swing
Retract

Back (Driver's) View

50 674512-R4
 S ERVICE

5.6-2 Shaft Service

(Seals-in-shaft type only)

1 Remove the Clamp from the lift truck as described in

Section 5.1.
2 45F Clamps – Remove the revolving connection keeper
bracket. For reassembly, tighten the capscrews to
8 ft.-lbs. (10 Nm).
3 Disconnect the hoses from the shaft end block only and
cap the fittings.
4 Clean the revolving connection and adjacent parts with
clean solvent or kerosene.
5 Remove the snap ring from the front of the revolving

2
conection shaft. CAUTION: Remove all burrs and paint

5
from exposed shaft surface prior to removal from the
body. Burrs or paint chips pulled through the bore
will permanently damage the valve body. Keeper
Bracket
6 Remove the shaft from the body. (if equipped)
Snap Ring

7 Remove and replace the shaft seals as described in

Section 5.6-3
8 For reassembly, reverse the above procedures.

RC0799.eps

674512-R4 51
 S ERVICE

5.6-3 Seals-in-Shaft Revolving O-Rings

Connection Service
1 Remove the revolving connection from the attachment
as described in Section 5.6-1.
2 Remove the snap ring from the revolving connection
shaft.
CAUTION: Remove all burrs and paint from exposed RC2504.eps
shaft surface prior to removal from the body. Burrs or Back-up Rings
paint chips pulled through the bore will permanently
COUNTERBALANCE VALVE
damage the valve body.
CARTRIDGE
3 Remove the shaft from the body. Back-up Rings
4 Swing Frame Clamps – Remove the counterbalance
valve cartridges.
5 Remove the O-rings and back-up rings from the shaft
and counterbalance valve cartridges.
6 Remove the fittings from the shaft and body.
7 Clean all parts with clean solvent or kerosene.
8 Inspect the body bore for grooves and scratches. If the
bore is worn, replace the body.
FIXED FRAME SHAFT
9 For reassembly, reverse the above procedures with the O-Rings
following exceptions: O-Rings

• Install new back-up rings and O-rings on the shaft

and counterbalance valve cartridges as shown.
• Lubricate the shaft and counterbalance valve
cartridges with O-ring lube or petroleum jelly prior to
reassembly.

Shaft

3 RC0803.eps
SWING FRAME SHAFT
Back-up Rings

SWING FRAME
REVOLVING CONNECTION

2
O-Rings, Snap
Back-up Ring
Rings

5 Counterbalance
Valve Cartridge

FIXED FRAME
REVOLVING CONNECTION 4
Body
5
O-Rings,
RC0779.eps

Back-up Rings

52 674512-R4
 S ERVICE

5.6-4 Seals-in Body Revolving

Connection Service
1 Remove the revolving connection from the attachment
as described in Section 5.6-1.
2 Remove the front snap ring from the shaft.
Seals
7 FIXED FRAME BODY
Back-up
Rings

CAUTION: Remove all burrs and paint from exposed

shaft surface prior to removal from the body. Burrs or
paint chips pulled through the bore will permanently

damage the valve body. O-Ring
3 Remove the shaft/end block assembly from the body.
4 Remove the end block from the shaft. NOTE: For
reassembly, orient block and shaft as shown. Apply RC0781.eps
Back-up
Loctite 271 (red) to the capscrews and tighten to 15 ft.-
Rings
lbs. (20 Nm).

7
5 Remove the O-rings and back-up rings from the body
and counterbalance valve cartridges using a hook-type
brass seal removal tool (Cascade Part No. 674424). SWING FRAME BODY
NOTE: Do not scratch grooved surfaces.
6 Clean all parts with clean solvent or kerosene and

inspect the following areas:
• Shaft sealing surface – Remove minor surface
imperfections with 320-grit emery paper. Sand
radially (around) shaft. Break sharp edges on front of
shaft. If severly worn, replace shaft.
• Body grooves – Remove minor nicks or projections
that may damage seals during installation. If severly Back-up
Rings O-Rings
worn, replace body.
7 For reassembly, reverse the above procedures with the
following exceptions:
• Install new back-up rings and O-rings as shown.
• Lubricate shaft and body with O-ring lube or
petroleum jelly. Use shaft/seal loader, rotate body
during installation.
RC0831.eps
Plug

End Block
4 O-Rings

3 Shaft

Plug
SWING FRAME
REVOLVING CONNECTION
O-Rings
Body
O-Rings,

5
Back-up Snap
Rings Ring Counter-
balance
Valve
Cartridges

FIXED FRAME 5
CL OP CL OP

REVOLVING CONNECTION
LONG ARM
CL OP CL OP
SHORT ARM

O-Rings,
Back-up
Rings
RC0782.eps

674512-R4 53
 S ERVICE

5.6-5 Two-Piece Seals-in-Body • Clean all traces of oil and moisture from seal
grooves inside revolving connection body using
Revolving Connection a non-petroleum based cleaner. (Example:
electronic contact cleaner).
Service • Clean hands thoroughly to remove all traces of oil
and moisture prior to 2-piece seal installation.
1 Remove the revolving connection from the attachment
as described in Section 5.6-1. • Install square rubber rings into revolving connection
body grooves.
2 Remove the front snap ring from the revolving • Install Teflon rings over rubber rings. IMPORTANT:
connection shaft.
Use a seal installation tool, or form seal rings into
CAUTION: Remove all burrs and paint from exposed a 'kidney' shape as shown to install. Avoid sharp
shaft surface prior to removal from the body. Burrs or bends. Use finger pressure to smooth rings into
paint chips pulled through the bore will permanently grooves.
damage the valve body.
• Lubricate shaft and body with hydraulic fluid prior to
3 Remove the shaft from the body. reassembly.
4 Remove the end block from the shaft. Remove the relief • Use seal/shaft loader and
cartridge (if equipped). For reassembly, apply Loctite apply gentle pressure to install
271 (red) to the capscrews and tighten to 15 ft.-lbs. shaft in body. Rotate body to
(20 Nm). ease installation.

5 Remove the two-piece seals from the body using a Seal AC0044.eps

7
FIXED FRAME Installation Tool
brass hook-type seal removal tool (Cascade Part No.
BODY (Cascade Part
674424). CAUTION: Do not scratch grooved surfaces. No. 599514)
6 Clean all parts with clean solvent or kerosene and
inspect the following areas: Body

• Check shaft sealing surface. Remove minor surface

imperfections with 320-grit emery paper. Sand
radially (around) shaft. Break edges on outer end of
shaft and snap ring grooves. If severly worn, replace
shaft.
• Check seal grooves in body. Remove minor nicks
or projections with 320-grit emery paper. If severly
worn, replace body.
7 For reassembly, reverse previous procedures with the
following exceptions for the two-piece seals:
• Install new O-rings between shaft and end block.
RC0372.eps
Teflon
Ring Square
Two-Piece Seals Rubber Ring
FIXED FRAME REVOLVING CONNECTIONS
Rear Snap Ring

4
End Block, Form seals into 'Kidney'
Capscrews shape to install

7 O-Rings Body

RC0488.eps

3
Shaft
CL
SHORT ARM

RC01973.eps
CL
LONG ARM
L

Front
C

Snap
P
O
L
C

Ring

2
P
O

LONG ARM

Two-Piece
SHORT ARM

Seals

38F 45F–100F
54 674512-R4
 S ERVICE

5.6-6 Split Arm Revolving O-Rings

Connection Service
NOTE: Various revolving connections and cartridges are
used with Split-Arm Clamps (see Section 4.2, Hydraulic
Schematics for versions). All are serviced in a similar
manner. A typical example is shown below. RC2494.eps
Back-Up Rings
1 Remove, disassemble and service the revolving SEQUENCE VALVE CARTRIDGE
connection using the same procedures as described in
previous Sections 5.6-3, 5.6-4 and 5.6-5.
O-Rings
2 Use illustration opposite when installing new Back-up
rings and O-Rings on the cartridges.

FIXED FRAME SPLIT ARM

REVOLVING CONNECTION RC2502.eps

Clamp Relief Valve Back-Up Rings

(if equipped) Sequence
FLOW DIVIDER CARTRIDGE
Valve
End Block
O-Ring
Shuttle
Spool Valve

Body

GA0203.eps

Back-Up Ring
SHUTTLE CHECK VALVE CARTRIDGE
O-Rings Flow
Divider O-Rings
Rear Shaft
Snap Ring

RC2501.eps

Front RC0454.eps
Shuttle Check Snap Back-Up Rings
Valve Two-Piece Ring
Seals RELIEF VALVE CARTRIDGE

5.6-7 Swing Frame Counterbalance Revolving

Connection

Valve Adjustment
1 Rotate the Clamp to the bilge (horizontal) position with
the short arm down.
2 Activate the SWING function and check for smooth
extend and retract at equal, moderate speeds.
SWR
• If Clamp moves upward suddenly when SWING Swing
EXTEND function is activated, adjust cartridge labeled Retract
'Swing Extend Adjust' (see illustration). Loosen nut Adjust
and turn adjustment screw counterclockwise (CCW) SWE
to reduce swing speed or clockwise (CW) to increase Swing
swing speed. Extend
• If Clamp moves downward suddenly when Adjust
SWING RETRACT function is activated, adjust
cartridge labeled 'Swing Retract Adjust' (see
RC0784.eps
illustration). Loosen nut and turn adjustment screw
counterclockwise (CCW) to reduce swing speed or
NOTE: Typical revolving connection, front view,
clockwise (CW) to increase swing speed.
Clamp rotated to bilge position, short arm down.

674512-R4 55
 S ERVICE

5.7 Cylinders
Servicing Cylinders
2
5.7-1
on the Clamp
1 Close the arm attached to the cylinder being serviced.
Rotate the Clamp to the vertical roll handling position.

4
2 Remove the cylinder rod anchors from both cylinders.
For reassembly, tighten the anchor capscrews to
35 ft.-lbs. (45 Nm).
3 Retract the cylinder rods.Swing the cylinder to be
serviced outward to expose the cylinder rod and
retainer.

WARNING: Before servicing hydraulic

components, relieve pressure in the
attachment hydraulic system. Turn the truck
off and move the auxiliary control handles

3
several times in both directions.

4 Place a drip pan under the cylinder and disconnect the

hoses from the cylinder ports. Plug the hose ends and
tag for reassembly.
1
5 Service the cylinder as described in Section 5.8.

RC0307.eps

Cylinder Removal –
2
5.7-2
Long or Short Arm
1 Close the arm attached to the cylinder being removed.
Rotate the Clamp to the vertical roll handling position.
2 Remove the cylinder rod anchor pins from both
4
cylinders. For reassembly, tighten the anchor
capscrews to 35 ft.-lbs. (45 Nm).

WARNING: Before removing hydraulic

3
hoses, relieve pressure in the hydraulic
system. Turn the truck off and open the
truck auxiliary control valves several times
in both directions.

3 Swing the arm inward. Place a drip pan under the

cylinders and disconnect the hoses from the cylinder

1
ports. Plug the hose ends and tag for reassembly.
4 Remove the cylinder base anchor pins. Note the
location of shims. For reassembly, tighten the anchor
capscrews to 35 ft.-lbs. (45 Nm).
4
5 Service the cylinder as described in Section 5.8.

RC0308.eps

56 674512-R4
 S ERVICE

5.7-3 Cylinder Removal –

Swing Frame
1 Position the swing cylinder rod to midstroke. Rotate the
Clamp to the vertical roll handling position.

WARNING: Before removing hydraulic

hoses, relieve pressure in the attachment
hydraulic system. Turn the truck off and
2
move the auxiliary control valves several
times in both directions.

2 Place a drip pan under the cylinder and disconnect the

hoses from the cylinder ports. Plug the hose ends and
tag for reassembly.
3
3 Remove the anchor pin retainer and anchor pin from
both ends of the cylinder. Remove the cylinder and
note location of shims. For reassembly, tighten the
anchor capscrews to 10 ft.-lbs. (13 Nm).
RC0309.eps
4 Service the cylinder as described in Section 5.8.

5.7-4 Cylinder Check Valve Service

1 Close the arm attached to the cylinder being serviced
to gain access to the cylinder check valve. Rotate the
Clamp to the vertical roll handling position.

2
WARNING: Before removing hydraulic Cylinder
hoses, relieve pressure in the attachment Check Valve
hydraulic system. Turn the truck off and Cartridge
move the auxiliary control valves several 45F–120F
times in both directions.

2 Remove the check valve cartridge from the cylinder

port.
3 Remove the O-Rings and Back-up rings. Clean the
check valve cartridge with clean solvent or kerosene.
4 Install new O-Rings and Back-up rings as shown.
5 Lubricate the check valve cartridge with O-Ring lube or
petroleum jelly prior to reassembly. Tighten the check
valve cartridge to 35 ft.-lbs. (45 Nm). 38F RC1980.eps

4
CHECK VALVE CARTRIDGE

O-Rings

RC0311.eps
Back-up Rings

674512-R4 57
 S ERVICE

5.7-5 Cylinder Bushing Service

NOTE: Bushings require replacement if bushing-to-pin
clearance exceeds 1/16 in. (1.6 mm).

1 Remove the cylinder from the Clamp as described in RC1984.ill

Section 5.7-2 or 5.7-3.
2 Remove the bushings from the cylinder using a bushing
driver. NOTE: Bushing drivers can be machined using
the dimensions shown below.
3 Install new bushings in the cylinder. Replace with the

same number of bushings removed.
CAUTION: Bushings may be damaged if installed
without a proper bushing driver.

Bushing Driver Dimensions
A B

2
Bushings
Bearing I.D. Driver O.D.

38F, 45F 1.11 in. (28.2 mm) 1.36 in. (34.5 mm)

60F, 66F 1.23 in. (31.2 mm) 1.48 in. (37.6 mm)

77F, 90F 1.23 in. (31.2 mm) 1.48 in. (37.6 mm)
and larger

7 in.
1.5 in. (178 mm)
(38 mm)

B A

RC0362.eps

58 674512-R4
 S ERVICE

5.8 Cylinder Service

1 2
5.8-1 Cylinder Disassembly RC0314.eps

NOTE: Use a soft jawed vise for all cylinder disassembly

and assembly procedures.

5
1 Clamp the cylinder so that the vise jaws contact only the
extreme end of the cylinder base.
2 Screw the piston retainer out with a pin type spanner
wrench or special socket.
3 Remove the piston/rod/retainer assembly from the cylin-
der shell.
4 Clamp the piston/rod/retainer assembly across the rod RC0315.eps
4
end. IMPORTANT: Never clamp directly on the rod
sealing surface.
5 Remove the piston nut from the rod.
6 Clamp the piston on the top and bottom in a soft-jawed
vise. Pry the seals up with a brass seal removal tool and
cut to remove. RC0346.eps
CAUTION: Do not scratch the seal grooves.

RC0359.eps
6
Check Cartridge
Piston Nut

5 Piston / Rod
assembly
3 Retainer

2
Shell

RC1977.eps

5.8-2

Cylinder Inspection
• Inspect the rod, piston and retainer for nicks or burrs.
Remove minor nicks or burrs with 320 grit emery cloth.
If they cannot be removed, replace the parts.
• Inspect the cylinder shell bore and remove any minor
nicks or burrs with a butterfly hone (320 grit). If the
nicks or burrs cannot be removed, replaced the part.
• Inspect the outside of the shell for any deformities or
cuts that could impare performance or cause leaks
under pressure. If necessary, replace the part.

674512-R4 59
 S ERVICE

Cylinder Reassembly
1
5.8-3 Chamfer
Angle
1 Polish the piston and retainer chamfer angle with 400
grit emery cloth to facilitate seal installation. Clean all
parts thoroughly.
2 Lubricate all new seals and O-Rings with O-Ring lube or
3
petroleum jelly.
3 Install new seals and O-Rings on the piston and retainer.
Hook one side of the seal in the groove and carefully

4
work it over the piston or retainer as shown. Note the Wear RC1982.eps
direction of the U-cup seals. Pressure seals must Ring
always be installed with the lip toward the high
pressure side of the cylinder.
4 Install the composite wear ring on the piston.
5 Install the retainer and then the piston on the cylinder Stop
rod. Tighten the piston retaining nut to the following Fins
torque value: Cylinder
Shell

6
38F – 90–110 ft.-lbs. (120–150 Nm). Piston
45F – 200–225 ft.-lbs. (270–305 Nm). Seal
60F, 66F 77F – 400–450 ft.-lbs. (545–610 Nm). Loader
90F, 100F – 400–450 ft.-lbs. (545–610 Nm).
RC0320.eps
6 Place the piston loader furnished with the seal kit into
the cylinder shell. Assure that the loader covers all Thread refief
the cylinder shell threads but does not contact the chamfer
thread relief chamfer. Trim the loader stop fins if more
engagement is needed.
CAUTION: The piston will not enter the cylinder shell Piston/Rod
properly if the loader contacts the thread relief chamfer. Assembly

7 Apply a thick film of petroleum jelly to the inside of the

cylinder shell, piston loader and piston seals. Using a
rubber mallet, tap the piston/rod assembly through the
loader into the cylinder shell.
8 Remove the loader by cutting down one side and
pulling it out of the cylinder bore.
9 Screw the retainer into the cylinder shell and tighten to
the following torque value: 8
7
RC1983.eps
38F – 150–200 ft.-lbs. (200–270 Nm).
45F – 350–400 ft.-lbs. (470–540 Nm).
60F, 66F, 77F – 400–450 ft.-lbs. (545–610 Nm).
90F, 100F – 400–450 ft.-lbs. (545–610 Nm).

45F–100F Seal 38F Seal

4 4
Piston Retainer
Seals Seals
Swing
Cylinder
45F–100F Seal 38F Seal

O-Ring O-Ring

60
Piston Nut

5 RC1978.eps
11 Retainer

674512-R4
 S ERVICE

Base Unit
5
Swing frame
5.9 Pivot Pins,
Retainers
5.9-1 Swing Frame Service
1 Rotate the Clamp to the vertical roll handling position. Connector Pin
Spacer

4
2 Remove the arms from the Clamp as described in
Section 5.2-1.
3 Remove the clamp and swing cylinders as described
in Sections 5.7-2 and 5.7-3.
Shims
4 Remove the pin connecting the swing casting and
rollers to the swing frames. For reassembly, tighten the

5
retainer capscrews to 35 ft.-lbs. (45 Nm).
5 Remove the swing frame pivot pins and spacers
(see note below). Note the location and quantity of
shims removed. For reassembly, tighten the retainer
capscrews to 35 ft.-lbs. (45 Nm).
Shims
NOTE: It is recommended that all Clamps be
equipped with spacers at the swing frame pivot points
as shown. Kits listed below include spacers for the
swing frame, arms and cylinder base pivots: Spacer
RC0323.eps
Clamp Model Spacer Kit
Swing Casting
45F 681774
60F, 66F 681775
1
77F, 90F,100F and larger 681776 2
6 For reassembly, reverse the above procedures. 1

5.9-2 Frame Bushing Service RC0324.eps

NOTE: Bushings require replacement if bushing-to-pin

2
clearance exceeds 1/16 in. (1.6 mm).
1 Swing Frame Clamps – Remove the swing frames
from the faceplate as described in Section 5.9-1.
Fixed Frame Clamps – Remove the arms from the
Clamp as described in Section 5.2-1. 1
2 Remove the bushings from the frames using a bushing 1
driver. NOTE: Bushing drivers can be machined using
the dimensions shown in the chart below.
3 Install new bushings in the frames (see chart below).
CAUTION: Bushings may be damaged if installed
without a proper bushing driver.

Bushing Driver Dimensions

RC0325.eps
A B
Bushing I.D. Driver O.D.

Bushing Bushing Bushing Bushing

1 2 1 2
38F, 45F 1.23 in. 1.11 in. 1.48 in. 1.36 in.
(31.2 mm) (28.2 mm) (37.6 mm) (34.5 mm)
7 in.
60F, 1.48 in. 1.23 in. 1.73 in. 1.48 in. 1.5 in. (17.8 cm)
66F (37.6 mm) (31.2 mm) (43.9 mm) (37.6 mm) (3.8 cm)
77F, 1.73 in. 1.23 in. 1.98 in. 1.48 in.
90F, (43.9 mm) (31.2 mm) (50.3 in.) (37.6 mm) B A
100F and larger
RC0362.eps

674512-R4 61
 S ERVICE

5.9-3 Rotation Bearing Assembly –

Capscrew Torque Inspection
1
Baseplate-to-Bearing
Capscrews
500-Hour Inspection
Every 500 hours perform the following inspection:
Baseplate

1 Check the accessible baseplate capscrews above

the upper mounting hooks for proper torque value as
follows: tighten each capscrew CW until torque is
10 ft.-lbs. (14 Nm) above torque value listed below.
Mark each capscrew after checking:
38F–100F – 75 ft.-lbs. (100 Nm).
120F–160F – 220 ft.-lbs. (300 Nm).
• If any baseplate capscrews rotate, are loose or
broken, go to 2000-hour inspection criteria and
replace complete set of baseplate fasteners as

described in Section .9-4.
RC2320.eps
• If capscrews do not rotate, continue with faceplate

2
capscrew inspection in Step 2. Bearing-to-Faceplate Baseplate
Capscrews
2 Check three (3) faceplate ews for oper torque
value as follows. Remove the acess plug from the
back of the baseplate and rotate the Clamp to the
predominent vertical roll-handling position. Locate
the three (3) capscrews closest
tighten each capscrew CW until torque is 10 ft.-lbs.
(14 Nm) above torque value listed below. Mark each
capscrew after checking:
38F–100F – 75 ft.-lbs. (100 Nm).
120F–160F – 220 ft.-lbs. (300 Nm).
• If any faceplate capscrews rotate, are loose or
broken, go to 2000-hour inspection criteria and
replace complete set of faceplate fasteners as RC2319.eps

described in Section .9-4. Access Plug
• If capscrews do not rotate, inspection is complete.
Faceplate

2000-Hour Inspection
Every 2000 hours perform the following inspection:

NOTE: Remove Clamp attachment from truck to provide

access to all baseplate capscrews. Remove baseplate
(shown) or use access hole to provide access to all
faceplate capscrews (see Section

1 Check all capscrews as follows: tighten CW until torque

is 10 ft.-lbs. (14 Nm) above torque values listed above.
Mark each capscrew after checking.
• If any capscrews rotate, are loose or broken, replace
complete set of rotation bearing fasteners as

described in Section .9-4.
• If capscrews do not rotate, inspection is complete.
Rotation Bearing
(Baseplate removed)

RC2316.eps
Back (Driver's) Views

62 674512-R4
 S ERVICE

Rotation Bearing Assembly –

2
5.9-4
Removal and Installation
1 Remove the Clamp from the lift truck as described in
Section 5.1.
2 Remove the drive group as described in Section 5.3-1.
3 Remove the upper mounting hooks. For reassembly,
tighten the capscrews as follows:
38F, 45F – 110 ft.-lbs. (150 Nm).
60F, 66F, 77F, CLIII – 110 ft.-lbs. (150 Nm).
60F, 66F, 77F, CLIV – 195 ft.-lbs. (265 Nm).
90F, 100F, 120F – 260 ft.-lbs. (360 Nm).
4 38F, 45F Clamps – Remove the revolving connection
keeper bracket. For ressembly, tighten the capscrews
to 8 ft.-lbs. (10 Nm). RC0326.eps

5 Remove the capscrews fastening the baseplate to the

bearing assembly. For reassembly, tighten capscrews
using the following technique:

WARNING: Install short capscrews

3
in counterbored holes only. Use
lockwashers if supplied in kit.

Baseplate-to-bearing capscrews –
A) Apply Loctite 242 (blue) to clean and dry
capscrews. Clean and dry the threaded holes in
the bearing. Threads must be clean and dry for WARNING: Make sure hoist used to
new Loctite to cure properly. remove the baseplate has a rated capacity
B) Tighten using the alternating cross-pattern shown of at least 1000 lbs. (450 kg).
to one-half the final torque value shown below.
C) Tighten using the alternating cross-pattern to the
final torque value, then double-torque by backing
off 1/2 turn and immediately retightening to the final
torque value shown below:
38F–100F – 75 ft.-lbs. (100 Nm). Faceplate
120F–160F – 220 ft.-lbs. (300 Nm).

CAUTION: Do not reuse old capscrews or

washers. Use new hardware kit when installing a
new bearing assembly.

Alternating
cross-pattern
tightening
sequence.
6

RC2306.eps RC0327.eps
Baseplate
NOTE: Remove center lower mounting spacer (if
Bearing

5
equipped) to gain access to bearing capscrews.
For reassembly, tighten capscrews to: Assembly,
Capscrews Center
60F, 66F, 77F – 15 ft.-lbs. (20 Nm). Lower
90F, 100F, 120F – 30 ft.-lbs. (40 Nm). Spacer

6 Attach two eyebolts to the baseplate. Attach an

overhead hoist and lift the baseplate away from the

faceplate/bearing assembly.
674512-R4 63
 S ERVICE

5.9-4 Rotation Bearing Assembly –

Removal and Installation (Continued)
7 Remove the capscrews fastening the bearing assembly
to the faceplate. For reassembly, apply threadlocker
and tighten the capscrews using the following

technique:
Faceplate
Bearing-to-faceplate capscrews –
A) Apply Loctite 242 (blue) to clean and dry capscrews.
Clean and dry the threaded holes in the faceplate.
Threads must be clean and dry for new Loctite to
cure properly.
B) Tighten using the alternating cross-pattern shown to
one-half the final torque value shown below.
C) Tighten using the alternating cross-pattern to the
final torque value, then double-torque by backing
off 1/2 turn and immediately retightening to the final
torque value shown below:
38F, 45F, 60F, 77F, 90F, 100F – 75 ft.-lbs. (100 Nm).
120F, 130F – 135 ft.-lbs. (180 Nm).
160F – 220 ft.-lbs. (300 Nm).

8

CAUTION: Do not reuse old capscrews or washers.
Use new hardware kit when installing a new bearing
assembly.

Alternating
cross-pattern
9
Felt Seal
tightening RC0328.eps
sequence.

7
RC2330.eps

8 Attach two eyebolts to the bearing assembly as shown.

Attach an overhead hoist and lift the bearing assembly Grease Fitting Heat Treat Zone Faceplate
away from the faceplate.
9 check the condition of the felt seal for the center hole.
Replace if necessary.
10 For reassembly, reverse the above procedures with the
following exceptions:
• When installing the rotation bearing assembly on the R
faceplate, align and position the heat-treated overlap
zone 'R' on the ring gear with the outer race grease
fitting as shown.
38F – 30 degrees above horizontal.
45F, 60F, 66F – 34 degrees above horizontal.
77F, 90F, 100F, 120F – 38 degrees above horizontal.
• Apply multi-purpose extreme pressure NLGI No. 2

10
grease (Whitmore 'OmniTask' or equivalent) to the RC0331.eps
teeth of the bearing assembly ring gear.
• After remounting the Clamp, apply chassis grease
to the bearing assembly grease fitting. Rotate the Back (Driver's) View
Clamp slowly during the procedure.

64 674512-R4
 S ERVICE

5.9-5 Adjustable Bumper Service

1 Rotate the Clamp to the vertical roll handling position.

2
Raise approximately 2 ft. (60 cm) off the ground. Cylinder Pivot Pin
Retainers
2 Remove the top and bottom cylinder pivot pin retainers. Tiedown
For reassembly, tighten the retainer capscrews to Capscrews

4
35 ft.-lbs. (50 Nm).

3
Cylinder
3 Pull the pivot pins out of engagement with the bumper Pivot
rollers approximately 2 in. ( 5 cm). Pins
CAUTION: Do not completely remove the cylinder pivot
pins.
4 Remove the tiedown capscrews from the arms. For
reassembly, tighten the capscrews to 15 ft.-lbs. (20 Nm).
5 Remove the capscrews fastening the belt anchor bars to
the arms. Remove the belt. For reassembly, tighten the
capscrews to 35 ft.-lbs. (50 Nm).

FIXED FRAME CLAMP

5
Belt Anchor Bar
Capscrews

RC0683.eps
Bumper
Rollers

2
Cylinder Pivot Pin
Retainers Tiedown
Capscrews

Cylinder
Pivot
Pins
3 4
5
Belt Anchor Bar
Capscrews

SWING FRAME CLAMP

RC0684.eps

674512-R4 65
 S ERVICE

5.9-5 Adjustable Bumper Service

(Continued) Bushing Driver Dimensions

6 For reassembly, reverse the above procedures with the A B

following exceptions: Bearing I.D. Driver O.D.
• Inspect bumper belt roller surface for wear and
replace if necessary. Remove by splitting surface 38F, 45F 1.11 in. (28.2 mm) 1.36 in. (34.5 mm)
down the side with a screwdriver.
• Install new bushings into the rollers using a bushing 60F and larger 1.23 in. (31.2 mm) 1.48 in. (37.6 mm)
driver.
NOTE: Bushing drivers can be machined using the
7 in.
dimensions shown in the table.
(178 mm)
1.5 in.
CAUTION: Bushings may be damaged if installed (38 mm)
without a proper bushing driver.

• Adjust belt tension by fully opening both arms and B A

attaching the long arm belt anchor bar to the set of
holes that allow the belt to lay flat against the frame.
RC0362.eps
NOTE: Belt anchor bars have offset holes which
allow additional tension adjustment.

6 6
Adjust Adjust
Long Arm Belt flat Long Arm Belt flat
Anchor Bar against frame Anchor Bar against frame

RC0685.eps

SWING FRAME CLAMP FIXED FRAME CLAMP

66 674512-R4
 S ERVICE

5.10 180-Degree Hydraulic

Stop Group
5.10-1 Stop Valve Service
180° Stop
Valve
12
WARNING: Before removing hydraulic
lines, relieve pressure in the hydraulic
system. Turn the truck off and open the
truck auxiliary control valves several times
3
in both directions.

1 Disconnect the hydraulic hose and tubing from the stop

valve fittings.
2 Remove the 90 degree fitting that extends through the
baseplate.
3 Remove the capscrews and remove the stop valve from
the baseplate. For reassembly, tighten the capscrews RC0690.eps
to 35 ft.-lbs. (50 Nm). Wiper Ring
4 Remove the end gland nuts, plungers and spring. Back-up Ring
Remove all fittings from the valve block. Stop Valve Block
O-Rings

4
5 Clean all parts with kerosene or solvent.
6 For reassembly, reverse the above procedures with the
following exceptions:
• Install new O-Rings, Back-up Rings, Wiper Rings.
Gland Nut
RC0691.eps
O-Rings Plunger
Wiper
Spring
Ring
Plunger

Gland Nut

Back-up Ring

5.10-2 Stop Position Adjustment

1 Rotate the Clamp in each direction and assure that the
Clamp stops in the proper vertical or horizontal position.
2 If the stops need to be adjusted, loosen the stop bolt
locknut and adjust the stop bolt as required. Tighten
the locknut.

RC0692.eps

674512-R4 67
 S ERVICE

5.11 Electronic Rotational

Control (ERC) 1
ROTATE
Supply
Hoses

5.11-1 Stop Valve Service

3
Stop
WARNING: Before removing hydraulic Valve
lines, relieve pressure in the hydraulic Block
system. Turn the truck off and open the
truck auxiliary control valves several times O-Rings
STOP
in both directions. Limit Switches,
Solenoid
Deceleration
Coil (side)
Ramps, Stop
1 Disconnect the ROTATE hydraulic hoses from the stop Capscrews
valve fittings and tag for reassembly.
2 Remove the solenoid coils by unscrewing the mounting
nut and sliding the coil off the valve cartridge. For
reassembly, tighten the nut lightly to 5 ft.-lbs. (7 Nm). DECEL
Solenoid
3 Remove the four capscrews and remove the stop valve Coil (top)
from the rotator drive assembly. Keep track of the two

2
O-Rings. For reassembly, tighten the capscrews to
35 ft.-lbs. (50 Nm).
4 Service the valve in a clean work area. Remove the Control
solenoid and cartridge valves. Remove all fittings
Box
from the valve block. Clean all parts with solvent or AC1102.eps
kerosene.
5 For reassembly, reverse the above procedures with the

5
following exceptions: 2-WAY
• Install new O-rings and back-up rings on cartridge SOLENOID
valves and valve block as shown. VALVE
O-Rings
• For complete installation procedures refer to
Electronic Rotational Control Installation Instructions
6048228.

Retainer Nut
4
DECEL Coil, Back-up Rings RC1014.eps

Wiring Harness Counterbalance 4-WAY

Valve Cartridges SOLENOID
Tighten to: VALVE
35 ft.-lbs. (45 Nm)
O-Rings

Two-Way Solenoid
Valve Tighten to:
80 ft.-lbs. (110 Nm)

RC1013.eps
Back-up Rings

O-Rings COUNTERBALANCE
VALVE

STOP Coil,
AC0339.eps
Wiring Harness
RC1015.eps
Valve Four-Way Solenoid
Block Valve Tighten to: Back-up Rings
18 ft.-lbs. (25 Nm)

68 674512-R4
 S ERVICE

5.11-2 Stop Position Adjustment

1 Rotate Clamp in each direction and assure Clamp stops Rotational Control stops
in vertical and horizontal (bilge) positions. Clamp at vertical positions
A top, B bottom, and C
• If rotation does not stop at vertical or bilge positions, bilge position.
proceed to Troubleshooting, Section 5.11-3.
A To continue rotation after
• If Clamp stops in vertical and horizontal (bilge) stopping, wait 3 seconds,
positions, proceed to Step 2. OR press overrride button.
• If rotation does not stop at exact vertical or bilge
positions, limit switches may be adjusted as For continuous rotation,
described in Step 4. C press and hold button.

2 Wait 3 seconds to rotate Clamp again, assuring Clamp

again stops in the vertical or horizontal (bilge) positions.
3 Press and hold override pushbutton and assure Clamp B
will rotate continuously without stopping. AC0231.eps

• If continuous rotation does not occur when holding

pushbutton, proceed to Troubleshooting, Section
5.11-3.
Limit Switches
4 Inspect limit switch end rollers for full engagement on (Normally Open)
deceleration ramps and stop capscrews. If required,
adjust limit switch position and/or stop capscrew to
precisely locate stop position within +/ – 0.5 in.
(13 mm). (Early Model)

AC0242.eps

Stop Capscrew Deceleration Ramp

5.11-3 Stop Troubleshooting

NOTE: Reference schematic on facing page. Limit Switches
(Normally Open)
1 Check ERC main power fuse/relay, control lever
pushbutton. NOTE: Pushbutton is normally closed
(NC), providing power to ERC. Assure 12V-96V is
reaching ERC control box when truck key is turned on. (Late Model)

2 Inspect all electrical cables. Look for and correct loose

connections, pinched wiring, or wrongly-connected
cables. NOTE: Cable connectors and control box are
labeled to show proper connections.
3 Check continuity of solenoid/cable assemblies and limit
switch/cable assemblies and replace if needed.
4 With truck key on, manually operate limit switches and
listen for 'clicks' at solenoids, indicating solenoid coil
operation. Or, rotate Clamp into ramps and check for
voltage at control box solenoid output connectors. AC1214.eps
5 Look for 3-second time delay between rotation Deceleration/Stop Ramp
decelerating and ability to restart rotation. If there is
no delay, or Clamp will not rotate continuously with
pushbutton depressed, replace ERC control box.
NOTE: Control box contains adjustable time delay,
contact Cascade for adjustment procedure.

674512-R4 69
 S ERVICE

Rotational Control Electrical Hookup

STOP
Limit Switch DECEL NOTES:
(Normally Open) Solenoid (top)
1. All cables are 2 conductor with Deutsch type connectors.

STOP 2. Electrical Supply:

Solenoid (side) Relay preferred for Rotational Control Only,
DECEL Rotator Drive Power Bus/Relay preferred for multiple accessories.
Limit Switch Valve Block
(Normally Open) 3. Refer to the following documents for additional help:
ERC Installation Instructions – Part No. 6048228
Relay Installation Instructions – Part No. 6006270
Power Bus/Relay Installation Instructions – Part No. 6048228

Cable Junction Box

NOTE: Factory adjusted time
delay relay inside. If necessary,
Contact Cascade to change setting.
Mast
DECEL Sol
DECEL Sw
STOP Sol
STOP Sw

Coil Cord
Power Supply/
Power

Communications
Group

ROTATE
Override Control
Push Button Lever
if equipped.
(Normally Closed)

Carriage

+
–

Relay
(12V–96V) Power Bus/Relay
(12V output only)
NOTE: Fuses inside:
Main Power – 20A
OR Circuits – 7.5A
+ – –+ –++–
3 4

+ +
2 1

Fuse,
7.5A@12V Unswitched Unswitched

Switched Switched

Truck Truck
Fuse Block Fuse Block

AC0662.eps
Truck 12V Truck
Battery Battery IC Trucks – Use chassis ground.
Electric Trucks – Use battery ground.

70 674512-R4
 S ERVICE

Solenoid Valve
5.12
5.12-1 All Clamps 2 3
(Except 77F Models with serial numbers 675414–675467)
1 Remove the cover from the valve assembly.

4
2 Disconnect the wires and diode from the coil terminals.
3 Loosen the end cover capscrews. Remove the end
cover and coil. Note the position of the coil terminals in
relation to the valve body.
RC0204.eps
4 Install the new coil and end cover. Assure that the
terminals are positioned correctly.
5 For reassembly, reverse the above procedures with the
following exceptions: Coil
• Refer to the electrical schematic in Section 4.5 for
correct wire and diode installation. Solenoid Valve

Solenoid
5.12-2 Early Swing Frame Clamps Coil

3
Cartridges

4 2
(Serial numbers 675414–675467)
NOTE: No longer available, replaced by above.
1 Remove the cover from the valve assembly.
2 Disconnect the wires and diode from the coil terminals.
3 Remove the solenoid cartridge top nut and coil.
4 Remove the solenoid cartridges and check valve
cartridges from the valve body. Remove the seals from
the cartridges.
5 For reassembly, reverse the above procedures with the
following exceptions:
• Install new O-rings and back-up rings as shown.
• Lubricate the cartridge seals with O-ring lube or
petroleum jelly prior to installation.
• Refer to the electrical schematic in Section 4.5 for
correct wire and diode installation.

O-Rings
RC0687.eps

O-Rings

5
Back-up Rings RC0689.eps
RC0688.eps
Back-up Rings

SOLENOID VALVE CARTRIDGE CHECK VALVE CARTRIDGE

674512-R4 71
 S PECIFICATIONS

6.1 Specifications
6.1-1 Hydraulics

Truck Relief Settings

45F–160F Clamp & Rotate Circuits, 38F Rotate Circuit
2000 psi (140 bar) Recommended
2300 psi (160 bar) Maximum
38F Clamp Circuit
2300 psi (160 bar) Recommended
2600 psi (180 bar) Maximum

Truck Flow Volume ➀

Min. ➁ Recommended Max. ➂

38F Clamp 5 GPM 10 GPM 12 GPM

(19 L/min.) (38 L/min.) (45L/min.)
Rotate 5 GPM 10 GPM 15 GPM
(19 L/min.) (38 L/min.) (57 L/min.)
GA0357.eps
45F, 60F, 5 GPM 10 GPM 15 GPM
66F (19 L/min.) (38 L/min.) (57 L/min.)

77F, 90F, 100F 10 GPM 15 GPM 20 GPM

120F (38 L/min.) (57 L/min.) (76 L/min.)

130F, 150F, 15 GPM 20 GPM 25 GPM

160F (57 L/min.) (76 L/min.) (95 L/min.)

➀ Cascade Roll 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 minimum will result in a rotate speed less
than 2 RPM.
➂ Flow greater than maximum can result in excessive heating,
reduced system performance and short hydraulic system life.

Hoses and Fittings

• ROTATE Function – Hoses and fittings should be No.
8 with 13/32 in. (10 mm) minimum I.D.
• CLAMP Function – Hoses and fittings should be No. 8
with 13/32 in. (10 mm) minimum I.D., except for internal
reeving arrangements where hoses and fittings may be
No. 6 minimum with 9/32 in. (7 mm) minimum I.D.

72 674512-R4
 S PECIFICATONS

6.1-2 Auxiliary Valve Functions

Check for compliance with ITA (ISO) standards:

Tilt
Forward Release
Rotate
CCW
(Swing
Hoist Down Extend)

GA0082.eps Hoist Up Rotate

CW
Tilt (Swing Clamp
Back Retract)

6.1-3 Truck Carriage

GA0091.eps

Carriage Mount Dimension (A) ITA (ISO)

Minimum Maximum
A
Class II 14.94 in. (380.0 mm) 15.00 in. (381.0 mm)
Class III 18.68 in. (474.5 mm) 18.74 in. (476.0 mm)
Class IV 23.44 in. (595.5 mm) 23.50 in. (597.0 mm)
GA0028.eps

674512-R4 73
 S PECIFICATIONS

6.1-4 Torque Values

Fastener torque values for the F-Series Roll Clamp are

4 37 6
shown in the table below in both U.S. and Metric units. All
torque values are also called out in each specific service (Access all

8
procedure throughout the Manual. through plug)

Ref. Fastener Size Ft.-lbs. Nm 2 10 Class IV

60F/66F/77F
1 Upper hook-to-baseplate (8) Class II/III

5
5/8 (M16) 110 150

1
Lower hook-to-baseplate (4)
Spacer, lower hook (4)
Center spacer-to-baseplate (4)

2 13
2
Bearing assy.-to-faceplate (✱) ■ ▲ 1/2 (M12) 75 100
Baseplate-to-bearing assy. (✱) ■ ▲ 5/8 (M16) 135 180

3 Rotator drive-to-baseplate (4)
3/4 (M20) 220 300
9 90F/100F/

15
1/2 (M12) 75 100 120F only
Center spacer-to-baseplate (2)

4 Rotator drive cover plate (4) 1 1

1
5/16 (M8) 15 20

5 Upper & lower hook-to-baseplate (8) 3/4 (M20) 195 265
ITA II ITA III
6 Valve-to-rotator motor (4) 5/16 (M8) 20 30 38F, 45F

12

7
8
Rotator motor-to-drive box (4)

Rotator drive end plate (4)

3/8 (M10) 40

7/16 (M12) 60
50

80
3 1
9

Shaft end block bracket (4) 3/8 (M10)

10 180-degree stop valve-to-baseplate(4) 3/8 (M10)

8

35
10

45
1 ITA II 60F, 66F ITA III

11 Pivot pin retainers (12) 3/8 (M10) 35 45 14 1

12 Spacer, lower hook (4)

5/8 (M16) 70 95
1
5
ITA III
13 Upper and lower hook-to-baseplate (12) M20 260 360 77F
ITA IV
14 Center spacer-to-baseplate (2) 3/8 (M10) 15 20

15 End block-to-shaft (2 or 3) ✖ 3/8 (M10) 15 20 13 16

16 Index block-to-baseplate (2) 3/4 (M20) 30 40

✱ Number of fasteners varies depending on Model ITA IV 90F, 100F, 120F RC0447.eps

■ Apply Loctite 242 (Blue)

▲ Double-torque (tighten, loosen 1/2-turn, retighten) NOTE: All lower hooks shown
✖ Apply Loctite 271 (Red) as 0-degree mounting.

11
11
RC0436.eps

74 674512-R4
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Visit us online at www.cascorp.com

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