cascade corporation D Series Operating manual

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corporation
ERVICE MANUAL SUPPLEMENT
S
Tipping Carton Clamps
D-Series
Manual Number 6905873
NOTE: This manual covers tipping components only. Refer to D-Series
Carton Clamp Service Manual, part number 228156, for periodic
maintenance, troubleshooting and service to carton clamp components
including arms, carton clamp cylinders and frame.

CONTENTS
i6905873
Page
INTRODUCTION, Section 1
Introduction 1
Special Definitions 1
PERIODIC MAINTENANCE, Section 2
Daily Inspection 2
1000-Hour Maintenance 2
TROUBLESHOOTING, Section 3
General Procedures 3
Truck System Requirements 3
Tools Required 3
Troubleshooting Chart 4
Plumbing 5
Hosing Diagram – Non-Sideshifting 5
Hydraulic Schematic – Non-Sideshifting 6
Hosing Diagram – Cartridge Type Solenoid/Radio Frequenct (RF) Control 7
Hydraulic Schematic – Cartridge Type Solenoid/Radio Frequenct (RF) Control 8
Hosing Diagram – Solenoid 9
Hydraulic Schematic – Solenoid 10
Tipping Function 11
Supply Circuit Test 11
Tipping Circuit Test 11
Electrical Circuit 12
SERVICE, Section 4
Attachment Removal 13
Arms 14
Clamp Cylinders 14
Clamp Valve 14
Base Unit 14
Back Mounting Frame 15
Removal and Installation 15
Bushing Service 16
Tipping Cylinder 17
Removal and Installation 17
Counterbalance Valve Cartridge Service 18
Cylinder Bushing Service 19
Cylinder Disassembly 20
Cylinder Inspection 20
Cylinder Reassembly 21
Valves 22
Counterbalance Valve Service 22
Cartridge Type Solenoid Valve or Radio Frequency Valve 23
Solenoid Valve Coil Service 25
SPECIFICATIONS, Section 5
Hydraulics 26
Auxiliary Valve Functions 26
Truck Carriage 27
Torque Values 28

INTRODUCTION
6905873 1
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SERIAL NO.
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Cascade Corporation • www.cascorp.com • Icons & Patents: www.cascorp.com/support 6095754
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CC0163.eps
1.1 Introduction
This manual provides the Periodic Maintenance, Troubleshooting,
Service and Specifications for Cascade D-Series Tipping Carton
Clamps.
In any communication about the attachment, refer to the product
catalog and serial numbers stamped on the nameplate, as shown.
If the nameplate is missing, the numbers can be found stamped
on the frame where the plate was mounted.
IMPORTANT: Cascade D-Series Tipping Carton Clamps are
custom built and size of connecting supply fittings on the
attachment will vary. Consult Cascade if fitting size and type can
not be determined.
NOTE: Specifications are shown in both US and (Metric) units.
All fasteners have a torque value range of ±10% of stated value.
1. 2 Special Definitions
The statements shown appear throughout this manual
where special emphasis is required. Read all WARNINGS
and CAUTIONS before proceeding with any work.
Statements labeled IMPORTANT and NOTE are provided
as additional information of special significance or to make
your job easier.
WARNING - A statement preceded by
WARNING is information that should be
acted upon to prevent bodily injury. A
WARNING is always inside a ruled box.
CAUTION - A statement preceded by CAUTION is
information that should be acted upon to prevent
machine damage.
IMPORTANT - A statement preceded by IMPORTANT is
information that possesses special significance.
NOTE - A statement preceded by NOTE is information that
is handy to know and may make your job easier.
Nameplate

6905873
PERIODIC MAINTENANCE
2
CC0164.eps
2.1 Daily Inspection
Prior to each shift of truck operation, complete the following
procedures:
• Check for loose or missing bolts, worn or damaged
hoses and hydraulic leaks.
• Check decals and nameplate for legibility.
2.2 1000-Hour Maintenance
After each 1000 hours of truck operation, in addition to the
daily inspection, perform the following procedures:
• Check lower mounting hooks for engagement. Hooks
should be tight against lower carriage. If adjustment is
necessary, refer to Section 4.1, Step 3.
• Tighten lower hook capscrews to 120 ft.-lbs. (165 Nm).
• Inspect all tipping pivot bushings and pins for wear.
Replace, as needed.
• Tighten tipping eye pin or retainers capscrews to:
Retainer Capscrews – 14 ft.-lbs. (19 Nm)
Eye Pin Capscrew – 28 ft.-lbs. (38 Nm)
WARNING: After completing any service
procedure, always test the attachment
through five complete cycles. First test
the attachment empty, then test with a load
to make sure the attachment operates
correctly before returning to the job.
OR
OR
Side View
IMPORTANT: This section covers periodic maintenance
for tipping components only. In addition to the periodic
maintenance below, perform the periodic maintenance
found in D-Series Carton Clamp Service Manual, Part No.
228156.
CC0166.eps
Eye Pin
Capscrew
Eye Pin
Capscrew
Tipping Cylinders
Lower Mounting Hooks
Back (Driver's) View
Retainer
Capscrews
Retainer
Capscrews

6905873
TROUBLESHOOTING
3
3.1 General Procedures
IMPORTANT: Troubleshooting the SIDESHIFT or CLAMP
circuits can be found in D-Series Carton Clamp Service
Manual 228156.
3.1-1 Truck System Requirements
• Truck hydraulic pressure should be within the range
shown in Specifications, Section 5.1. Pressure to the
attachment must not exceed 2300 psi (160 bar).
• Hydraulic flow should be within the volume range as
shown in Specifications, Section 5.1.
• Hydraulic fluid supplied to the attachment must meet the
requirements as shown in Specifications, Section 5.1.
3.1-2 Tools Required
In addition to a normal selection of hand tools, the following
will be required:
• Inline Flow Meter Kit:
20 GPM (75 L/min.) - Cascade Part No. 671477.
• Pressure Gauge Kit:
5000 psi (345 bar) - Cascade Part No. 671212. Two kits
are required.
OR
Wireless Pressure Monitor Kit:
Pressure transducers monitor the hydraulic pressure
and wirelessly transmit the data to the receiver display.
• Assorted fittings and hoses to adapt the gauge and flow
meter to the components being tested.
WARNING: Before servicing any
hydraulic component, relieve pressure
in the system. Turn the truck off and
move the truck auxiliary control valves
several times in both directions.
After completing any service procedure, test the
attachment through several cycles. First test
the attachment empty to bleed any air trapped
in the system to the truck tank. Then test the
attachment with a load to be sure it operates
correctly before returning to the job.
Stay clear of the load while testing. Do not raise
the load more than 4 in. (10 cm) off the floor while
testing.
Pressure
Gauge ▲
No. 6 and No. 8
JIC Swivel Tee
No. 4-6 Pipe/JIC ▲
No. 6-6 Hose ▲
(2) No. 6-8 JIC Reducer
Flow Meter
No. 4, No. 6 ▲
and No. 8
JIC/O-Ring
No. 6-8 JIC
Reducer
(2) No. 8-12 JIC/
O-Ring
Diagnostic Quick-Disconnects
Male Straight Thread
O-Ring Coupler:
No. 4 (Part No. 212282) ▲
No. 5 (Part No. 210378)
No. 6 (Part No. 678592)
Female JIC Thread Coupler:
No. 4 (Part No. 210385) ▲
No. 6 (Part No. 678591)
▲Included in Diagnostics Kit 394382.
GA0013.eps
GA0014.eps
AC0127.eps
AC1983.eps
Receiver/Display
Transmitter
Pressure
Transducer
Alarm
(if equipped)
Flow Meter Kits:
671476 – 37 L/min (10 GPM)
671477 – 75 L/min (20 GPM)
Pressure Gauge Kit:
671212
Wireless Pressure Monitor Kits
6803614 – 12V Kit
6815672 – 12V Kit, includes alarm
6803617 – 24V-48V Kit
6815675 – 24V-48V Kit, includes alarm

TROUBLESHOOTING
69058734
3.1-3 Troubleshooting Chart
Determine All The Facts
It is important that all the facts regarding the problem
are gathered before beginning service procedures.
The first step is to talk to the equipment operator.
Ask for a complete description of the malfunction.
The following guidelines can then be used as a
starting point to begin troubleshooting procedures:
Tipping Circuit
• Attachment does not tip forward or back.
To correct this problem, see Section 3.3.

6905873
TROUBLESHOOTING
5
CC0167.eps
3.2 Plumbing
3.2-1 Hosing Diagram – Non-Sideshifting
TIP BACK
PRESSURE
RETURN
NOTE: For TIP FORWARD reverse the
colors shown.
2-Port Hose Reel or
Internal Hose Reel
Tipping
Cylinders
2-Port Hose Reel or
Internal Hose Reel
Hose Terminal
Arm Cylinders
Arm Cylinders
Carton Clamp Valve
Carton Clamp Valve
TIP
Truck
Auxiliary
Valve
CLAMP
Truck
Auxiliary
Valve
CLAMP
PRESSURE
RETURN
NOTE: For OPEN reverse the
colors shown.
To CLAMP
Hose Terminal
Counterbalance
Valve

TROUBLESHOOTING
69058736
OP,
LH
CL,
RH
OP,
RH
OP
CL
CL,
LH
3
1
2
CC0168.eps
3.2-2 Hydraulic Schematic – Non-Sideshifting
Arm Cylinders
Counterbalance
Valve
Carton Clamp Valve
Tipping Cylinders
2-Port Hose Reel or
Internal Hose Reel
2-Port Hose Reel or
Internal Hose Reel
TIP
Truck
Auxiliary
Valve
CLAMP
Truck
Auxiliary
Valve
Truck Pump
Truck Relief
Valve
Truck Tank

6905873
TROUBLESHOOTING
7
CC0169.eps
3.2-3 Hosing Diagram –
Cartridge Type Solenoid Valve/
Radio Frequency (RF) Control
TIP BACK
PRESSURE
RETURN
NOTE: For TIP FORWARD reverse the
colors shown.
SIDESHIFT LEFT
PRESSURE
RETURN
NOTE: For SIDESHIFT
RIGHT reverse the
colors shown.
CLAMP
PRESSURE
RETURN
NOTE: For OPEN, reverse
the colors shown.
Tipping
Cylinders
Arm Cylinders
Arm Cylinders Arm Cylinders
2-Port Hose Reel or
Internal Hose Reel
2-Port
Hose Reel
or Internal
Hose Reel
To Hose
Terminal
To Hose
Terminal
TIP and SIDESHIFT
Truck Auxiliary Valve
CLAMP
Truck Auxiliary
Valve
Counterbalance
Valve
Cartridge Type
Solenoid Valve or
RF Control Valve
To Solenoid Valve or
RF Valve
To Solenoid Valve or
RF Control Valve
Carton Clamp Valve
Carton Clamp Valve Carton Clamp Valve
Hose Terminal

TROUBLESHOOTING
69058738
OP,
LH
CL,
RH
OP,
RH
OP
CL
SSR
SSL
CL,
LH
3
1
2
C3
C2
C1 C4
PT
CC0170.eps
3.2-4 Hydraulic Schematic –
Cartridge Type Solenoid Valve/
Radio Frequency (RF) Control
Arm Cylinders
Counterbalance
Valve
Carton Clamp Valve
Cartridge Type
Solenoid Valve or
RF Control Valve
Tipping Cylinders
2-Port Hose Reel or
Internal Hose Reel
2-Port Hose Reel or
Internal Hose Reel
Truck Pump
Truck Tank
TIP and SIDESHIFT
Truck Auxiliary Valve
CLAMP
Truck
Auxiliary
Valve
Truck Relief
Valve