cascade corporation J Series User manual

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ERVICE MANUAL SUPPLEMENT
S
Tipping Carton Clamps
J-Series
Manual Number 6914321
NOTE: This manual covers tipping components only. Refer to
J-Series Carton Clamp Service Manual, part number 6883648,
for periodic maintenance, troubleshooting and service to carton
clamp components including arms, carton clamp cylinders, valve
and frame.

BLANK

CONTENTS
i6914321
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 Clamp 5
Hydraulic Schematic – Non-Sideshifting Clamp 6
Hosing Diagram – Sideshifting Clamp with Solenoid 7
Hydraulic Schematic – Sideshifting Clamp with Solenoid 8
Tipping Function 9
Supply Circuit Test 9
Tipping Circuit Test 9
Electrical Circuit 10
SERVICE, Section 4
Attachment Removal 11
Arms 12
Clamp Cylinders 12
Clamp Valve 12
Base Unit 12
Back Mounting Frame 13
Removal and Installation 13
Bushing Service 14
Tipping Cylinder 15
Removal and Installation 15
Counterbalance Valve Cartridge Service 16
Cylinder Bushing Service 17
Cylinder Disassembly 18
Cylinder Inspection 18
Cylinder Reassembly 19
Valves 20
Counterbalance Valve Service 20
Solenoid Valve Coil Service 21
SPECIFICATIONS, Section 5
Hydraulics 22
Auxiliary Valve Functions 22
Truck Carriage 23
Torque Values 24

INTRODUCTION
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Cascade Corporation • www.cascorp.com • Icons & Patents: www.cascorp.com/support 6095754
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CC0244.eps
1.1 Introduction
This manual provides the Periodic Maintenance, Troubleshooting,
Service and Specifications for Cascade J-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 J-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

6914321 2
PERIODIC MAINTENANCE
CC0202.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 165 ft.-lbs. (225 Nm).
• Inspect all tipping pivot bushings and pins for wear.
Replace as needed.
• Tighten tipping eye pin or retainer 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 J-Series Carton Clamp Service Manual, part
number 6883648.
Eye Pin
Capscrew
Eye Pin
Capscrew
Tipping Cylinders
Lower Mounting Hooks
Back (Driver's) View
Retainer
Capscrews
Retainer
Capscrews
CC0203.eps

TROUBLESHOOTING
69143213
3.1 General Procedures
IMPORTANT: Troubleshooting the SIDESHIFT or CLAMP
circuits can be found in J-Series Carton Clamp Service
Manual, part no. 6883648.
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:
Low Pressure – 2755 Psi (189 bar)
High Pressure – 3625 Psi (250 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 Kit
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

6914321
TROUBLESHOOTING
4
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.

TROUBLESHOOTING
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CC0167.eps
3.2 Plumbing
3.2-1 Hosing Diagram – Non-Sideshifting Clamp
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

6914321
TROUBLESHOOTING
6
OP,
LH
CL,
RH
OP,
RH
OP
CL
CL,
LH
3
1
2
CC0168.eps
3.2-2 Hydraulic Schematic – Non-Sideshifting Clamp
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

TROUBLESHOOTING
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CC0171.eps
3.2-5 Hosing Diagram –
Sideshifting Clamp with Solenoid
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
To Solenoid
Valve
To Solenoid
Valve
TIP and SIDESHIFT
Truck Auxiliary Valve
CLAMP Truck
Auxiliary Valve
Counterbalance Valve
Solenoid Valve
Carton Clamp Valve
Hose Terminal
Carton Clamp Valve Carton Clamp Valve