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
69143215
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
69143217
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

6914321
TROUBLESHOOTING
8
OP,
LH
CL,
RH
OP,
RH
OP
CL
SSR
SSL
CL,
LH
3
1
2
T
1234
P
CC0172.eps
3.2-6 Hydraulic Schematic –
Sideshifting Clamp with Solenoid
Arm Cylinders
Counterbalance
Valve
Carton Clamp Valve
Solenoid
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

TROUBLESHOOTING
69143219
CC0246.eps
3.3 Tipping Function
There are five potential problem areas that can affect the
TIP function:
• Incorrect load handling. Refer to Operator’s Guide,
Cascade part no. 210135, for suggested handling
procedures.
• Incorrect hydraulic pressure or flow from the lift truck.
• External leaks.
• Solenoid Equipped – Defective solenoid coil or valve.
• Worn or defective cartridge valves or cylinder seals.
3.3-2 Tipping Circuit Test
1 Solenoid equipped –Press the solenoid button. Listen for
a 'click' at the solenoid valve. If no sound is heard, check
the fuse, wiring and coil. Refer to Section 3.4.
IMPORTANT: Solenoid operated valves must be plumbed
so that the solenoid is energized during the TIP function.
2 Install a tee fitting and gauge to a tipping cylinder base end
supply hose.
3 Tilt the attachment FORWARD until the tipping cylinders
are bottomed out and build up pressure. Note the gauge
reading.
4 Release the lever and watch the pressure gauge:
• If the pressure drop is less than 150 psi (10 bar) initially,
and additional drop does not exceed 30 psi (2 bar) per
minute, the problem is not hydraulic. Refer to the five
potential problems at the beginning of Section 3.3.
• If the pressure drop is more than 150 psi (10 bar)
initially, and additional drop exceeds 30 psi (2 bar) per
minute, the counterbalance cartridge may be faulty.
Replace the cartridge. Refer to Section 4.8.
5 Tilt the attachment BACK and hold the lever in this position
for a few seconds. If the pressure still drops, after replacing
counterbalance valve cartridge, one of the cylinders is
faulty and must be serviced. Refer to Section 4.7.
3.3-1 Supply Circuit Test
1 Check the pressure delivered by the truck at the carriage
hose terminal. Pressure must 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)
2 Check the flow volume at the carriage hose terminal.
Flow must be within the range shown in Specifications,
Section 5.1.
3 Tilt the attachment and hold the lever in the FORWARD
position for 2 seconds. Release the lever. Check for
external leaks at fittings, hoses and valve.
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. 18J
8J
Cylinder
Counterbalance
Cartridge
Valve
Counterbalance
Cartridge
Cylinder Base End
Supply Hose
Cylinder Base End
Supply Hose
35

6914321
TROUBLESHOOTING
10
RC0736.eps
3.4 Electrical Circuit
(Solenoid-equipped attachments)
Use the schematic shown and follow the steps below.
1 Check the control knob circuit fuse. Replace as
necessary.
2 Check for loose electrical connections at the truck
ignition switch, control knob button, solenoid coil
terminals and diode.
3 Remove the diode from the solenoid coil terminal. Test
with an ohmmeter for high resistance in one direction
and no resistance in the other direction. If there is no
resistance in both directions, replace the diode.
NOTE: When replacing the diode, the banded end
must be connected to the coil and wiring as shown.
4 Use a voltmeter to determine if correct voltage is
present at the electrical leads when the button is
pressed.
• If there is no voltage at the solenoid, troubleshoot the
electrical circuit for shorts or open circuits.
• If there is insufficient voltage to the solenoid, check
the circuit for excessive voltage drop.
• If there is sufficient voltage to the solenoid, test for
coil continuity. Continue to Step 5.
5 Test for coil continuity by placing an ohmmeter test lead
on each solenoid coil terminal (ohmmeter on Rx1 scale).
• If there is an ohmmeter reading, and the coil matches
the values below for the truck voltage, the coil is
good.
• If the coil is good, but the solenoid does not 'click'
when the control knob button is depressed, the
solenoid cartridge may be jammed. Refer to Section
4.7-2.
• If there is no ohmmeter reading, the coil is defective
and should be replaced. Refer to Section 4.7-2.
7.5 Amp
Fuse
Push
Button
White
Black
Coil
Diode
Diode
IMPORTANT: Banded
end must connect to
positive (+) side of
circuit.
Control Knob
with Push Button
12V: 2.4–2.8 Ohm
24V: 9.5–11 Ohm
36V: 24-28 Ohm
48V: 40-46 Ohm
Push button attached
to control lever with
heat shrink tubing
Solenoid
Coil
Solenoid
Valve
Cable

6914321
SERVICE
11
CC0174.eps
ADJUST
RC0368.eps
Carriage Bar
LH lower
Hook
3BOLT-ON HOOKS
4.1 Attachment Removal
1 Position the attachment's arm to the width of the frame.
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.
2 Disconnect and plug the hydraulic supply hoses to the
attachment. Tag hoses for reassembly.
3 Disconnect the lower hooks. Remove the capscrews and
mounting hooks. For reassembly, tap hooks tight against
carriage bar and tightened capscrews to 165 ft.-lbs.
(225 Nm).
4 Set the attachment on a pallet. Tilt the mast forward
and lower the carriage to remove the attachment from
the truck.
5 For installation, reverse the above procedures with the
following exceptions:
• Refer to Installation Instructions, part number
6871082, for complete installation procedure.
1
4
2
3
Tip Forward
or
Sideshift Left Clamp
Open
Tip Back
or
Sideshift Right
CC0199.eps

6914321 12
SERVICE
CC0256.eps
4.4 Carton Clamp Valve
To remove and service the valve, refer to J-Series Carton
Clamp Service Manual, part number 6883648.
4.5 Base Unit
To remove and service the base unit, refer to J-Series
Carton Clamp Service Manual, part number 6883648.
Arms
Contact Pads
Arm Bearings
Arm Cylinders
Carton
Clamp
Valve
Base Unit
NOTE: Manuals are available at www.cascorp.com under
the support tab, "Technical Support Manuals" link.
4.2 Arms
To remove and service arms, contact pads, arm bearings,
refer to J-Series Carton Clamp Service Manual, part
number 6883648.
4.3 Arm Cylinders
To remove and service arm cylinders, refer to J-Series
Carton Clamp Service Manual, part number 6883648.

6914321
SERVICE
13
CC0257.eps
Pivot Pin
Capscrew
Eye Pin and
Capscrew
Retainer and
Capscrews
Retainer and
Capscrews
Shims
Pivot Pin
Shims
Cylinder
Base End
Pivot Pin
Cylinder
Base End
Pivot Pin
4.6 Back Mounting Frame
4.6-1 Removal and Installation
1 Remove the attachment from the lift truck as described
in Section 4.1.
WARNING: Before removing any hoses,
relieve pressure in the hydraulic system.
With the truck off, open the truck
auxiliary control valve(s) several times in
both directions.
2 Disconnect and plug supply hoses at the back
mounting frame. Disconnect and plug any hoses
connecting the frame to the back mounting frame.
Tag hoses for reassembly.
3 Remove cylinder base end pivot pins. Take note
of the location and number of shims, if equipped.
For reassembly, install shims (if equipped) and tighten
capscrews to:
Retainer Capscrews – 14 ft.-lbs. (19 Nm)
Pivot Pin Capscrew – 28 ft.-lbs. (38 Nm)
4 Remove back mounting frame pivot pins and spacers.
For reassembly, tighten capscrews to:
Retainer Capscrews – 14 ft.-lbs. (19 Nm)
Eye Pin Capscrew – 28 ft.-lbs. (38 Nm)
5 Attach an overhead hoist to back mounting frame (or
frames) and take up the slack with chains or straps.
Lift away back mounting frame (or frames).
6 For reassembly, reverse the above procedures with the
following exceptions:
• Install new bushings in back mounting frame.
• Replace pivot pins if wear is detected.
WARNING: Verify that the overhead
hoist and chains or straps are rated for
the weight of the attachment. Refer to
nameplate for attachment weight.
3
4
Back Mounting Frame
Frame
Back Mounting Frame
(Front View Shown)
Back (Driver's) View
OR
OR

6914321 14
SERVICE
4.6-2 Bushing Service
1 Remove the back mounting frame (or frames) as
described in Section 4.6-1.
2 Remove the pivot bushings from back mounting frame
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
Bearing ID
B
Driver OD
2.000 in.
(50.8 mm)
2.188 in.
(55.6 mm)
RC0362.eps
BA
9.64 in.
(245 mm)
1.77 in.
(45 mm)
One-Piece Back Mounting Frame
Bushing
CC0258.eps

6914321
SERVICE
15
CC0282.eps
CC0259.eps
WARNING: Before removing any hoses,
relieve pressure in the hydraulic system. With
the truck off, open the truck auxiliary control
valve(s) several times in both directions.
2
Tipping
Cylinder
3
Retainer and
Capscrews
Shims
Pivot Pin
Capscrew
4.7 Tipping Cylinder
4.7-1 Removal and Installation
1 Remove the attachment from the lift truck as described
in Section 4.1.
2 Disconnect and plug hoses from the cylinder junction
block or cylinder ports. Tag hoses for reassembly.
3 Remove cylinder base end pivot pins. Take note
of the location and number of shims, if equipped.
For reassembly, install shims (if equipped) and tighten
capscrews to:
Retainer Capscrews – 14 ft.-lbs. (19 Nm)
Pivot Pin Capscrew – 28 ft.-lbs. (38 Nm)
4 Remove upper frame pivot pins and spacers.
For reassembly, install shims (if equipped) and tighten
capscrews to:
Retainer Capscrews – 14 ft.-lbs. (19 Nm)
Pivot Pin Capscrew – 28 ft.-lbs. (38 Nm)
5 To service the cylinder, perform one of the following:
• 8J Cylinders – The cylinders do not have
serviceable components. Replace the entire
cylinder.
• 18J Cylinders – Service the cylinder's internal
components as described in Section 4.7-4.
Cylinder Base
End Pivot Pin
Cylinder
Base End
Pivot Pin
Back Mounting Frame
OR
Back Mounting Frame
(Front View Shown)
Back (Driver's) View
4
Retainer and
Capscrews
Shims
OR
Eye Pin and
Capscrew
Pivot Pin

6914321 16
SERVICE
4.7-2 18J Counterbalance Valve
Cartridge Service
1 Position the cylinders to gain access to the cylinder
counterbalance valve.
2 Remove counterbalance valve cartridge from cylinder
junction block.
3 Remove O-rings and back-up rings. Clean the
counterbalance valve cartridge with solvent.
4 Install new O-rings and back-up rings, as shown.
5 Lubricate the counterbalance valve cartridge with
hydraulic oil prior to reassembly.
WARNING: Before removing any hoses,
relieve pressure in the hydraulic system.
With the truck off, open the truck
auxiliary control valve(s) several times in
both directions.
CC0181.eps
PP1518.eps
O-Rings
Back-Up Rings
Tipping Cylinder
Junction Block
Counterbalance
Valve Cartridge
Counterbalance Valve Cartridge

6914321
SERVICE
17
CC0273.eps
4.7-3 18J Cylinder Bushing Service
NOTE: Bushings require replacement if the clearance
between the bushing and pin exceeds 1/16 in. (1.6 mm).
1 Remove the tipping cylinder from the attachment as
described in Section 4.7-1.
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
Bushing ID
B
Driver OD
18J 1.00 in.
(25.4 mm)
1.25 in.
(31.7 mm)
RC0362.eps
BA
10.0 in.
(245 mm)
1.75 in.
(45 mm)
Bushing
Spacer
2