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Summary of Contents for cascade corporation J Series
- Page 1 ERVICE MANUAL J-Series Revolving Carton Clamps Manual Number 6921413 cascade corporation Cascade is a Registered Trademark of Cascade Corporation...
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Page 3: Table Of Contents
CONTENTS Page Page INTRODUCTION, Section 1 SERVICE, Section 4 - Continued Introduction Drive Motor (1.2 ci motor) Special Definitions Drive Motor Removal and Installation PERIODIC MAINTENANCE, Section 2 Drive Motor Disassembly Daily Inspection Drive Motor Inspection 1000-Hour Maintenance Drive Motor Reassembly 2000-Hour Maintenance Drive Motor (2.8 ci motor and greater) 4000-Hour Maintenance... -
Page 4: Introduction, Section
INTRODUCTION Introduction This manual provides the Periodic Maintenance, IMPORTANT: Supply input fittings are JIC. Troubleshooting, Service and Specifications for Cascade NOTE: All specifications are shown in US and (metric) J-Series Revolving Carton Clamps. units where applicable. All fasteners have a torque In any communication about the attachment, refer to value range of ±10% of stated value. -
Page 5: Periodic Maintenance, Section
PERIODIC MAINTENANCE Daily Inspection WARNING: After completing any service procedure, always test the attachment Prior to each shift of truck operation complete the through five complete cycles. First test following procedures: the attachment empty, then test with • Check for loose or missing bolts, worn or damaged a load to make sure the attachment hoses and hydraulic leaks. -
Page 6: 2000-Hour Maintenance
PERIODIC MAINTENANCE 1000-Hour Maintenance Ball Race Grease Stabilizer Capscrews (Continued) Fitting (A) Every time the lift truck is serviced or every 1000 hours of truck operation, whichever comes first, complete the following maintenance procedures: • Check rotator drive gearcase lubricant level. Lubricant should be filled up to end cover level hole. -
Page 7: General Procedures
TROUBLESHOOTING General Procedures WARNING: Before servicing any hydraulic component, relieve pressure in the system. Truck System Requirements 3.1-1 Turn the truck off and move the truck auxiliary control valves several times in • Truck hydraulic pressure should be within the range both directions. -
Page 8: Plumbing
TROUBLESHOOTING Plumbing Hosing Diagram – Non-Sideshift 3.2-1 CLAMP ARMS/ROTATE CW PRESSURE RETURN NOTE: For OPEN ARMS/ROTATE CCW, reverse the colors shown. SOLENOID EQUIPPED Rotate CW/CLAMP Rotate CCW/Release (TANK Port) (PRESSURE Port) Cylinders To Hose Reel CLOSE Port CLOSE Port Revolving Connection Hose Reels or Body... -
Page 9: Hydraulic Schematic - Non-Sideshift
TROUBLESHOOTING Hydraulic Circuit – Non-Sideshift 3.2-2 Cylinders OPCK1 OPCK2 Check Valves CLCK1 CLCK2 Revolving Body Connection Flow Divider/Combiner, "FD" Rotator Drive Shaft End Block Pressure Control Solenoid Equipped OPEN CLAMP Drive Port Port Control Valve 1 2 3 4 2-Port Hose Reel 2-Port Hose Reel... -
Page 10: Hosing Diagram - Sideshift
TROUBLESHOOTING Hosing Diagram – Sideshift 3.2-3 Rotate CW/ Sideshift Left (PRESSURE Port) CLAMP ARMS/ROTATE CW PRESSURE Rotate CCW/ RETURN Sideshift Right (TANK Port) NOTE: For OPEN ARMS/ROTATE CCW, reverse the colors shown. Cylinders Hose Reel or Internal Hose Reeving CLOSE Port CL OPEN Port OP Hose Terminal... -
Page 11: Hydraulic Schematic - Sideshift
TROUBLESHOOTING Hydraulic Circuit – Sideshift 3.2-4 Cylinders Body Check Valves Revolving Connection Flow Divider/Combiner Drive Control Valve Rotator Drive Shaft End Block Orifice Sideshift Pressure Clamp Control Pressure Control 1 2 3 4 2-Port Hose Reels or Internal Reeving Truck Auxiliary Truck Auxiliary Valve Valve... -
Page 12: Clamp Function
TROUBLESHOOTING Clamp Function WARNING: Before removing any hoses, relieve pressure in the hydraulic system. There are five potential problems that could affect the With the truck off, open the truck auxiliary CLAMP function: control valve(s) several times in both • Incorrect load handling. Refer to the Operator's Guide directions. - Page 13 TROUBLESHOOTING Clamp Circuit Test (Continued) 3.3-2 Release the lever and watch the pressure gauge(s): • If the pressure drop is less than 150 psi (10 bar) initially and additional drop does not exceed 25 psi (1.7 bar) per minute, the problem is not hydraulic. Refer to Section 3.3. •...
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Page 14: Sideshift Function
TROUBLESHOOTING Sideshift Function There are six potential problems that could affect the SIDESHIFT function: • Incorrect load handling. Refer to the Operator's Guide (part no. 6892529) for suggested procedures. • Incorrect hydraulic pressure or flow from the lift truck. • External leaks. •... -
Page 15: Sideshift Circuit Test
TROUBLESHOOTING Sideshift Circuit Test 3.4-2 Solenoid equipped – Press the solenoid button and listen for a 'click' at the solenoid valve. If no sound is heard, first check the fuse, wiring and coil. Make sure that the solenoid valve is not jammed. Repair as necessary, refer to Section 4.11. -
Page 16: Rotation Function
TROUBLESHOOTING Rotation Function WARNING: Before removing any hoses, relieve pressure in the hydraulic system. There are six potential problems that could affect the With the truck off, open the truck auxiliary ROTATE function: control valve(s) several times in both • Incorrect load handling. Refer to the Operator's Guide directions. -
Page 17: Rotation Circuit Test With Load
TROUBLESHOOTING Rotation Circuit Test with Load 3.5-3 Rotate a load requiring approximately 3/4 of the attachment's maximum torque capacity: 14J – 40,000 in.-lbs. @ 2,300 psi 4,520 Nm @ 160 bar 18J – 63,000 in.-lbs. @ 2,300 psi 7,120 Nm @ 160 bar Note gauge readings during rotation: •... -
Page 18: Electrical Circuit
TROUBLESHOOTING Electrical Circuit (Solenoid equipped attachments) Use the electrical schematic and diagram shown and follow the steps below: Check the control knob circuit fuse. Replace as necessary. Check for loose electrical connections at the truck ignition switch, control knob button, solenoid coil terminals and diode. -
Page 19: Attachment Removal
SERVICE Attachment Removal Clamp Rotate CCW Position the attachment's arms to the width of the frame. Open Rotate CW 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. -
Page 20: Arms
SERVICE Arms Arm Assemblies – 4.2-1 Removal and Installation The following procedures can be performed with the Bearings attachment mounted on the truck. Position the arms to frame width. Lower the attachment to position the contact pads 0.5 in. (12 mm) above the floor. Disconnect the arms from the cylinders. -
Page 21: Arm Bearings - Removal And Installation
SERVICE Arm Bearings − 4.2-2 Removal and Installation NOTE: Arms must be removed to install new bearings. Bearings are most easily installed with the attachment on the truck. Remove the attachment arms as shown in Section 4.2-1. Remove the bearing retainer plugs using the Cascade Tool 6042633, as shown. -
Page 22: Drive Group (1.2 Ci Motor)
SERVICE Drive Group (1.2 ci motor) Drive Group − 4.3-1 Removal and Installation Remove the attachment from the truck as described in End Cover Section 4.1. Level Hole Remove tubes connecting the motor to the valve. Remove the four capscrews fastening the drive group to the baseplate. - Page 23 SERVICE Drive Group Disassembly and 4.3-2 Service (Continued) Tap the worm and bearing assembly out through the end cover side of the housing. Note direction of bearings. Bearings are directional. RR0571.eps Worm Press the pinion gear, seal, pinion bearings and worm gear out of the housing as an assembly.
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Page 24: Drive Group Reassembly
SERVICE Drive Group Reassembly 4.3-3 PINION AND BEARING WITH EXTERNAL SEAL Build up the pinion/worm gear assembly vertically with the pinion gear down. Install pinion seal onto seal seating area. Pinion Seal Housing Apply Loctite 271 (red) to the bearing seating area as Pinion shown. - Page 25 SERVICE Drive Group Reassembly 4.3-3 Housing (Continued) Temporarily install the end cover without shims. Tighten the capscrews sequentially to 9.5 ft.-lbs. (13 Nm). Measure the gap between the end cover and housing in three places with a feeler gauge or 'Plastigage' thread and determine the minimum gap.
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Page 26: Drive Group (2.8 Ci Motor And Greater)
SERVICE Drive Group (2.8 ci motor and greater) Drive Group − 4.4-1 Removal and Installation Remove the attachment from the truck as described in Section 4.1. Remove the four capscrews fastening the drive group to the baseplate. For reassembly, tighten the capscrews to 48 ft.-lbs. - Page 27 SERVICE Drive Group – 4.4-2 Disassembly and Service Bearing Outer Race (Continued) 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. RC0173.eps Press the pinion gear, seal, pinion bearings and worm gear out of the housing.
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Page 28: Drive Group Reassembly
SERVICE Drive Group Reassembly 4.4-3 PINION WITH SEAL AND NON-SEALED BEARING Build up the pinion/worm gear assembly vertically with the pinion gear down. Pinion with seal and non-sealed bearing – Position External the seal against the pinion gear, spring-side facing Seal housing. - Page 29 SERVICE Drive Group Reassembly 4.4-3 (Continued) Temporarily install the end cover without shims. Tighten the capscrews sequentially in 10 ft.-lbs. (15 Nm) increments to 20 ft.-lbs. (30 Nm). Measure the gap between the end cover and housing in three places with a feeler gauge or 'Plastigage' thread and determine the minimum gap.
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Page 30: Drive Motor (1.2 Ci Motor)
SERVICE Drive Motor (1.2 ci motor) Drive Motor Removal and 4.5-1 WARNING: Before removing hydraulic lines, relieve pressure in the hydraulic Installation system. Turn the truck off and open the truck auxiliary control valves several times Remove the attachment from the truck as described in both directions. -
Page 31: Drive Motor Disassembly
SERVICE Output Shaft Drive Motor Disassembly 4.5-2 Cascade provides service replacement parts for the seals indicated with a below. Due to cost, if other parts need ▲ replacement, the complete drive motor assembly should be replaced. Remove the drive motor from the drive group as described in Section 4.5-1. -
Page 32: Drive Motor Inspection
SERVICE Drive Motor Disassembly 4.5-2 (Continued) Remove wiper seal and pressure seal from the bearing housing using a seal removal tool or modified screwdriver as shown. IMPORTANT: Note the direction of the seals and thickness. RR0593.eps CAUTION: Do not scratch either of the seal cavities. Modified Screwdriver Spool Valve Drive Motor Inspection... - Page 33 SERVICE Drive Motor Reassembly 4.5-4 Pressure Seal (Continued) RR0775.eps Apply a coating of a lithium based bearing grease, such as Mobilith SCH220, to inner edges of wiper seal, pressure seal, thrust bearing and washer. Install wiper seal with the u-shape facing outward from its seat.
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Page 34: Drive Motor (2.8 Ci Motor And Greater)
SERVICE Drive Motor (2.8 ci motor and greater) WARNING: Before removing hydraulic lines or components, relieve pressure in the hydraulic system. Turn truck off and open Drive Motor Removal and 4.6-1 the truck auxiliary control valve(s) several times in both directions. Installation Remove the attachment from the truck as described in Section 4.1... -
Page 35: Drive Motor Disassembly
SERVICE Drive Motor Disassembly 4.6-2 RR1485.eps Cascade provides service replacement parts for the seals indicated with a below. Due to cost, if other parts need ▲ O-Ring ▲ replacement, the complete drive motor assembly should be replaced. Capscrews Remove the drive motor from the drive group as described in Section 4.6-1. - Page 36 SERVICE Drive Motor Disassembly 4.6-2 (Continued) Remove the four Loctited capscrews from the flange with a X10 Torx Socket. Do not use an impact wrench. CAUTION: Thread sealant used on the capscrews may Flange require a small amount of heat to the housing to remove the capscrews.
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Page 37: Drive Motor Inspection
SERVICE Drive Motor Inspection 4.6-3 • Remove all Loctite residue from the threaded holes. • Clean all parts with solvent and blow dry. Do not use paper or cloth towels. • Inspect all parts for small nicks, burrs or scratches. Remove imperfections with emery cloth. - Page 38 SERVICE Drive Motor Reassembly 4.6-4 (Continued) Turn the housing over and clamp across the flange with the output shaft taper facing down. Lubricate the O-rings and install into the housing, gerotor set and end cap grooves. Align the output shaft timing dot with the screw hole that is aligned to the port surface.
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Page 39: Check Valve Assembly
SERVICE Drive Control Valve 14J Attachments Drive Control Valve Service 4.7-1 Valve Tubes Hoses 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. Disconnect the hydraulic hoses and tubes (if equipped) to the drive control valve. -
Page 40: Revolving Connection
SERVICE Revolving Connection WARNING: Before removing any hoses, relieve pressure in the hydraulic system. Removal and Installation With the truck off, open the truck 4.8-1 auxiliary control valve(s) several times in both directions. Remove the attachment from the truck as described in Section 4.1. -
Page 41: Revolving Connection Service
SERVICE Revolving Connection Service 4.8-2 IMPORTANT: Make sure work area is clean and dust-free For reassembly, reverse the previous procedures with when servicing the revolving connection. the following exceptions: CAUTION: Remove all burrs and paint from the exposed • Install new O-rings and back-up rings on all valve revolving connection shaft surface prior to servicing the cartridges, as shown. - Page 42 SERVICE Revolving Connection Service (Continued) 4.8-2 O-Rings 210377 6038929 Front View CKCB-XCN O-Rings CL2686.eps Back-Up Rings Check Valve Cartridge O-Rings CL2687.eps Back-Up Rings Relief Cartridge 210266 6034595 Deltrol CL0341.eps Flow Divider/Combiner Back-Up Rings Cartridge Revolving Connection (Non-Sideshift) End Block End Block Capscrews Fittings CLAMP Relief...
- Page 43 SERVICE Revolving Connection Service (Continued) 4.8-2 Revolving Connection (Sideshift) End Block Fittings End Block SIDESHIFT Relief Capscrews Cartridge Two-Piece Seals CAUTION: See seal installation procedure on page 42. Shaft Revolving CLAMP Relief Connection Cylinder Connection Cartridge Body Fittings (Flareless Plug type shown) CC0350.eps End Block...
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Page 44: Relief Valve Adjustment
SERVICE Relief Valve Adjustment 4.8-3 WARNING: Before removing hydraulic (CLAMP Circuit) lines or components, relieve pressure in the hydraulic system. With the truck off and move the truck auxiliary control valve(s) IMPORTANT: Check the attachment nameplate for several times in both directions. hydraulic pressure settings. -
Page 45: Cylinders
SERVICE Cylinders Cylinder Removal and Cylinder Rod 4.9-1 Hex Beveled Washer Installation Spherical Nut NOTE: The following procedures can be performed with the attachment mounted on the truck and the arms Locking Cap remaining on the attachment. Extend the arms outside the width of the frame. If equipped, remove the bumper capscrews and remove the bumper. -
Page 46: Cylinder Disassembly
SERVICE Cylinder Disassembly 4.9-2 Clamp the cylinder in a soft-jawed vise at the extreme head end only. Do not clamp on the shell. Unscrew and remove the retainer using a claw-type spanner wrench (Cascade Part No. 678598). Remove the piston/rod assembly from the cylinder. To remove piston, clamp the rod assembly in a vise on the wrench flats, as shown. -
Page 47: Cylinder Reassembly
SERVICE Cylinder Reassembly 4.9-4 Using 400-grit emery cloth, polish the piston and retainer chamfer angles. Remove sharp edges on internal threads in the cylinder shell. Clean all parts thoroughly. Lubricate all new seals and O-rings with petroleum jelly. Chamfer CL1070.eps Install a new O-ring in the piston ID and the two-piece angle seal on the piston OD. -
Page 48: Base Unit
SERVICE Base Unit 4.10 Bearing Assembly – 4.10-1 Capscrew Torque Inspection 1000-Hour Inspection Every 1000 hours perform the following inspection: Check the accessible baseplate capscrews above upper mounting hooks for an initial torque of: 14J Attachments 18J Attachments 14J – 38 ft.-lbs. (52 Nm) 18J –... -
Page 49: Bearing Assembly Removal And Installation
SERVICE Bearing Assembly Removal 4.10-2 and Installation Remove the attachment from the truck as described in Section 4.1. Remove the drive group as described in Section 4.3-1 or 4.4-1. 14J Attachments – Remove from Drive Control Valve baseplate. For reassembly, tighten the capscrews to 70 in.-lbs. - Page 50 SERVICE Bearing Assembly Removal 4.10-2 Cross Pattern Tightening and Installation (Continued) Sequence WARNING: Verify that the overhead hoist and chains or straps are rated for the weight of the attachment. Refer to nameplate for attachment weight. Attach two eyebolts to the baseplate. Attach an overhead hoist and take up the slack in the chains.
- Page 51 SERVICE Bearing Assembly Removal 4.10-2 and Installation (Continued) Faceplate Attach two eyebolts to the outer race on the bearing assembly. Attach an overhead hoist to the bearing and take up the slack in the chains. Bearing Capscrews − Remove the capscrews fastening the bearing assembly to the faceplate.
- Page 52 SERVICE Bearing Assembly Removal 4.10-2 Heat treat and Installation (Continued) zone 'R' Grease at 40° Fitting Faceplate For reassembly, reverse the above procedures with the following exceptions: • When installing the rotation bearing assembly on the faceplate, align and position the heat-treated overlap zone 'R' on the inner ring gear with the outer race grease fitting, as shown, at the angle noted above horizontal.
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Page 53: Solenoid Valve
SERVICE Solenoid Valve 4.11 Coil Service 4.11-1 Remove the cover from the valve assembly. Disconnect the wires and diode from the coil terminals. Loosen the end cover capscrews. Remove the end cover and coil. Note the position of coil terminals. Install the new coil and end cover. -
Page 54: Hydraulics
SPECIFICATIONS Hydraulics Truck Relief Setting (see attachment nameplate) 2250 psi (155 bar) Recommended 2755 psi (190 bar) Maximum NOTE: The attachment revolving connection has separate pressure relief control, see Section 4.9-3 for adjustment. Truck Flow Volume ➀ Min. ➁ Recommended Max. -
Page 55: Auxiliary Valve Functions
SPECIFICATIONS Auxiliary Valve Functions Rotate Rotate Left Left (CCW) (CCW) Tilt Forward Tilt Forward Release Sideshift Left Hoist Down Release Hoist Down (Push Button) GA0082.eps GA0082.eps GA0082.eps GA0082.eps Hoist Up Hoist Up Clamp Clamp Tilt Back Rotate Tilt Back Rotate Right Right Sideshift Right... -
Page 56: Torque Values
SPECIFICATIONS Torque Values Fastener torque values for 14J and 18J attachments are in both US and metric units in the table. All torque values are also called out in each specific service procedure section throughout the manual. Ref. Fastener Location Size Ft.-lbs. - Page 57 SPECIFICATIONS Torque Values (continued) CC0287.eps Back (Driver's) View CC0289.eps Back (Driver's) View 6921413...
- Page 58 Pte. Ltd. Rocklea, QLD 4107 East Tamaki, Auckland 18 Tuas South Street 5 Australia New Zealand Singapore 637796 Tel: 1-800-227-223 Tel: +64-9-273-9136 Tel: +65-6795-7555 Fax: +61 7 3373-7333 Fax: +64-9-273-9137 Fax: +65-6863-1368 © Cascade Corporation 2020 01-2020 Part Number 6921413...
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