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Summary of Contents for Cascade J-Series
- Page 1 ERVICE MANUAL J-Series Integral Carriages − Sideshifter, Fork Positioner, Sideshifting Fork Positioner, Swing Frame & Slope Frame Manual Number 6052504 c sc de corpor tion Cascade is a Registered Trademark of Cascade Corporation...
- Page 2 ONTENTS Page INTRODUCTION, Section 1 Introduction Special Definitions PERIODIC MAINTENANCE, Section 2 100-Hour Maintenance 500-Hour Maintenance 1000-Hour Maintenance Swing Frame and Slope Frame Hook-Type Fork Positioner Attachments TROUBLESHOOTING, Section 3 General Procedures Truck System Requirements Tools Required Troubleshooting Chart Plumbing Hosing Diagram –...
- Page 3 IMPORTANT: Information in this manual is based Troubleshooting, Service and Specifications for Cascade on a general attachment. Some functions are not J-Series Integral Fork Positioner/Sideshifter, Swing Frame shown. Contact Cascade for specific information. and Slope Frame. In any communication about the attachment, refer to the product I.D.
- Page 4 (see Service Manual for repair procedures). • Inspect forks for wear. NOTE: Cascade fork safety kit 3014162 is available with wear calipers, inspection sheets and safety poster. Also available Cascade fork hook & carriage bar wear gauge FP1218.eps 209560 (CL II), 209561 (CL III) and 6105257 (CL IV).
- Page 5 ERIODIC MAINTENANCE Swing and Slope Attachments In addition to the previous page maintenance schedule, where applicable, the following maintenance procedures Frame must be completed on swing and slope attachments: Pivot Pins 300 Hours – Apply general purpose chassis grease to •...
- Page 6 GA0013.eps • Inline Flow Meter Kit: (2) No. 6-8 JIC Reducer 10 GPM (37 L/min) – Cascade Part No 671476 20 GPM (75 L/min) – Cascade Part No. 671477 • Pressure Gauge Kit: Pressure Gage Kit: 671212 5000 psi (345 bar) – Cascade Part No. 671212 •...
- Page 7 ROUBLESHOOTING Plumbing 4.2 Hosing Diagram – OPEN CLOSE 4.2-1 Forks Forks Sideshift and Fork Position Relief Valve SIDESHIFT LEFT, CLOSE FORKS PRESSURE RETURN NOTE: For SIDESHIFT RIGHT, SPREAD FORKS reverse the colors shown. Sideshift Cylinder SIDESHIFT Truck Auxiliary Valve FP0733.eps Hydraulic Schematic 4.2-2 Fork Positioning FORK POSITION Cylinders Truck Auxiliary Valve Flow Restrictor Flow...
- Page 8 ROUBLESHOOTING Fork Position WARNING: Before removing hydraulic 3.3 lines or components, relieve pressure in the Function hydraulic system. Turn truck off and open the truck auxiliary control valve(s) several times in both directions. There are five potential problems that could affect the fork positioning function: •...
- Page 9 ROUBLESHOOTING Sideshift Function WARNING: Before removing hydraulic 3.4 lines or components, relieve pressure in the There are five potential problems that could affect the hydraulic system. Turn truck off and open sideshifting function: the truck auxiliary control valve(s) several times in both directions. •...
- Page 10 ROUBLESHOOTING Electrical Circuit 3.5 (Solenoid Equipped Attachments) Use the electrical schematic and diagram shown and follow the steps below: Check the control knob circuit fuse. Replace if necessary. Check for loose electrical connections at the truck ignition switch, control knob button, solenoid coil terminal and diode.
- Page 11 Remove the clevis pins and remove the sideshift cylinder from the frame. FP1198.eps Backrest may be removed or left in place to assist in lifting frame from carriage. For Cascade backrests reassembly, tighten backrest capscrews to 145 ft.-lbs. (195 Nm). Upper Remove the lower retainers.
- Page 12 ERVICE Bearing Service 4.1-2 Remove the Sideshift/Fork Position frame from the truck carriage as described in Section 4.1-1. Remove and inspect the upper bearings. If any bearing is worn to less than .4 in. (10 mm) thickness, replace all bearings. IMPORTANT: Make sure upper bearings are properly positioned and seated on the upper integral carriage bar, as shown.
- Page 13 ERVICE Mechanical Swing 4.2 Wedge Bearing Service WARNING: Before disconnecting hoses, relieve pressure in the Attachment hydraulic system. Turn the truck off and move the truck auxiliary valve control lever several times in both directions. Disconnect the supply hoses to the swing cylinder. Cap hoses and tag for reassembly.
- Page 14 ERVICE Valves 4.3 Valve NOTE: Not all valves are covered. Contact Cascade to replace valve components. Fork Position Valve Removal 4.3-1 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.
- Page 15 ERVICE Sideshift Cylinder 4.4 Removal and Installation 4.4-1 NOTE: The following procedures can be performed with the Sideshift/Fork Position frame mounted on the truck. Sideshift SIdeshift Base End WARNING: Before disconnecting hoses, Rod End relieve pressure in the attachment hydraulic system. Turn the truck off and move the truck auxiliary valve control lever several times in both directions.
- Page 16 ERVICE Cylinder Disassembly 4.4-2 Pin-Type NOTE: Use a soft-jawed vise for all cylinder disassembly Spanner Wench and assembly procedures. Clamp the cylinder so that the vise jaws contact only the extreme end of the cylinder base. Do not clamp on the shell.
- Page 17 ERVICE Cylinder Inspection 4.4-3 • Inspect the rod, piston and retainer for nicks or burrs. Minor nicks or burrs may be removed with 400-grit emery cloth. If they cannot be removed, replace the parts. • Inspect the cylinder bore and remove any minor nicks or burrs with a butterfly.
- Page 18 ERVICE Cylinder Reassembly 4.3-4 Polish the piston and retainer chamfer angles with 400-grit emery cloth to ease seal installation. Note the direction of the pressure seals. Pressure seals must be installed with the lip toward the high pressure side of the cylinder. Lubricate new seals and O-rings with O-ring lube or petroleum jelly. Install a new pressure seal and back-up ring (if equipped), wear ring (if equipped) on the piston.
- Page 19 ERVICE TYPE 2 Wear Ring O-Ring Piston U-cup Back-up Pressure Seal Ring Note Seal Wiper Direction Pressure Seal Torque Piston Nut 100-120 ft.-lbs. 271-339 Nm SS0822.eps Spiral Snap Ring Retaining Ring TYPE 3 Wear Ring O-Ring Piston U-cup Pressure Seal Note Seal Direction Wiper Pressure Seal Torque Piston Nut 100-120 ft.-lbs.
- Page 20 4.5 Removal and Installation 4.5-1 If equipped, remove the backrest to provide access to the cylinder head end anchors. For cascade backrest reassembly, tighten backrest capscrews to: M12 Capscrew − 75 ft.-lbs. (100 Nm) M16 Capscrew − 145 ft.-lbs. (195 Nm) Refer to the truck service manual for truck manufacturer's backrest.
- Page 21 ERVICE Cylinder Disassembly 4.5-2 Clamp the cylinder in a soft-jawed vise at the extreme base end. Do not clamp on the shell. Unscrew and remove the retainer using a claw-type spanner wrench as shown. (Part No. 678598) Remove the rod assembly from the cylinder. Clamp the rod at the clevis end in a soft-jawed vise as shown.
- Page 22 ERVICE Cylinder Reassembly 4.5-4 Polish the piston and retainer chamfer angles with 400-grit emery cloth to ease seal installation. Note the direction of the U-cup seals. Pressure seals must be installed with the lip toward the high Chamfer Angle CL1070.eps pressure side of the cylinder. Lubricate all new seals and O-rings with petroleum jelly. Piston Install a new seal and O-ring on the piston.
- Page 23 ERVICE Flow Restrictor Adjustment 4.5-5 Fork Positioning NOTE: If forks have unequal movement, use the following Cylinder steps to adjust the flow rate for the fork position cylinders. Locate cylinder restrictor fittings. Loosen jam nuts and screw both flow restrictors in until they bottom. Screw each restrictor out (CCW) three turns.
- Page 24 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 recommended will result in reduced system performance.
- Page 25 PECIFICATIONS Torque Values 5.1-3 Fastener torque values for J-Series Integral Carriages are shown in the table below in both U.S. and (Metric) units. All torque values are also called out in each specific service procedure section throughout the manual. Ref.
- Page 26 Do you have questions you need answered right now? Call your nearest Cascade Service Department. Visit us online at www.cascorp.com AMERICAS Cascade Corporation Cascade Canada Inc. Cascade do Brasil Parts Sales 5570 Timberlea Blvd. Rua João Guerra, 134 2501 Sheridan Ave.
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