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S
ERVICE MANUAL SUPPLEMENT
J-Series
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.
Tipping Carton Clamps
Manual Number 6914321
cascade
corporation
Cascade is a Registered Trademark of Cascade Corporation
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Summary of Contents for cascade corporation J Series
- Page 1 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. Manual Number 6914321 cascade corporation Cascade is a Registered Trademark of Cascade Corporation...
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Page 3: Table Of Contents
CONTENTS Page INTRODUCTION, Section 1 Introduction Special Definitions PERIODIC MAINTENANCE, Section 2 Daily Inspection 1000-Hour Maintenance TROUBLESHOOTING, Section 3 General Procedures Truck System Requirements Tools Required Troubleshooting Chart Plumbing Hosing Diagram – Non-Sideshifting Clamp Hydraulic Schematic – Non-Sideshifting Clamp Hosing Diagram – Sideshifting Clamp with Solenoid Hydraulic Schematic –... -
Page 4: Introduction, Section
All fasteners have a torque value range of ±10% of stated value. 8J-CCU-2A-12345 A2-Z PTL012345678 Nameplate Cascade Corporation • www.cascorp.com • Icons & Patents: www.cascorp.com/support 6095754 CC0244.eps Special Definitions The statements shown appear throughout this manual where special emphasis is required. Read all WARNINGS and CAUTIONS before proceeding with any work. -
Page 5: Periodic Maintenance, Section
PERIODIC MAINTENANCE IMPORTANT: This section covers periodic maintenance WARNING: After completing any service for tipping components only. In addition to the periodic procedure, always test the attachment maintenance below, perform the periodic maintenance through five complete cycles. First test found in J-Series Carton Clamp Service Manual, part the attachment empty, then test with a load number 6883648. -
Page 6: General Procedures
TROUBLESHOOTING General Procedures WARNING: Before servicing any hydraulic component, relieve pressure IMPORTANT: Troubleshooting the SIDESHIFT or CLAMP in the system. Turn the truck off and circuits can be found in J-Series Carton Clamp Service move the truck auxiliary control valves Manual, part no. -
Page 7: Troubleshooting Chart
TROUBLESHOOTING Troubleshooting Chart 3.1-3 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. -
Page 8: Plumbing
TROUBLESHOOTING Plumbing Hosing Diagram – Non-Sideshifting Clamp 3.2-1 Arm Cylinders TIP BACK PRESSURE RETURN Tipping NOTE: For TIP FORWARD reverse the Cylinders colors shown. Counterbalance Valve 2-Port Hose Reel or Internal Hose Reel Carton Clamp Valve 2-Port Hose Reel or Truck Internal Hose Reel Auxiliary... -
Page 9: Hydraulic Schematic - Non-Sideshifting Clamp
TROUBLESHOOTING Hydraulic Schematic – Non-Sideshifting Clamp 3.2-2 Arm Cylinders Tipping Cylinders Counterbalance Valve Carton Clamp Valve 2-Port Hose Reel or 2-Port Hose Reel or Internal Hose Reel Internal Hose Reel CLAMP Truck Truck Auxiliary Auxiliary Valve Valve Truck Relief Valve Truck Pump Truck Tank CC0168.eps... -
Page 10: Hosing Diagram - Sideshifting Clamp With Solenoid
TROUBLESHOOTING Hosing Diagram – 3.2-5 Arm Cylinders Sideshifting Clamp with Solenoid TIP BACK PRESSURE RETURN Tipping NOTE: For TIP FORWARD reverse the Cylinders colors shown. Counterbalance Valve Solenoid Valve 2-Port Hose Reel Carton Clamp Valve or Internal Hose Reel TIP and SIDESHIFT 2-Port Hose Reel or Truck Auxiliary Valve Internal Hose Reel... -
Page 11: Hydraulic Schematic - Sideshifting Clamp With Solenoid
TROUBLESHOOTING Hydraulic Schematic – 3.2-6 Sideshifting Clamp with Solenoid Arm Cylinders Tipping Cylinders Counterbalance Valve Carton Clamp Valve Solenoid Valve 2-Port Hose Reel or 2-Port Hose Reel or Internal Hose Reel Internal Hose Reel CLAMP TIP and SIDESHIFT Truck Auxiliary Valve Truck Auxiliary Valve Truck Relief Valve... -
Page 12: Tipping Function
TROUBLESHOOTING Tipping Function Valve Counterbalance There are five potential problem areas that can affect the Cartridge 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. •... -
Page 13: Electrical Circuit
TROUBLESHOOTING Electrical Circuit (Solenoid-equipped attachments) Use the schematic 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. Remove the diode from the solenoid coil terminal. -
Page 14: Attachment Removal
SERVICE Attachment Removal 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. Disconnect and plug the hydraulic supply hoses to the attachment. -
Page 15: Arms
SERVICE NOTE: Manuals are available at www.cascorp.com under the support tab, "Technical Support Manuals" link. Arms To remove and service arms, contact pads, arm bearings, refer to J-Series Carton Clamp Service Manual, part number 6883648. Arm Cylinders To remove and service arm cylinders, refer to J-Series Carton Clamp Service Manual, part number 6883648. -
Page 16: Back Mounting Frame
SERVICE Back Mounting Frame Back Mounting Frame Removal and Installation 4.6-1 Frame 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. -
Page 17: Bushing Service
SERVICE Bushing Service 4.6-2 One-Piece Back Mounting Frame Remove the back mounting frame (or frames) as described in Section 4.6-1. Remove the pivot bushings from back mounting frame using a bushing driver. NOTE: Bushing drivers can be machined using the dimensions shown below. -
Page 18: Tipping Cylinder
SERVICE Tipping Cylinder Back Mounting Frame Removal and Installation 4.7-1 Tipping Cylinder 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. -
Page 19: Counterbalance Valve Cartridge Service
SERVICE 18J Counterbalance Valve 4.7-2 Cartridge Service Counterbalance Position the cylinders to gain access to the cylinder Valve Cartridge counterbalance valve. Tipping Cylinder Junction Block 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: 18J Cylinder Bushing Service
SERVICE 18J Cylinder Bushing Service 4.7-3 NOTE: Bushings require replacement if the clearance between the bushing and pin exceeds 1/16 in. (1.6 mm). Remove the tipping cylinder from the attachment as described in Section 4.7-1. Remove the bushings from the cylinder using a bushing driver. -
Page 21: Cylinder Disassembly
SERVICE Cylinder Disassembly 4.7-4 Clamp the cylinder using the vise jaws to contact only the extreme end of the cylinder base. NOTE: Use a soft-jawed vise for all cylinder disassembly and assembly procedures. RC0314.eps Remove the cylinder retainer by unscrewing it with a pin-type spanner wrench. -
Page 22: Cylinder Reassembly
SERVICE Cylinder Reassembly Chamfer 4.7-6 Angle Using 400-grit emery cloth, polish the piston and retainer chamfer angles. Remove sharp edges on internal threads in cylinder shell. Clean all parts thoroughly. Lubricate all new seals and O-rings with petroleum jelly. Install a new O-ring and back-up seal in the piston ID and piston seal on the piston OD. -
Page 23: Valves
SERVICE Valves Counterbalance Valve Service 4.8-1 The following procedure can be performed with the attachment mounted on the truck. Raise the attachment so that the valve is accessible. 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 24: Solenoid Valve Coil Service
SERVICE Solenoid Valve Coil Service 4.8-2 Disconnect the wires and diode from the coil terminals. Remove the end cover capscrews and remove the end cover and coil. Note the position of the coil terminals. Install the new coil and end cover. Verify that the terminals are positioned correctly. -
Page 25: Hydraulics
SPECIFICATIONS Hydraulics Truck Relief Setting Low Pressure High Pressure 2000 psi (140 bar) 2755 psi (190 bar) Recommended 2760 psi (190 bar) 3625 psi (250 bar) Maximum Truck Flow Volume ➀ Recommended ➁ ➂ 8J & 18J Min. Max. 1 GPM 5 GPM 10 GPM SIDESHIFT,... -
Page 26: Truck Carriage
SPECIFICATIONS Truck Carriage Carriage Mount Dimension (A) ITA (ISO) Minimum Maximum 14.94 in. (380.0 mm) 15.00 in. (381.0 mm) Class II GA0389.eps 6914321... -
Page 27: Torque Values
SPECIFICATIONS Torque Values Fastener torque values for the tipping attachments are NOTE: For additional torque values related carton clamp shown in the table below in both US and Metric units. All components, refer to J-Series Carton Clamp Service torque values are also called out in each specific service Manual 6883648. - Page 28 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 2019 01-2019 Part Number 6914321...
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