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cascade corporation D Series Service Manual Supplement

Tipping carton clamps
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S
ERVICE MANUAL SUPPLEMENT
D-Series
NOTE: This manual covers tipping components only. Refer to D-Series
Carton Clamp Service Manual, part number 228156, for periodic
maintenance, troubleshooting and service to carton clamp components
including arms, carton clamp cylinders and frame.
Tipping Carton Clamps
Manual Number 6905873
cascade
corporation
Cascade is a Registered Trademark of Cascade Corporation

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  • Page 1 NOTE: This manual covers tipping components only. Refer to D-Series Carton Clamp Service Manual, part number 228156, for periodic maintenance, troubleshooting and service to carton clamp components including arms, carton clamp cylinders and frame. Manual Number 6905873 cascade  corporation Cascade is a Registered Trademark of Cascade Corporation...

  • Page 2: 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 Hydraulic Schematic – Non-Sideshifting Hosing Diagram – Cartridge Type Solenoid/Radio Frequenct (RF) Control Hydraulic Schematic –...

  • Page 3: Introduction, Section

    All fasteners have a torque value range of ±10% of stated value. 15D-CCU-2A-12345 A2-Z PTL012345678 Nameplate Cascade Corporation • www.cascorp.com • Icons & Patents: www.cascorp.com/support 6095754 CC0163.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 4: 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 D-Series Carton Clamp Service Manual, Part No. the attachment empty, then test with a load 228156.

  • Page 5: 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 D-Series Carton Clamp Service move the truck auxiliary control valves Manual 228156.

  • Page 6: 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. The following guidelines can then be used as a starting point to begin troubleshooting procedures: Tipping Circuit...

  • Page 7: Plumbing

    TROUBLESHOOTING Plumbing Hosing Diagram – Non-Sideshifting 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 Valve...

  • Page 8: Hydraulic Schematic - Non-Sideshifting

    TROUBLESHOOTING Hydraulic Schematic – Non-Sideshifting 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 6905873...

  • Page 9: Hosing Diagram - Cartridge Type Solenoid/Radio Frequenct (Rf) Control

    TROUBLESHOOTING Hosing Diagram – 3.2-3 Cartridge Type Solenoid Valve/ Arm Cylinders Radio Frequency (RF) Control TIP BACK PRESSURE RETURN Tipping Cylinders NOTE: For TIP FORWARD reverse the colors shown. Cartridge Type Solenoid Valve or RF Control Valve 2-Port Carton Clamp Valve Hose Reel or Internal Hose Reel...

  • Page 10: Hydraulic Schematic - Cartridge Type Solenoid/Radio Frequenct (Rf) Control

    TROUBLESHOOTING Hydraulic Schematic – 3.2-4 Cartridge Type Solenoid Valve/ Radio Frequency (RF) Control Arm Cylinders Tipping Cylinders Counterbalance Valve Carton Clamp Valve Cartridge Type Solenoid Valve or RF Control Valve 2-Port Hose Reel or 2-Port Hose Reel or Internal Hose Reel Internal Hose Reel CLAMP Truck...

  • Page 11: Hosing Diagram - Solenoid

    TROUBLESHOOTING Hosing Diagram – Solenoid 3.2-5 Arm Cylinders 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 CLAMP Truck...

  • Page 12: Hydraulic Schematic - Solenoid

    TROUBLESHOOTING Hydraulic Schematic – Solenoid 3.2-6 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 Truck Pump...

  • Page 13: Tipping Function

    TROUBLESHOOTING Tipping Function WARNING: Before removing hydraulic lines, relieve pressure in the hydraulic system. There are five potential problem areas that can affect the Turn the truck off and open the truck TIP function: auxiliary control valves several times in both •...

  • Page 14: 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 15: 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 16: 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 D-Series Carton Clamp Service Manual 228156. Arm Cylinders To remove and service arm cylinders, refer to D-Series Carton Clamp Service Manual 228156.

  • Page 17: Back Mounting Frame

    SERVICE Back Mounting Frame Back Mounting Frame Removal and Installation 4.6-1 Remove the attachment from the lift truck as described in Section 4.1. Frame WARNING: Before removing any hoses, relieve pressure in the hydraulic system. With the truck off, open the truck supply auxiliary control valve(s) several times in both directions.

  • Page 18: Bushing Service

    SERVICE Bushing Service 4.6-2 One-Piece Back Mounting Frame Remove the back mounting frame (or frames) as described in Section 4.5-1. Remove the pivot bushings from back mounting frame using a bushing driver. NOTE: Bushing drivers can be machined using the dimensions shown below.

  • Page 19: Tipping Cylinder

    SERVICE Tipping Cylinder WARNING: Before removing any hoses, relieve pressure in the hydraulic system. Removal and Installation 4.7-1 With the truck off, open the truck auxiliary control valve(s) several times in both Remove the attachment from the lift truck as described directions.

  • Page 20: Counterbalance Valve Cartridge Service

    SERVICE Counterbalance Valve 4.7-2 Cartridge Service (if equipped) Counterbalance Position the cylinders to gain access to the cylinder Valve Cartridge Tipping counterbalance valve. Cylinder Flange 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 21: Cylinder Bushing Service

    SERVICE 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. Remove the bushings from the cylinder using a bushing driver.

  • Page 22: 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 23: 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 in the piston ID and piston seal on the piston OD.

  • Page 24: 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 25: Cartridge Type Solenoid Valve Or Radio Frequency Valve

    SERVICE Cartridge Type Solenoid Valve or 4.8-2 Radio Frequency Valve 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 26 SERVICE Cartridge Type Solenoid Valve 4.8-2 or Radio Frequency Valve Directional Valve Cartridge (Continued) Fittings CC0190.eps Coil Solenoid Valve Cartridge Check Cartridge Fitting Shuttle Valve Solenoid Valve Cartridge Check Cartridge O-Rings O-Rings GA0426.eps Back-Up Rings GA0482.eps Back-Up Rings Directional Shuttle O-Rings O-Rings Valve Cartridge...

  • Page 27: Solenoid Valve Coil Service

    SERVICE Solenoid Valve Coil Service 4.8-3 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 28: Hydraulics

    SPECIFICATIONS Hydraulics Truck Relief Setting 2000 psi (140 bar) Recommended 2300 psi (160 bar) Maximum Truck Flow Volume ➀ Recommended ➁ ➂ D-Series Min. Max. 4 GPM 7 GPM 7 GPM TIPPING (15 L/min.) (26 L/min.) (26 L/min.) ➀ Cascade attachments are compatible with SAE 10W petroleum base hydraulic fluid meeting Mil.

  • Page 29: 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 Class III 18.68 in. (474.5 mm) 18.74 in. (476.0 mm) GA0389.eps 6905873...

  • Page 30: Torque Values

    SPECIFICATIONS Torque Values Fastener torque values for the tipping attachments are shown in the table below in both US and Metric units. All torque values are also called out in each specific service procedure throughout this manual. NOTE: All fasteners have a torque value range of ±10% of stated value.
  • Page 31 SPECIFICATIONS Torque Values (Continued) Ref. Fastener Location Size Ft.-lbs. Mounting Bracket Capscrew 5/16, M8 Lower Hook Capscrew Hose Clamp Capscrew 1/4, M6 Solenoid Capscrew 1/4, M6 Valve Capscrew 5/16, M8 CC0192.eps CC0193.eps Back (Driver's) View 6905873...
  • Page 32 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 6905873...

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