Cascade J Series User manual

Brand: Cascade

Model: J Series

Type: User manual

Cascade is a Registered Trademark of Cascade Corporation

cascade



corporation

ERVICE MANUAL

J-Series

Integral Carriages −

Sideshifter, Fork Positioner,

Sideshifting Fork Positioner,

Swing Frame & Slope Frame

Manual Number 6052504

ONTENTS

6052504

Page

INTRODUCTION, Section 1

Introduction 1

Special Deﬁnitions 1

PERIODIC MAINTENANCE, Section 2

100-Hour Maintenance 2

500-Hour Maintenance 2

1000-Hour Maintenance 2

Swing Frame and Slope Frame 3

Hook-Type Fork Positioner Attachments 3

TROUBLESHOOTING, Section 3

General Procedures 4

Truck System Requirements 4

Tools Required 4

Troubleshooting Chart 4

Plumbing 5

Hosing Diagram – Sideshift and Fork Position 5

Hydraulic Schematics 5

Fork Position Function 6

Supply Circuit Test 6

Fork Position Cicuit Test 6

Sideshift Function 7

Supply Circuit Test 7

Sideshift Circuit Test 7

Electrical Circuit 8

SERVICE, Section 4

Sideshift/Fork Position Frame 9

Removal and Installation 9

Bearing Service 10

Mechanical Swing Wedge Bearing Service 11

Valve 12

Fork Position Valve Removal 12

Fork Position Valve Service 12

Sideshift Cylinder 13

Removal and Installation 13

Cylinder Disassembly 14

Cylinder Inspection 14

Cylinder Reassembly 15

Fork Positioner Cylinder 17

Removal and Installation 17

Cylinder Disassembly 18

Cylinder Inspection 18

Cylinder Reassembly 19

Flow Restrictor Adjustment 20

Solenoid Valve 20

Coil Service 20

Valve Service 20

SPECIFICATIONS, Section 5

Speciﬁcations 21

Hydraulics 21

Auxiliary Valve Functions 21

Torque Values 22

NTRODUCTION

6052504

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.

1.1 Introduction

This manual provides the Periodic Maintenance,

Troubleshooting, Service and Speciﬁcations for Cascade

J-Series Integral Fork Positioner/Sideshifter, Swing Frame

and Slope Frame.

In any communication about the attachment, refer to the

product I.D. number stamped on the nameplate as shown.

If the nameplate is missing, the numbers can be found

stamped on the top left surface of the attachment.

IMPORTANT: All hoses, tubes and ﬁttings on these

attachments are JIC.

NOTE: Speciﬁcations are shown in both US and (Metric)

units.

MAXIMUM STRUCTURAL CAPACITY

OF ATTACHMENT ONLY IS:

CATALOG

NUMBER

SERIAL

NUMBER

ADDITIONAL

EQUIPMENT

SYSTEM PRESSURE

PSI

BAR

INCH

LOAD

CENTER

LOAD

CENTER

LBS

cascade

�

corporation

WEIGHT

FOR TECHNICAL ASSISTANCE CONTACT:

SERVICE: 1-800-227-2233 PORTLAND, OREGON USA

PARTS: 1-888-227-2233 SPRINGFIELD, OHIO USA

667635R6

CAPACITY OF TRUCK AND ATTACHMENT COMBINATION MAY BE LESS

THAN ATTACHMENT CAPACITY SHOWN.

CONSULT TRUCK NAMEPLATE.

WEIGHT

LBS.

35E-PPS-A001

PTL 604920-1R0

35E-PPS-A001

PTL 604920-1R0

FP1194.eps

Nameplate

IMPORTANT: Information in this manual is based

on a general attachment. Some functions are not

shown. Contact Cascade for speciﬁc information.

6052504

ERIODIC MAINTENANCE

2.1 100-Hour Maintenance

Every time the lift truck is serviced or every 100 hours

of truck operation, whichever comes ﬁrst, complete the

following maintenance procedures:

Check for loose or missing capscrews, worn or

damaged hoses, and hydraulic leaks.

Check fork shafts for bends, damage or wear. Replace

if bent. Consult Cascade if damaged or worn.

2.2 300-Hour Maintenance

After each 300 hours of truck operation, in addition to the

100-hour maintenance, perform the following procedures:

Tighten Cascade backrest (if equipped) capscrews to

the following torque values:

M12 Capscrew – 75 ft.-lbs. (100 Nm)

M16 Capscrew – 145 ft.-lbs. (195 Nm)

For other backrests, see OEM recommendations.

If equipped with zerk ﬁttings – Apply general purpose

chassis grease to upper and lower bearings.

Inspect frame retainers for wear. Replace if necessary.

Tighten lower frame retainer capscrews to 165-200 ft.-lbs.

(225-275 Nm).

Inspect fork shaft and front of lower frame bar for

grease contamination. Remove contaminated grease

from fork shaft and lower frame bar. Apply a general

purpose chassis grease to the fork shaft. Apply a

general purpose chassis grease or Slip-Plate (or a

'paint-on' graphite equivalent) to the lower frame bar.

2.3 1000-Hour Maintenance

After each 1000 hours of truck operation, in addition to

the 100 and 300-hour maintenance, perform the following

procedures:

Inspect sideshift upper and lower bearings for wear.

If the frame is rubbing the carriage or lower bearing

capscrews, replace the entire bearing set (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

209560 (CL II), 209561 (CL III) and 6105257 (CL IV).

Inspect sideshift cylinder pivot pins and clevis pins for

wear. Replace part as necessary.

Inspect fork position cylinder anchor nuts for wear.

Replace if necessary.

NOTE: Anchors operate with a loose clearance.

Tighten lower bearing capscrews to 200 ft.-lbs. (270 Nm).

Tighten fork shaft retainers capscrews (if equipped) to

49 ft.-lbs. (66 Nm).

•

WARNING: After completing any service

procedure, always test the Fork Positioner/

Sideshifter through ﬁve complete cycles

to make sure the attachment operates

correctly before returning it to the job.

FP0736.eps

Shaft Retainer

capscrews

Fork Shaft Upper Bearing

Sideshift Cyinder

Clevis Pin Mounts

Lower

Frame Bar

Lower Bearing

Front View

Back (Driver's) View

FP1218.eps

Backrest Capscrews

(if equipped)

Fork Positioner

Cylinder Anchors

Lower Frame

Retainer Capscrews

6052504

ERIODIC MAINTENANCE

SS0817.eps

2.4 Swing and Slope

Attachments

In addition to the previous page maintenance schedule,

where applicable, the following maintenance procedures

must be completed on swing and slope attachments:

300 Hours – Apply general purpose chassis grease to

pivot pin zerk ﬁttings and cam rollers.

1000 Hours – Inspect swing and slope frame pivot

points for wear.

1000 Hours – Inspect wedge bearings (Mechanical

swing frame) for wear.

1000 Hours – Inspect swing and slope cylinder

pivot pins and clevis pins for wear. Replace part as

necessary.

•

Cylinder

Pivot Pins

Frame

Pivot Pins

Cam Rollers

Wedge

Bearings

FP1212.eps

Upper Fork

Carrier Bearings

Lower Fork

Carrier Bearings

FP Cylinder

Lug

Capscrews

Fork Carrier

Capscrews

Fork Pad Capscrews

2.5 Hook-Type Fork

Positioner Attachments

In addition to the previous page maintenance schedule,

where applicable, the following maintenance procedures

must be completed on hook-type fork positioner

attachments:

300 Hours – Apply general purpose chassis grease to

fork carrier bearings.

300 Hours – Tighten capscrews as follows:

FP Cylinder Lug – 13-15 ft.-lbs. (18-20 Nm)

Fork Pad – 500 ft.-lbs. (678 Nm)

Fork Carrier – 28 ft.-lbs. (38 Nm)

NOTE: Apply Loctite 242 to FP Cylinder Lug and Fork

Pad capscrews.

300 Hours – Apply general purpose chassis grease or

Slip-Plate (or a 'paint-on" graphite equivalent) to the fork

slider bars.

•

Fork Slider

Bars

ROUBLESHOOTING

6052504

3.1 General Procedures

3.1-1 Truck System Requirements

Truck hydraulic pressure should be within the pressure

range as shown in Section 5.1. PRESSURE MUST NOT

EXCEED 2500 psi (170 bar).

Truck hydraulic ﬂow should be within the volume range

as shown in Section 5.1

Truck hydraulic ﬂuid supplied to the attachment must

meet the speciﬁcations as shown in Section 5.1.

•

3.1-2 Tools Required

In addition to a normal selection of mechanic's hand tools,

the following are required:

Inline Flow Meter Kit:

10 GPM (37 L/min) – Cascade Part No 671476

20 GPM (75 L/min) – Cascade Part No. 671477

Pressure Gauge Kit:

5000 psi (345 bar) – Cascade Part No. 671212

Assorted ﬁttings, lines, drain hoses and quick-couplers

as required.

•

3.1-3 Troubleshooting Chart

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.

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:

Fork Position Function

• Forks open and close unevenly.

• Forks will not open and close.

To correct one of these problems, see Section 3.3.

Sideshift Function

• Attachment sideshifts too fast or too slow.

• Attachment will not sideshift.

To correct one of these problems, see Section 3.4.

Other Functions

Contact Cascade, see back cover.

GA0013.eps

GA0014.eps

AC0127.eps

Flow Meter Kits: 671476 – 37 L/min (10 GPM)

671477 – 75 L/min (20 GPM)

(2) No. 8-12

JIC/ O-Ring

(2) No. 6-8 JIC Reducer

Flow Meter

Pressure Gage Kit: 671212

Pressure Gauge★

No. 6-6 Hose★

No. 6 and No. 8

JIC Swivel Tee

No. 4. No.

6★ and No. 8

JIC/O-ring

No. 6-8 JIC

Reducer

No. 4-6 Pip/JIC★

Quick-Disconnect Couplers

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)

★ NOTE: Diagnostics Kit 394382

includes items marked.

6052504

ROUBLESHOOTING

4.2 Plumbing

4.2-1 Hosing Diagram –

Sideshift and Fork Position

FP0733.eps

Forks

OPEN

Forks

Relief

Valve

Fork Positioning

Cylinders

Sideshift

Cylinder

SIDESHIFT LEFT, CLOSE FORKS

PRESSURE

RETURN

NOTE: For SIDESHIFT RIGHT, SPREAD

FORKS reverse the colors shown.

SIDESHIFT Truck

Auxiliary Valve

FORK POSITION

Truck Auxiliary Valve

4.2-2 Hydraulic Schematic

FP0732.eps

Flow

Restrictor

Flow

Restrictor

Relief

Valve

Sideshift Cylinder

Hose Reel or

IHR

Terminals

SIDESHIFT Truck

Auxiliary Valve

FORK POSITION

Truck Auxiliary Valve

Truck Pump

Truck Relief

Valve

Truck Tank

SSR SSL

OPEN

ROUBLESHOOTING

6052504

3.3 Fork Position

Function

There are ﬁve potential problems that could affect the fork

positioning function:

Forks and fork carriers binding on bearings

Incorrect hydraulic pressure or ﬂow.

External leaks.

Loose electrical connection or defective solenoid coil or

valve (if equipped).

Worn/defective cartridge valves or cylinder seals.

3.3-1 Supply Circuit Test

1 Check the truck pressure at the carriage hose terminal.

Pressure must be within 100 psi (7 bar) of that speciﬁed

in the truck service manual. PRESSURE MUST NOT

EXCEED 2500 psi (170 bar) to the fork positioner/

sideshifter. See Section 5.1 for recommended

operating pressure.

2 Check the ﬂow volume at the carriage hose terminal.

See Section 5.1 for recommended ﬂow volume.

3 Fully spread forks. Hold the lever in the OPEN position

for 2 seconds. Release the lever. Check for external

leaks at ﬁttings, hoses and valve.

3.3-2 Fork Position Circuit Test

1 If equipped, press the solenoid button. Listen for a

'click' at solenoid valve. If no sound is heard, check the

fuse, wiring and coil. See Section 3.5.

IMPORTANT: Solenoid operated valves must be

plumbed so that the solenoid is energized during the

fork positioning function.

2 Fully open and close forks. If the forks move at different

speeds, adjust the ﬂow restrictors for equal fork speed.

See Section 4.5-5.

3 Turn the truck off. Connect a 5000 psi (345 bar)

pressure gauge to the OPEN line below the valve.

4 Start the truck. Fully spread forks. Hold the lever in the

OPEN position for a few seconds.

5 Release the lever. Watch the pressure gauge:

If the pressure drop is less than 150 psi (10 bar)

initially and additional drop does not exceed 25 psi

(2 bar) per minute, the problem is not hydraulic. See

Section 3.3, above.

If the pressure drop is more than 150 psi (10 bar)

initially, one of the relief valve's cartridges is faulty.

Replace both cartridges.

6 Fully close forks. Hold the lever in OPEN position for

a few seconds. If the pressure still drops more than

150 psi (10 bar), the cylinders are faulty and should be

serviced. See Section 4.5.

•

WARNING: Before removing hydraulic

lines or components, relieve pressure in the

hydraulic system. Turn truck off and open

the truck auxiliary control valve(s) several

times in both directions.

FP1195.eps

FP1196.eps

Flow Meter

Flow Restrictor

Pressure

Gauge

Back (Driver's) View

Front View

6052504

ROUBLESHOOTING

3.4 Sideshift Function

There are ﬁve potential problems that could affect the

sideshifting function:

Binding due to bending damage, wear, lack of

lubrication. See Periodic Maintenance, Section 2.

Incorrect hydraulic pressure or ﬂow to sideshift cylinder.

External leaks.

Lower mounting hooks installed incorrectly. Refer to

User Manual 6082563 Installation Section.

Worn or defective cylinder seals.

3.4-1 Supply Circuit Test

1 Check the pressure supplied by the truck at the carriage

hose terminal. Pressure must be within the range

shown in Speciﬁcations, Section 5.1. PRESSURE TO

THE FORK POSITIONER/ SIDESHIFTER MUST NOT

EXCEED 2500 psi (170 bar).

2 Check the ﬂow volume at the carriage hose terminal.

Flow must be within the range shown in Speciﬁcations,

Section 5.1

3 Fully sideshift left and right, holding the lever in each

SIDESHIFT position for a few seconds. Release the

lever and check for external leaks at ﬁttings, hoses,

valve and cylinders.

3.4-2 Sideshift Circuit Test

1 If equipped, press the solenoid button. Listen for a

'click' at the solenoid valve. If no sound is heard, check

the fuse, wiring and coil. See Section 3.5.

IMPORTANT: Solenoid operated valves must be

plumed so that the solenoid is not energized during the

sideshifting function.

2 Turn the truck off. Relieve system pressure. Disconnect

the sideshift base end supply hose from the internal

reeving or hose terminal ﬁtting. Cap the supply ﬁtting

and place the hose end in a drain.

3 Start the truck and actuate the SIDESHIFT LEFT lever

for 5 seconds:

If there is substantial hydraulic ﬂow out of the drain

hose, the sideshift cylinder is faulty and requires

service.

If there is no hydraulic ﬂow out of the hose, the

problem is not hydraulic. See Section 3.4, above.

•

WARNING: Before removing hydraulic

lines or components, relieve pressure in the

hydraulic system. Turn truck off and open

the truck auxiliary control valve(s) several

times in both directions.

FP1197.eps

Sideshift base

end hose

Back (Driver's) View

ROUBLESHOOTING

6052504

3.5 Electrical Circuit

(Solenoid Equipped Attachments)

Use the electrical schematic and diagram shown and

follow the steps below:

1 Check the control knob circuit fuse. Replace if

necessary.

2 Check for loose electrical connections at the truck

ignition switch, control knob button, solenoid coil

terminal 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 connect to the positive (+) side of the coil and

wiring as shown.

4 Disconnect the electrical leads from the solenoid coil

terminals. Use a voltmeter to determine if voltage

is present at the electrical leads when the button is

pressed.

If there is no current to the solenoid, troubleshoot

the electrical circuit for shorts.

If there is current to the solenoid, test for coil

continuity.

5 Test the coil continuity by placing an ohmmeter test lead

on each solenoid coil terminal (ohmmeter on Rx1 scale).

If there is an ohmmeter reading, the coil is good.

If the coil is good, but the solenoid does not 'click'

when the control knob button is pressed, the

solenoid cartridge may be jammed.

If there is no ohmmeter reading, the coil is defective.

Replace coil.

•

CL0258.eps

CL0257.eps

7.5 amp

Fuse

White

Black

Knob

Button

(Normally

Open)

Diode

Solenoid Coil

Diode

7.5 amp

Fuse

Black

White

Solenoid Coil

User supplied wire

6052504

ERVICE

4.1 Sideshift/ Fork

Position Frame

4.1-1 Removal and Replacement

NOTE: The Sideshift/Fork Position frame, with forks in

place, may be removed from the integral carriage bars to

service the sideshifter bearings.

6 For installation, reverse the above procedures with the

following exceptions:

Clean and inspect carriage bars for damage and

smoothness. Bars should be parallel and ends

should be ﬂush.

Clean all bearing areas of built-up dirt and grease.

Inspect bearings for wear and replace if necessary

(see Section 5.1-2).

•

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.

1 Disconnect the supply hoses to the fork positioner

valve and sideshift cylinder. Cap hoses and tag for

reassembly.

2 Remove the clevis pins and remove the sideshift

cylinder from the frame.

3 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).

4 Remove the lower retainers. For reassembly, tighten

capscrews to 120 ft.-lbs. (165 Nm).

5 Attach an overhead hoist and slings to the frame. Lift

away from the truck carriage.

NOTE: Bearings may remain on the carriage bars.

WARNING: Check the attachment weight

(located on the nameplate) to make sure the

overhead hoist is at least the rated capacity

of the attachment.

FP1198.eps

FP1199.eps

Upper

Bearings

Lower

Bearings

6052504

ERVICE

4.1-2 Bearing Service

1 Remove the Sideshift/Fork Position frame from the truck

carriage as described in Section 4.1-1.

2 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. Proper lower hook clearance requires

that all bearings be properly positioned on the top

carriage bar.

3 Remove and inspect the lower bearings. If any bearing

is worn to less than .4 in (10 mm) thickness, replace all

bearings.

4 For reassembly, reverse the above procedures with the

following exceptions:

Use grease to hold the upper bearings in position on

the carriage bar when replacing the frame.

Tighten lower bearing capscrews to 202 ft-lbs.

(274 Nm).

•

FP1200.eps

6052504

ERVICE

FP1205.eps

4.2 Mechanical Swing

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.

1 Disconnect the supply hoses to the swing cylinder. Cap

hoses and tag for reassembly.

2 Remove the clevis pin from the swing cylinder rod end.

3 Remove the clevis pins from the push rod assembly and

remove the push rod assembly from the wedges.

4 Remove the retainers from the cam pins and remove the

cam rollers from the frame.

5 Rotate the swing frame to one side. Slide out the

opposite side wedge.

6 Replace the upper and lower wedge bearings.

7 Reinstall wedge and rotate the swing frame to the

center.

8 For the opposite side, repeat steps 5 and 6.

9 For reassembly reverse the steps 1-4 with the following

exceptions:

If the swing frame slops or binds between the cam

rollers and wedges, adjust the push rod assembly

ends to extend or shorten.

•

Retainer

Cam Roller

Cam Pin

Push Rod

Assembly

Wedge

Bearings

6052504

ERVICE

4.3 Valves

NOTE: Not all valves are covered. Contact Cascade to

replace valve components.

4.3-1 Fork Position Valve Removal

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.

1 Disconnect the hoses from the valve. Tag hoses for

reassembly.

2 Disconnect the tubing at the bottom of the valve. Plug

the tubing ends.

3 Remove the capscrews fastening the valve to the frame

and remove the valve. For reassembly, tighten the

capscrews to 15 ft.-lbs. (22 Nm).

4 For reassembly, reverse the above procedures with the

following exceptions:

Service that valve as describe in Section 4.3-2.•

4.3-2 Fork Position Valve Service

IMPORTANT: Service the valve in a clean work area.

1 Remove the valve from the sideshift frame as described

in Section 4.3-1.

2 Remove the crossover relief valve cartridges from the

valve. Remove the O-rings and back-up rings from the

cartridges.

3 Remove the ﬁttings from the valve.

4 Clean all parts with solvent.

5 For reassembly, reverse the above procedures with the

following exceptions:

Replace O-rings and back-up rings on relief valve

cartridges as shown.

•

FP0731.eps

Crossover Relief

Valve Cartridge

Body

FP0730.eps

O-Rings

Back-Up Rings

FP1207.eps

Valve

Crossover Relief Cartridge

6052504

ERVICE

4.4 Sideshift Cylinder

4.4-1 Removal and Installation

NOTE: The following procedures can be performed with

the Sideshift/Fork Position frame mounted on the truck.

1 Disconnect the hoses from the cylinder ports and tag for

reassembly.

2 Remove the clevis pins from the cylinder ends and

remove the cylinder from the sideshifting frame.

3 For reassembly, reverse the above procedures with the

following exceptions:

Service the cylinder as described in Section 4.4-2.

Operate the sideshifter through several full cycles to

clear the system of any entrapped air. Check ﬁttings

and hoses for leaks.

•

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.

FP0773.eps

SIdeshift

Rod End

Sideshift

Base End

Clevis Pins

6052504

ERVICE

SS0088.eps

4.4-2 Cylinder Disassembly

NOTE: Use a soft-jawed vise for all cylinder disassembly

and assembly procedures.

1 Clamp the cylinder so that the vise jaws contact only the

extreme end of the cylinder base. Do not clamp on the

shell.

2 Threaded Retainers – Use a pin-type spanner wrench

or special socket to screw out piston retainer.

Snap Ring Retainers – Fully extend cylinder rod.

Remove the spiral snap from the retainer.

Tap the retainer into the shell approximately 2 in. (50

mm). Pry out the circular retaining ring from it's groove

on the opposite side from the split ends.

CAUTION: Do not scratch cylinder bore.

3 Remove the rod assembly from the cylinder shell.

4 Clamp the rod assembly in a vise on the clevis end as

shown.

CAUTION: Never clamp directly on the rod sealing

surface.

5 Remove the piston nut from the rod. Remove the piston

from the cylinder rod.

6 Place the piston or retainer in a soft-jawed vise to

remove seals. Pry the seals and O-rings up with a brass

seal removal tool (part no. 674424) and cut the seals

and O-rings to remove them.

CAUTION: Do not scratch the seal grooves.

FP0743.eps

SS0061.eps

Pin-Type

Spanner

Wench

Threaded

Retainer

Piston

Retainer

SS0059.eps

SS0336.eps

Spiral Snap Ring

NOTE: Service Tool

Kit 674424 includes

two double edged

brass tools to ease

seal and retaining

ring removal.

6052504

ERVICE

4.4-3 Cylinder Inspection

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. If they cannot be removed,

replace the part.

NOTE: Minor nicks are those that will not pass

hydraulic ﬂuid under pressure.

Inspect the outside of the shell for any deformities or

cuts that could impair performance or cause leaks

under pressure. If necessary, replace the part.

•

FP0738.eps

Piston Nut

Piston Shell

Rod Retainer

NOTE: Snap Ring

Retainer not shown

6052504

ERVICE

4.3-4 Cylinder Reassembly

1 Polish the piston and retainer chamfer angles with

400-grit emery cloth to ease seal installation.

2 Note the direction of the pressure seals. Pressure

seals must be installed with the lip toward the high

pressure side of the cylinder.

3 Lubricate new seals and O-rings with O-ring lube or

petroleum jelly.

4 Install a new pressure seal and back-up ring (if

equipped), wear ring (if equipped) on the piston. If

equipped, install a new O-ring in the piston.

5 Install a new pressure seal, wiper, O-ring and back-up

ring on the retainer, as shown.

6 Clamp the rod at the clevis end in a soft-jawed vise.

CAUTION: Do not clamp on the cylinder rod sealing

surface.

7 Threaded Retainers – Apply a thick ﬁlm of petroleum

jelly to the retainer ID. Install the retainer on the rod.

Use a seal loader as required to prevent damage to the

seals.

8 Install the piston on the rod. Tighten the nut as shown.

9 Apply a thick ﬁlm of petroleum jelly to the cylinder

shell and piston OD. Install the rod assembly into the

cylinder shell. Use a piston/seal loader as required to

prevent damage to the seals.

10 Threaded Retainers – Use a pin-type wrench to screw

the retainer into the shell. Tighten the retainer as shown.

Snap Ring Retainers – Tap retainer into shell far

enough to install the circular retaining ring in its groove.

Fully extend rod. Install the spiral snap ring on the

retainer.

SS0063.eps

SS0061.eps

SS0334.eps

1,4

Nut

Piston

Retainer

Piston/Seal

Loader

Piston/Rod Assembly

FP0739.eps

Wear Ring

Back-up Ring

O-Ring

Piston U-cup

Pressure Seal

Note Seal

Direction

Wiper

Back-up Ring

O-Ring

Pressure

Seal

Torque Piston Nut

200-250 ft.-lbs.

271-339 Nm.

Torque Retainer

350-400 ft.-lbs.

475-542 Nm.

TYPE 1

6052504

ERVICE

SS0822.eps

TYPE 2

TYPE 3

SS0823.eps

Piston U-cup

Pressure Seal

Note Seal

Direction

Pressure Seal

O-Ring

Back-up

Ring

Wiper

Wear Ring

Torque Piston Nut

100-120 ft.-lbs.

271-339 Nm

Retaining Ring

Spiral Snap Ring

Piston U-cup

Pressure Seal

Note Seal

Direction

Pressure Seal

O-Ring

Wiper

Wear Ring

Torque Piston Nut

100-120 ft.-lbs.

271-339 Nm

Retaining Ring

Spiral Snap Ring

O-Ring

6052504

ERVICE

5 Disconnect the hydraulic lines from the cylinder to be

removed. Plug the lines and cap the cylinder ports.

Tag lines for reassembly.

6 Disconnect the cylinder base end from the frame by

removing the cotter pin, locking cap and spherical nut.

Lift the cylinder away from the frame.

NOTE: Some cylinders have a cotter pin and clevis pin

assembly.

7 For reassembly, reverse the above procedures with the

following exceptions:

Service cylinder as described in Section 4.5-2.

Lubricate threads and spherical nuts with chassis

grease.

Install hex beveled washer on cylinder rod end.

NOTE: Beveled side faces lug, as shown.

Tighten spherical nuts to 160 ft.-lbs. (220 Nm).

NOTE: Nut tightens against hex washer, providing a

loose operating clearance. Lubricate anchor joints

with chassis grease.

Install locking caps using new cotter pins, if equipped.

Secure cylinder base ends with dowel pin, if

equipped.

•

4.5 Fork Position Cylinders

4.5-1 Removal and Installation

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.

2 Position the forks to mid range. Disconnect the cylinder

rod ends from the lugs by removing the cotter pin,

locking cap and spherical nut.

3 Retract the cylinder rods until they disengage from the

lugs.

4 Slide the forks to maximum frame width to provide room

to remove the cylinders.

WARNING: After completing this service

procedure, test the attachment through ﬁve

complete cycles. First test empty, then test

with a load to make sure the attachment

operates correctly before returning it to the

job.

WARNING: Before disconnecting

hydraulic lines, relieve pressure in the

attachment hydraulic system. Turn the

truck off and move the auxiliary control

levers several times in both directions.

FP1208.eps

Lug

Cotter Pin

Spherical Nut,

Locking Cap

Cylinder

Rod End

Hex Washer

(beveled side

toward lug)

Cotter pin

and clevis

pin assembly

shown

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Cascade J Series User manual

Cascade J Series User manual

Cascade J Series User manual

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