S ERVICE MANUAL

D-Series
Carton Clamps

This Manual applies to Attachments with model

numbers appearing below:
Model: 15D-CCS-XXX
20D-CRS-XXX
20D-ACS-XXX
25D-CCD-XXX
25D-CCS-XXX
35D-CCS-XXX
50D-CCS-XXX

Manual Number 228156-R1

cascade
corporation
Cascade is a Registered Trademark of Cascade Corporation
 C ONTENTS

Page Page
INTRODUCTION, Section 1 SERVICE, Section 5
Introduction, 1.1 1 Clamp Removal, 5.1 21
Special Definitions, 1.2 1 Arms, 5.2 22
INSTALLATION, Section 2 Arm Assemblies – Removal, Installation, 5.2-1 22
Truck System Requirements, 2.1 2 Contact Pad Rotation, Replacement, 5.2-2 23
Recommended Hydraulic Supply Options, 2.2 3 Contact Pad, Stabilizer Repair, 5.2-3 24
Clamp Installation, 2.3 4 Contact Pad Camber Adjustment, 5.2-4 25
PERIOD MAINTENANCE, Section 3 Arm Bearings – Replacement, Shimming, 5.2-5 26
100-Hour Maintenance, 3.1 9 Valve, 5.3 27
500-Hour Maintenance, 3.2 9 Valve Removal, Installation, 5.3-1 27
1000-Hour Maintenance, 3.3 9 Eliminating Regeneration Circuit, 5.3-2 27
2000-Hour Maintenance, 3.4 9 Valve Service, 5.3-3 28
TROUBLESHOOTING, Section 4 Cylinders, 5.4 30
General Procedures, 4.1 10 Cylinder Removal, Installation, 5.4-1 30
Truck System Requirements, 4.1-1 10 Cylinder Disassembly, 5.4-2 31
Tools Required, 4.1-2 10 Cylinder Inspection, 5.4-3 31
Troubleshooting Chart, 4.1-3 11 Cylinder Reassembly, 5.4-4 32
Troubleshooting Carton Clamp Loads, 4.1-4 12 Base Unit, 5.5 33
Plumbing, 4.2 14 Frame, Mounting Plate Replacement, 5.5-1 33
Hosing Diagram, Clamp Circuit, 4.2-1 14 Solenoid Valve, 5.6 35
Hosing Diagram, Sideshift Circuit, 4.2-2 15 Coil Service, 5.6-1 35
Hydraulic Circuit, 4.2-3 16 Valve Service, 5.6-2 35
Clamp Function, 4.3 17 SPECIFICATIONS, Section 6
Supply Circuit Test, 4.3-1 17 Specifications, 6.1 36
Clamp Circuit Test, 4.3-2 17 Hydraulics, 6.1-1 36
Valve Test, 4.3-3 18 Auxiliary Valve Functions, 6.1-2 36
Cylinder Test, 4.3-4 18 Truck Carriage, 6.1-3 36
Sideshift Function, 4.4 19 Torque Values, 6.1-4 37
Supply Circuit Test, 4.4-1 19
Sideshift Circuit Test, 4.4-2 19
Electrical Circuit, 4.5 20

i 228156 Rev. 1
 I NTRODUCTION

1.1 Introduction
This Manual provides the Installation, Periodic Mainte-
nance, Troubleshooting, Service and Specifications for
Cascade D-Series Carton Clamps.
In any communication about the Carton Clamp, 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 back of the baseplate.
IMPORTANT: All hoses, tubes and fittings on D-Series
Clamps are JIC.
NOTE: Specifications are shown in both U.S. and
(Metric) units.

c cascade

 
姞 ATTACHMENT CAPACITY
POUNDS INCH LOAD
SERIAL
NUMBER

 AT CENTER
CAPACITY OF TRUCK AND ATTACHMENT COMBINATION
CATALOG
NUMBER  WEIGHT
LBS.
MAY BE LESS THAN ATTACHMENT CAPACITY SHOWN
ABOVE. CONSULT TRUCK NAMEPLATE.
RECOMMENDED SYSTEM PRESSURE – 2000 PSI
ADDITIONAL
MAXIMUM SYSTEM PRESSURE – 2300 PSI
EQUIPMENT
ADDITIONAL
EQUIPMENT
cascade姞 corporation
FOR TECHNICAL FOR PARTS AND SERVICE
ASSISTANCE, CONTACT MANUALS, CONTACT
ADDITIONAL
800-227–2233 800-227–2233
EQUIPMENT PORTLAND, OREGON USA SPRINGFIELD, OHIO USA

CL1541.eps
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S/N S -0 1A
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Nameplate D-
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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 the 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 the job easier.

228156 Rev. 1 1
 I NSTALLATION

2.1 Truck System WARNING: Rated capacity of the truck/

attachment combination is a responsibility of
Requirements the original truck manufacturer and may be
less than that shown on the attachment
nameplate. Consult the truck nameplate.
D-Series Clamps will provide maximum operating capability
when the following requirements are met.

Truck Relief Setting

2000 psi (140 bar) Recommended
2300 psi (160 bar) Maximum
Truck Flow Volume ➀
Min. ➁ Recommended Max. ➂

15D, 25D, 4 GPM 7 GPM 7 GPM

35D, 50D (15 L/min.) (26 L/min.) (26 L/min.)

➀ Cascade D-Series Clamps are compatible with 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.
➂ Flow greater than maximum can result in excessive heating,
reduced system performance and reduced hydraulic system life.

GA0080.ill

Carriage Mount Dimension (A) ITA (ISO)

Minimum Maximum
A
Class II 14.96 in. (380.0 mm) 15.00 in. (381.0 mm) Carriage
Class III 18.68 in. (474.5 mm) 18.74 in. (476.0 mm) Clean and inspect carriage bars for
damage and smoothness. Repair any
GA0028.ill protruding welds or damaged notches.

Auxiliary Valve Functions

Check for compliance with ITA (ISO) standards:

Tilt
Forward Release

Sideshift
Hoist Down Left

GA0082.ill
Hoist Up Sideshift
Right
Tilt Clamp
Back

2 228156 Rev. 1
 I NSTALLATION

2.2 Recommended
Hydraulic Supply
Options
D-Series Clamps provide the best performance with one of
the hydraulic supply arrangements shown below. Refer to
Cascade Hose and Cable Reel Selection Guide, Part No.
212119, to select the correct hose reel for the mast and truck.
The hose and fitting requirements are:
• CLAMP function – No. 8 with a minimum internal diameter
of 13/32 in. (10 mm).

• SIDESHIFT function – No. 6 with a minimum internal

diameter of 9/32 in. (7 mm).

Non-Sideshifting
A or B
RH or LH THINLINE™ 2-port hose reel group.
OR
C Mast single internal hose reeving group.

A B Sideshifting
A and B
RH and LH THINLINE™ 2-port hose reel groups.

C OR
C Mast double internal hose reeving group.

Sideshifting with Solenoid

A 6-N-1 cable/hose reel group.
OR
A and C
GA0033.ill
Cable reel and single internal hose reeving group.

228156 Rev. 1 3
 I NSTALLATION

2.3 Clamp Installation

Follow the steps shown to install the Clamp on the truck.
Read and understand all WARNING and CAUTION
statements. If you don't understand a procedure, ask
your supervisor, or call the nearest Cascade Service
Department for assistance.

1 Prepare Attachment
A Remove banding.
B Remove bolt-on lower
mounting hooks (if equipped).

Bolt-On
B Lower Hooks

CL1088.ill

2 Unlock Quick-Change lower mounting hooks

A Remove pin and drop hooks into unlocked position.
B Re-install pin in lower hole.
NOTE: Guides can be reversed to
A change hook-to-carriage clearance
Guide (See lower hook installation, Step 6).

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14
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67
C-
5/8-in. (16 mm)
B LH lower offset on top
Hook provides max.
clearance. CL0097.ill
Pin (Unlocked
Position)
Tighten Capscrews to 110 ft.-lbs. (150 Nm)

4 228156 Rev. 1
 I NSTALLATION

3 Prepare Hoses
A Determine hose lengths required for hydrau-
lic supply configuration of truck.
B Cut hoses to length, install end fittings or WARNING: Do not remove the special
Quick-Disconnect coupling kits. fitting from the valve CLAMP (CL) port. Use
a 6-8 reducer for No. 6 hose connection.

Sideshift
Sideshift Left Right Open Clamp

CL1053.ill
CL1098.ill

Sideshifting – Double Hose Reels Sideshifting – Double Internal Hose Reeving

SSR / Clamp
(PRESSURE Port)

SSL / Open
(TANK Port)

Solenoid
Cable

CL0902.ill CL1099.ill

Sideshifting with Solenoid – IHR and Cable Reel Sideshifting with Solenoid – 6-N-1 Cable/Hose Reel

4 Flush hydraulic supply hoses

A Install hoses using union fittings.
B Operate auxiliary valves for 30 seconds.
C Remove union fittings.

GA0092.ill

228156 Rev. 1 5
 I NSTALLATION

5 Mount Clamp on truck carriage

A Center truck behind Carton Clamp.
A
B Tilt forward and raise carriage into position. B
C Engage upper mounting hooks with carriage.
Make sure centering tab engages a notch on
the top carriage bar. NOTE: Centering tab
can be oriented in 4 different positions to
center the Clamp (see illustration).
D Lift Clamp 2 in. (5 cm) off pallet.

CL0241.ill

ITA Class II – 0.60–0.66 in. (15–17 mm)

ITA Class III – 0.72–0.78 in. (18–20 mm)

C C
Notch
Engage Tab
C Centering Tab
Positions

1 2

ITA Class II – 0.32–0.36 in. (8–9 mm)

ITA Class III – 0.39–0.43 in. (10–11 mm) 3 4

Truck Upper CL1097.ill

Carriage Bar
CL0242.ill

6 Install and engage lower hooks

QUICK-DISCONNECT TYPE BOLT-ON TYPE

Inspect hooks for
excessive clearance.
(Reverse guides to reduce
Lower
Lower clearance – See Step 2.)
Carriage
Carriage
Bar
Bar

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Slide hook up
to engage 67
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C-
bar, install
pin in upper
hole (locked.) 3/16 in.
(5 mm)
Max.

SD0065.ill SD0066.ill
Tighten Capscrews: 110 ft.-lbs. (150 Nm)

6 228156 Rev. 1
 I NSTALLATION

7 Connect hoses prepared in

Step 3 to Attachment

CL1100.ill
CL1098.ill

Double Hose Reels Hydraulic Supply Internal Hose Reeving Hydraulic Supply

8 Install solenoid control knob or

pushbutton switch – (solenoid-equipped)
Pushbutton
NOTE: Shrink tubing
may be removed around
Snap Ring Switch
button as desired
Indicator
Plate

Cable
PRESS
BUTTON SIDESHIFT Ties 3 in. (60 mm)
Button TO CLAMP

toward Typical
Foam Tape
driver

Heat-Shrink Tubing
Nut

AC0898.ill
Adapter
Control Levers
AC0897.ill

9 Install wiring –
(Solenoid-equipped units) Control Lever Knob
with Pushbutton Diode

Diode
Solenoid Coil
Knob
7.5-Amp Fuse Button White Black
White Black 7.5-Amp
Fuse

CL0258.ill CL0257.ill

User-supplied wire Solenoid Coil

Solenoid Coil

228156 Rev. 1 7
 I NSTALLATION

10 Cycle Clamp functions

• With no load, cycle each Carton Clamp
function several times.
WARNING: Make sure all personnel are
clear of the Clamp during testing.

• Check for operation in accordance with

ITA (ISO) standards.
• Clamp and lift a maximum load. Side-
shift left and right. Check for proper
clamp force, equal arm movement and
adequate speed.
• Check for leaks at fittings, valve, and
cylinders.

NON-SIDESHIFTING CLAMPS SIDESHIFTING CLAMPS SIDESHIFTING CLAMPS WITH

A Release Arms A Sideshift Left
SOLENOID VALVE
B Clamp Arms B Sideshift Right A Sideshift Left
C (not used) C Release Arms A Release Arms
D (not used) D Clamp Arms (press knob button)
B Sideshift Right
B Clamp Arms
(press knob button)

B
A
C CL0085.ill
B
D A
C
A CL0461.ill
A CL0085.ill

B A B A

AUXILIARY VALVE
FUNCTIONS
Tilt Forward
Hoist Down

A C

B D
GA0005.ill

Hoist Up Tilt Back

8 228156 Rev. 1
 P
T ERIODIC MAINTENANCE
ROUBLESHOOTING

3.1 100-Hour WARNING: After completing any service

procedure, always test the Clamp through
Maintenance five complete cycles. First test the Clamp
empty, then test with a load to make sure the Clamp
Every time the lift truck is serviced or every 100 hours of operates correctly before returning it to the job.
truck operation, whichever comes first, complete the
following maintenance procedures on the Clamp:
Application Lubrication
• Check for loose or missing bolts, worn or damaged
supply hoses and hydraulic leaks. General Products Chassis Grease w/Moly

• Inspect the cylinder anchor nuts for proper connection Food Industry Chassis Grease
and tightness. Lubricate with chassis grease. (DuBois FGG-2)

• Lubricate the four arm bars (see Table). Dry Lube Conditions Slip Plate No. 3
(Superior Graphite)
• Check decals and nameplate for legibility.
• Check contact pads for wear, nicks, distortion.
Cylinder Rod End Anchors

3.2 500-Hour
Maintenance
After each 500 hours of truck operation, in addition to the
100-hour maintenance, perform the following procedures:
• Check the lower mounting hook engagement clearance
with the truck carriage bar:
Quick-Change Hooks – 3/32 in. (2.5 mm) min.
3/16 in. (5 mm) max.
Bolt-On Hooks – Tight against lower carriage bar.
If adjustment is necessary, refer to Installation Step 6.
Tighten lower hook capscrews to 110 ft.-lbs. (150 Nm).
CL1101.ill
• Check Clamp force (Cascade Clamp Force Indicators
200645, 680072, 830141 are available for this test). Frame Bolt-On Lower Quick-Change Upper
• Perform Clamp Circuit Pressure Test (see Section 4.3-2). Capscrews Mounting Hook Lower Mounting Mounting
(from frontside) Hook Hook
Back (Driver's) View

3.3 1000-Hour Arm Bar Bearings

Maintenance
After each 1000 hours of truck operation, in addition to the
100 and 500-hour maintenance, perform the following
procedures:
• Inspect arm bearings for wear. If any bearing is worn to
less than .040 in. (1 mm) thickness, replace all bearings
(see Section 5.2-5).
• Tighten contact pad mounting bolts to 50 ft.-lbs. (65 Nm).
• Inspect and replace wear tiles if worn (see Section 5.2-3).
• Inspect pad pivot pins and bushings and replace if worn
(see Section 5.2-3).

3.4 2000-Hour
Maintenance CL1115.ill

After each 2000 hours of truck operation, in addition to the

100, 500 and 1000-hour maintenance, perform the following: Contact Pad Cylinder Head End Cylinder Rod End
• Replace all arm bar bearings (see Section 5.2-5). Mounting Bolts (6) Anchor Nut (2) Anchor Nut (2)

• Tighten frame capscrews to 75 ft.-lbs. (100 Nm). Left Side

228156 Rev. 1 9
 T ROUBLESHOOTING

4.1 General Procedures WARNING: Before servicing any

hydraulic component, relieve pressure in
the Attachment system. Turn the truck off
4.1-1 Truck System Requirements and move the truck auxiliary control lever
several times in both directions.
• Truck hydraulic pressure should be within the range
shown in Specifications, Section 6.1. PRESSURE TO After completing any service procedure, always test
THE CLAMP MUST NOT EXCEED 2300 psi (160 bar). the Clamp through several cycles. First test the
Clamp empty to bleed any air trapped in the system to
• Truck hydraulic flow should be within the range shown
the truck tank. Then test the Clamp with a load to be
in Specifications, Section 6.1.
sure it operates correctly before returning to the job.
• Hydraulic fluid supplied to the Clamp must meet the
Stay clear of the load while testing. Do not raise the
requirements shown in Specifications, Section 6.1.
load more than 4 in. (10 cm) off the floor while testing.

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

671477 (20 GPM – 75 L/min)
(2) No. 8-12 JIC/
O-Ring Flow Meter

GA0013.ill

(2) No. 6-8 JIC Reducer

4.1-2 Tools Required
In addition to a normal selection of mechanic's hand tools,
the following are required:
• InLine Flow Meter Kit: Pressure Gauge Kit: 671212
10 GPM (37 L/min) – Cascade Part No. 671476.
Pressure No. 6 and No. 8
OR
Gauge* No. 6-6 Hose* JIC Swivel Tee
20 GPM (75 L/min) – Cascade Part No. 671477.
• Pressure Gauge Kit:
5000 psi (345 bar) – Cascade Part No. 671212.
GA0014.ill
• Assorted fittings, lines, drain hoses and quick-discon-
nect couplers as required.
No. 4-6 Pipe/JIC* No. 6-8 JIC No. 4, No. 6*
Reducer and No. 8
JIC/O-Ring

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)* AC0127.ill
No. 6 (Part No. 678591)

* NOTE: Diagnostics Kit 394382

includes items marked.

10 228156 Rev. 1
 T ROUBLESHOOTING

4.1-3 Troubleshooting Chart

Determine All The Facts – It is important to gather all
the facts about the problem before beginning any service
procedures. The first step is to talk to the equipment
operator. Ask for a complete description of the malfunc-
tion. Guidelines below and on the following pages can
then be used as a starting point to begin troubleshooting.

Clamp Circuit
• Clamp drops load after it has been picked up.
• Clamp will not carry load up to its rated capacity.
• Clamp arms have uneven travel.
• Clamp arms travel slowly.
• Clamp arms will not move.
To correct these problems, see Section 4.3.
NOTE: Some Clamps have a regenerative
hydraulic circuit that causes the arms to open at a
faster speed than when closing. This is a normal
Clamp function.

Sideshift Circuit
• Clamp drops load while sideshifting.
• Clamp drops load at end of sideshift stroke.
• Clamp sideshifts left and right at different speeds.
• Clamp will not sideshift.
To correct these problems, see Section 4.4.

Carton Clamp Loads

• Front stack of load tilts out.
• Lower tier of load bridges down or slides out.
• Lower tier of load is creased.
To correct these problems, see Section 4.1-4.

228156 Rev. 1 11
 T ROUBLESHOOTING

IMPORTANT: Before adjusting contact pad camber to

4.1-4 Carton Clamp Loads solve handling problems, make sure the Clamp is being
used correctly and is not damaged. Use the Trouble-
shooting procedure shown and, if necessary, adjust the
contact pad camber using a Cascade Shim Service Kit.

IF FRONT STACK OF
LOAD TILTS OUT:

Re-clamp Check for bent

1 load against
backrest
stabilizers;
straighten or
replace
3

Check for bent

4 pads; straighten
or replace
Assure center of
CL0086.ill
load is between
pad pivot and
backrest
2
IF LOWER TIER OF LOAD BRIDGES
DOWN OR SLIDES OUT:
2
4 Check
hydraulics
Check for bent for low
pads; straighten supply
or replace pressure

CL0087.ill
Add or increase
positive camber
(See Section 5.2-4)
Check for worn

3 lower surfaces;
rotate pads 180 ° Re-clamp load
5
and exchange
sides or replace 1 so bottom edge
is even with
bottom of pads

12 228156 Rev. 1
 T ROUBLESHOOTING

4.1-4 Carton Clamp Loads (Continued)

IF LOWER TIER OF LOAD

IS CREASED:
Re-clamp load
2 squarely
between pads

3
Check
4 hydraulics
for high
supply
Check for bent pressure
pads; straighten
or replace
CL0088.ill

Re-clamp load Add or increase

1 so bottom edge
is even with
bottom of pads
negative camber
(See Section 5.2-4) 5

TYPICAL PAD CAMBER FOR HANDLING CARTON CASE LOADS

Front View – Pads

CANNED / BOTTLED / DENSE CASE GOODS Neutral-to-Positive

SOFT CASE GOODS Neutral-to-Negative

APPLIANCE / LARGE CASE GOODS Neutral-to-Negative

Start with neutral,

OTHER LOADS look for creases
and adjust camber CL0093.ill
as required.

228156 Rev. 1 13
 T ROUBLESHOOTING

4.2 Plumbing
4.2-1 Hosing Diagram, Clamp Circuit

Cylinders (2)
SOLENOID ADAPTION

To
Cylinders

Solenoid Valve
(Energized)

CL
CLAMP CLAMP Port
Port
CL OP
OPEN Port
Attachment T
Valve Tank Port
P
OP Pressure Port
OPEN
Port Truck Auxiliary Valve
(with pushbutton)

CL0880.eps

Hose Reel or Hose/Cable Reel

Internal Reeving or Internal Reeving
Truck Auxiliary
Valves

CLAMP ARMS RELEASE ARMS

Pressure:
Return:

14 228156 Rev. 1
 T ROUBLESHOOTING

4.2-2 Hosing Diagram, Sideshift Circuit

Cylinders (2)
SOLENOID ADAPTION

To
Cylinders

Solenoid Valve
(De-energized)

SSL
SSR
SSR

T
Hose Reel or Tank Port
Internal Reeving SSL

P
Attachment Pressure Port
Valve

Truck Auxiliary Valve

(with pushbutton)
CL0882.eps

Hose/Cable Reel
Truck Auxiliary or Internal Reeving
Valves

SIDESHIFT LEFT SIDESHIFT RIGHT

Pressure:
Return:
Slave:

228156 Rev. 1 15
 T ROUBLESHOOTING

4.2-3 Sideshifting Clamps –

Hydraulic Circuit D-SERIES CARTON CLAMP

Cylinders (2)

SSL

Clamp
SIDESHIFT Check
Cross-Over Relief Valve
(if equipped) SSR

Arm-activated
stop valves
(Appliance
Sideshift
Clamps only)
Check Attachment
Valves (2) Valve

Poppet
Reliefs (2)

Regeneration
Directional
Valve

SOLENOID ADAPTION

CLAMP
Flow Divider/Combiner
Relief
(if equipped)

Solenoid Valve OP CL
G OPEN Port CLAMP Port
T P Test
Tank Pressure Port
Port Port

2-Port Hose/Cable Reel 2-Port Hose Reels (2) or

Internal Hose Reeving
Truck Auxiliary Valve
(Sideshift/Clamp) Truck Auxiliary Truck Auxiliary
Valve Valve (CLAMP/
(SIDESHIFT) RELEASE)

CL1046.ill Truck Truck

Pump Truck Relief Valve Tank

CL0884.ill

16 228156 Rev. 1
 T ROUBLESHOOTING

4.3 Clamp Function WARNING: Before removing hydraulic

lines or components, relieve pressure in the
There are five potential problems that could affect the Attachment hydraulic system. Turn the
CLAMP function: truck off and move the auxiliary control
lever several times in both directions.
• Incorrect load handling. Refer to Operator’s Guide for
suggested procedures.
• Incorrect hydraulic pressure or flow from the lift truck. Flow Meter
• External leaks.
• Defective solenoid coil or valve (if equipped).
2
• Worn/defective cartridge valves or cylinder seals.

4.3-1 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 6.1. PRESSURE TO THE
CLAMP MUST NOT EXCEED 2300 PSI (160 bar).
2 Check the flow volume at the carriage hose terminal.
Flow must be within the range shown in Specifications,
Section 6.1.
3 Close the arms fully, holding the lever in the CLAMP
position for a few seconds. Release the lever and check
for external leaks at fittings, hoses and valve.
Back View CL1045.ill

4.3-2 Clamp Circuit Pressure Test

1 Press the solenoid button (if equipped) and listen for a
'click' at the solenoid valve. If no sound is heard, first
check the fuse, wiring and coil (see Section 4.5). Assure
that the valve is not jammed (see Section 5.6).
IMPORTANT: Solenoid-operated valves must be
plumbed so that the solenoid is energized during the
CLAMP/RELEASE function.
2 Position the arms to mid-stroke. Turn the truck off and
connect a 5000 psi (345 bar) pressure gauge to the 'G'
test port at the back of the main valve.
IMPORTANT: Before installing pressure gauge, move
the CLAMP lever back and forth to relieve pressure

3
trapped by the system check valves.
Start the truck and close the arms fully, holding the lever
in the CLAMP position for a few seconds.
Pressure Gauge
on 'G' test port
2
4 Release the lever and watch the pressure gauge:
• 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 (see
Section 4.3).
• If the pressure drop is more than 150 psi (10 bar)
initially, and additional drop exceeds 25 psi (1.7 bar)
per minute, Turn the truck off and proceed to the valve
3
test in Section 4.3-3.
NOTE: Above pressure drop based on operating CL1049.ill
pressure at 2300 psi Max.
Front View

228156 Rev. 1 17
 T ROUBLESHOOTING

4.3-3 Valve Test

1 Remove the bumper (see Section 5.4-1, Step 2).
2 Disconnect the hydraulic supply lines at the rod ends of
both cylinders. Cap the ports and plug the lines.
3 Start the truck and hold the lever in the CLAMP position
for a few seconds.
4 Release the lever and watch the pressure gauge:
• If the pressure drop is more than 150 psi (10 bar)
initially, and additional drop exceeds 25 psi (1.7 bar)
per minute, the valve is faulty and requires service
(see Section 5.3.)
• 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, one or both cylinders require
service. Turn the truck off and proceed to the
cylinder test.

CL0886.ill
2
Rod end supply lines.
(plug lines and cap ports)

4.3-4 Cylinder Test

1 Connect one of the rod end hydraulic lines to its cylinder.
IMPORTANT: The other line and cylinder port must
remain plugged.
2 Start the truck and hold the lever in the CLAMP position
for a few seconds.
3 Release the lever and watch the pressure gauge:
• If the pressure drop is more than 150 psi (10 bar)
initially, and additional drop exceeds 25 psi (1.7 bar)
per minute, the cylinder connected to the valve is
faulty and requires service (see Section 5.3).
• 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 other cylinder is faulty and
requires service (see Section 5.4).
It is recommended that a similar pressure test be
performed on the other cylinder before servicing.

CL1050.ill
1
Rod end supply
line connected to
one (1) cylinder.

18 228156 Rev. 1
 T ROUBLESHOOTING

4.4 Sideshift Function WARNING: Before removing hydraulic

lines or components, relieve pressure in
There are five potential problems that could affect the the Attachment hydraulic system. Turn the
sideshift function: truck off and move the auxiliary control
valve lever several times in both directions.
• Incorrect load handling. Refer to the Operator’s Guide
for suggested procedures.
• Incorrect hydraulic pressure or flow from the lift truck.
• External leaks.
• Defective solenoid coil or valve (if equipped).
Flow Meter
2
• Worn/defective valve, cartridges or cylinder seals.

4.4-1 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 6.1. PRESSURE TO THE
CLAMP MUST NOT EXCEED 2300 PSI (160 bar).
2 Check the flow volume at the carriage hose terminal.
Flow must be within the range shown in Specifications,
Section 6.1.
3 Sideshift left or right fully, holding the lever in the
SIDESHIFT position for a few seconds. Release the lever
and check for external leaks at fittings, hoses and valve.
Back View CL1048.ill

4.4-2 Sideshift Circuit Test

1 Press the solenoid button (if equipped) and listen for a
'click' at the solenoid valve. If no sound is heard, first
check the fuse, wiring and coil (see Section 4.5).
Assure that the valve is not jammed (see Section 5.6).
IMPORTANT: Solenoid-operated valves must be
Pressure Gauge
on 'G' test port
2
plumbed so that the solenoid is not energized during
the SIDESHIFT function.
2 Position the arms to mid-stroke. Turn the truck off and
connect a 3000 psi (200 bar) pressure gauge to the 'G'
gauge port on the main valve.
3 With a maximum load, sideshift left and hold the lever
for a few seconds.
4 Release the lever and watch the pressure gauge:
• If the pressure drop is more than 150 psi (10 bar)
initially, and additional drop exceeds 25 psi (2 bar)
per minute, the SIDESHIFT LEFT check valve
cartridge may be faulty. Replace the cartridge.
• If the pressure drop is less than above, sideshift
right and hold the lever for a few seconds.
5 Release the lever and watch the pressure gauge:
• If the pressure drop is more than 150 psi (10 bar)
initially, and additional drop exceeds 25 psi (2 bar)
per minute, the SIDESHIFT RIGHT check valve
cartridge may be faulty. Replace the cartridge.
• If the pressure drop is less than 150 psi (10 bar) CL0887.ill
initially, and additional drop does not exceed 25 psi
(1.7 bar) per minute, the problem is not hydraulic Sideshift Left Sideshift Right

6
(see Section 4.4).
If pressure still drops at end of sideshift stroke, adjust
sideshift relief cartridges for lower pressure.
4 Check Valve
Cartridge
Front View
3 Check Valve
Cartridge

228156 Rev. 1 19
 T ROUBLESHOOTING

4.5 Electrical Circuit

(Solenoid-equipped Clamps)
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
terminals 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 be connected to 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
depressed.
• 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 for 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 depressed, the
solenoid cartridge may be jammed. Refer to
Section 5.6.
• If there is no ohmmeter reading, the coil is defective
and should be replaced. Refer to Section 5.6.

Control Lever Knob

with Pushbutton Diode

Diode
Solenoid Coil
Knob
7.5-Amp Fuse Button White Black
White Black 7.5-Amp
Fuse

CL0258.ill CL0257.ill

User-supplied wire Solenoid Coil

Solenoid Coil

20 228156 Rev. 1
 S ERVICE

Clamp Removal
2
5.1
1 Position the Clamp's arms to the width of the frame.

WARNING: Before removing hydraulic

lines or hoses, relieve pressure in the Sideshift Left Sideshift Right Open Clamp
Attachment hydraulic system. Turn the
truck off and move the auxiliary control
lever several times in both directions.

2 Disconnect and plug the hydraulic supply hoses to the

Clamp. Tag hoses for reassembly.
3 Disconnect the lower hooks:
Quick-Change Hooks – Remove the locking pins and
drop the hooks into the unlocked position. Replace the
pins in the lower holes. For reassembly, remove the
pins and slide the hooks up to the locked position.
Replace the pins in the top holes.
Back (driver's) View
Bolt-On Hooks – Remove the capscrews and mounting CL0901.ill
hooks. For reassembly, tap hooks tight against carriage
bar and tighten the capscrews to110 ft.-lbs. (150 Nm).
4 Lower the Clamp onto a pallet. Tilt the mast forward and
lower the carriage to disengage the upper hooks.
5 For Clamp installation, reverse the above procedures
except as follows:
• Refer to Section 2.3 for complete installation
procedure.

4
CL1086.ill

3 QUICK-CHANGE LOWER HOOKS BOLT-ON LOWER HOOKS

Guide Carriage Bar

RC0368.ill
RC0367.ill
®

d e
ca ST
s JU
ca AD
Left Hook
1
14-
55
67
C-

Left Hook

Locking Pin
(Unlocked Position)

228156 Rev. 1 21
 S ERVICE

5.2 Arms
5.2-1 Arm Assemblies –
Removal and Installation
The following procedures can be performed with the Clamp
mounted on the truck.
1 Position the arms to frame width. Lower the Clamp to
position the contact pads 1/2 in. (13 mm) above the floor. WARNING: Make sure the hoist used to
remove the arm has a rated capacity of at
2 Disconnect the cylinder rod end anchor. least 1000 lbs. (450 kg.)
For reassembly, assemble the parts as shown. Install a
new cotter pin. Tighten the rod end nut to 160 ft.-lbs.
(220 Nm). NOTE: Rod end nut tightens against hex
washer, providing a loose operating clearance for the
anchor joint. Lubricate with chassis grease.
3 Attach an overhead hoist and chains to the arm assem-
bly. Position the chain clear of the arm bearing surfaces.

4
CAUTION: If removing arm with contact pad, use a lift
eyebolt on the contact pad to stabilize the assembly.
Retract the cylinder rod until it disengages from the arm.
3
5 Slide the arm assembly out of the frame. Do not damage
the bearings when removing the arm.
6 For reassembly, reverse the above procedures with the
following exceptions:
• Inspect the upper and lower bearing strips for wear
(Refer to Arm Bearing Replacement and Shimming,
Section 5.2-5).
• Inspect the arm bar bearing contact and chamfered
areas for nicks or damage. Break any sharp edges
and polish with 400-grit emery paper as necessary.
• Apply chassis grease to the bearing contact areas.

2
Arm Lug Cotter Pin

Cylinder
Rod End

1/2-in. (13 mm)

Above Floor
CL1055.ill

Rod End Nut, Hex washer (beveled

Locking Cap side faces arm lug)
CL0458.ill

22 228156 Rev. 1
 S ERVICE

5.2-2 Contact Pad –

Replacement or Rotation
The following procedures can be performed with the Clamp
mounted on the truck.
NOTE: Contact pad surfaces that are worn or damaged
over the entire pad area will require pad replacement. If
only the lower surface is worn, the pads can be rotated
180 degrees and swapped side-for-side.
1 Extend the arms to frame width. Lower the Clamp so that
the contact pads just touch the floor.
2 Remove the stabilizer filler blocks. For reassembly,
tighten the capscrews to 18 ft.-lbs. (25 Nm).
CAUTION: Do not overtighten capscrews.
3 Remove the capscrews and nuts fastening the contact
pad to the stabilizer. Remove the contact pads. For
reassembly, tighten the capscrews to 50 ft.-lbs. (65 Nm).
4 Install new pads, or rotate the pads 180 degrees and
swap side-for-side and reinstall.
5 For reassembly, reverse the above procedures with the
following exceptions:
• Inspect contact pad mounting holes for wear or
elongation. Repair using Hole Service Kit 676841.

Contact Pad Filler

Stabilizer Blocks

3 2
Arm

4
5 CL0371.ill

228156 Rev. 1 23
 S ERVICE

5.2-3 Contact Pad and Stabilizer

Repair
The following procedures can be performed with the arms
in place and the Clamp mounted on the truck.
1

2
Extend the arms to frame width. Lower the contact
pads so that they just touch the floor.
Remove the contact pad from the Clamp as described
3
in Section 5.2-2.
3 Inspect the contact pad for flatness and replace or
straighten as required. Inspect the contact pad
mounting holes for wear or elongation. Repair using
Hole Service Kit 676841.
4 Remove the stabilizer from the arm by removing the two
pin retainers and pivot pins. For reassembly, tighten
the retainer capscrews to 15 ft.-lbs. (20 Nm).
5 Inspect the stabilizer pivot pin and bushings for wear
and replace as necessary. Check for pad
flatness within ±
CAUTION: Use a bushing driver to replace the 1/8 in. (3 mm)
bushings in the arm. Do not damage the bushing I.D.
6 Inspect the wear tiles on the bottom front surface of
each stabilizer for wear and replace as necessary.
New wear tiles (Part No. 208860) can be ordered from CL0405.ill
Cascade Parts Sales, 888-CASCADE (227-2233).
IMPORTANT: If wear extends into the stabilizer bottom
surface, build up with weld and grind flat to within 1/16 Pin Retainers,

7
in. (1.5 mm) along the full length of the stabilizer.
Weld new wear tiles to the bottom front surface of
Bushings (2)

5 4 Pivot Pins (2)

each stabilizer using AWS E-7018, 3/16-in. (5 mm)

diameter rod.
NOTE: Weld only to the steel backing of the wear tile.
Weld will not stick to the wear tile hard surfacing.
8 Grind the weld along the inside edge of the stabilizer
flush with the inside surface. The contact pads must
bolt up flat against the stabilizer without interference
from the welds.
9 For reassembly, reverse the above procedures.

Wear Tile
Hard Surface
1/16 in. (1.5 mm) CL0406.ill
Weld 1/4-in. (6 mm)
fillet around tile
Grind weld flush with

7 8
stabilizer surface

6
Wear Tile
2.5 in. (64 mm)
Inside
Surface

Bottom View Ref: S-4221

24 228156 Rev. 1
 S ERVICE

5.2-4 Contact Pad Camber

Adjustment
The following procedures can be performed with the arms Position contact
in place and the Clamp mounted on the truck. pads to frame width
1

2
Extend the arms to frame width. Lower the contact
pads so that they just touch the floor.
Measure the distance between the pads in two places:
at the bottom center (in line with the pivot pins), and
1 Positive
Camber

29 in. (73 cm) above the pad bottom centers as shown.

3
The difference between the two measurements is the
pad camber.
Determine the camber adjustment required.
3
(See Troubleshooting Section 4.1-4.)
29 in. (73 mm)
4 Loosen the contact pad capscrews and nuts.
Negative
NOTE: It is not necessary to remove the capscrews
Camber
and nuts to insert the shims.
CL0095.ill
5 Install shims as required. Installing shims at the bottom
and middle of the pad provide positive camber.
Installing shims at the top and middle of the pad
provide negative camber.
CAUTION: Use an equal number of shims on each
contact pad. Pad camber must be the same on both
2 Measure from
pad centers

sides of the Clamp for proper load handling.

FOR MINIMUM
POSITIVE CAMBER:

Contact Pad
One Each
Top Shim 1/16-in. (1.6 mm)
Middle Shim

5 One Each
1/8-in. (3.2 mm)
Bottom Shim

4
Pad Capscrews
and Nuts
FOR MAXIMUM
(6 per side)
POSITIVE CAMBER:

Two Each
Arm 1/16-in. (1.6 mm)
CL0089.ill
Middle Shims

5
Middle Shim
Two Each
1/8-in. (3.2 mm)
Pad Stabilizer
5
Bottom Shim CL0556.ill
Bottom Shims

NOTE: For negative camber adjustment,

Front Views install thick shims at top of pad.

228156 Rev. 1 25
 S ERVICE

5.2-5 Arm Bearings – Replacement

and Shimming
The following procedure can be performed with the Clamp
mounted on the truck.

1 Remove the arm assemblies from the Clamp as

described in Section 5.2-1.
2 Remove the bearing spacer located between the upper

3
and lower bearings in each arm slot.
Pry the bearings out of the frame with a screwdriver
and slide outward.
2
Bearing Spacer

CAUTION: Do not gouge aluminum frame surfaces. Bearings

CL1296.eps

Boss
3 Innermost Boss (push to
disengage bearing)

Slide outward
Aluminum Frame

CL0890.ill
Slide outward
Bearing Spacer

4 Use dial calipers to measure dimension A of both ends

of arm bearing openings in upper and lower aluminum Aluminum Frame
frames.
5 Place an upper and lower bearing on each arm bar.
Measure dimension B.
4 Arm Bar
6 Determine the shim thickness required to leave .015 in.
(.38 mm) clearance between each set of bearings and A
each arm bar opening. Use the following formula:

[A – clearance] – B = shim thickness required

Example: A = 2.165 in. (54.99 mm)
B = 2.085 in. (52.96 mm)
U.S.: [2.165 – .015] – 2.085 = .065 in.
Metric: [55.99 – .38] – 52.96 = 1.65 mm
Pink shim = .015 in. (.38 mm)
Yellow shim = .020 in. (.50 mm)
Bearings
B
5
Use 3 yellow shims to come closest to the Upper Bearing
required clearance: .020 in. x 3 = .060 in.
(.50 mm x 3 = 1.50 mm)
.080 in.
7 Decrease the width of the bearing spacer to the (2 mm)
dimension shown to provide room to install the
shimmed bearings.
8 Tape the required shims for each arm bar opening to
the lower bearings only. Install the bearings and
bearing spacers.
7
Bearing
Spacer
9 Lubricate the bearings with light grease.
Shim

8
CL0891.eps
10 For reassembly, reverse the above procedures with the
following exceptions: Lower Bearing NOTE: Place under
lower bearing only.
• Manually check arms for freedom of movement.
26 228156 Rev. 1
 S ERVICE

5.3 Valve
Valve Removal and
5.3-1
Installation SSR
SSL 3 CLAMP
OPEN

The Clamp must be removed from the truck to service the

valve.
1 Remove the Clamp from the truck as described in
Section 5.1.
2 Disconnect the cylinder tubes/hoses from the bottom of
the Valve. Plug the ends and tag for reassembly.
3 Disconnect the supply hoses from the sides of the

4
Valve. Plug the hose ends and tag for reassembly.
Remove the capscrews fastening the Valve mounting
plate to the frame. For reassembly, tighten the 4 CL1008.ill
5
capscrews to 15 ft.-lbs. (20 Nm).
Mounting Plate
5 Remove the two (2) flathead capscrews fastening the Capscrews

2
valve to the mounting plate. For reassembly, tighten Back (Driver's) View
the capscrews to 15 ft.-lbs. (20 Nm).
6 For reassembly, reverse the above procedures with the Cylinder Hoses (4)
following exceptions:
• Service the Valve as described in Section 5.3-3.

5.3-2 Eliminating Regenerative

Circuit (fast arm opening)
The regenerative circuit can be deactivated to reduce the
CL1015.ill
arm opening speed. This procedure can be accom-
plished with the Clamp mounted on the truck. CL

OP
1 Open the Clamp arms to frame width.

WARNING: Before removing hydraulic

lines or components, relieve pressure in Spool
the Attachment hydraulic system. Turn the
truck off and move the auxiliary control

2
levers several times in both directions.

Disconnect the hydraulic hose from the Valve CLAMP

3 Special Fitting
in CLAMP port

(CL) port.
WARNING: Special fitting must be
3 Remove the special fitting and spool. reinstalled in CLAMP (CL) port. Clamp
4 Install a 1/4-in. NPTF pipe plug with .030 in. (0.8 mm) arms will not function properly without
orifice (Cascade Part No. 673271) within the port. special fitting installed.
Thread seat is approximately 4 in. (10 cm) inside port.
NOTE: Standard pipe plug may be drilled as shown
(see dimensions in detail illustration below).
.125 in. (3.2 mm) drill to depth shown,
5 For reassembly, reverse the above procedures with the .030 in (0.8 mm) drill through.
following exceptions:
• Do not reinstall spool in port.
• Reinstall special fitting in CLAMP (CL) port.

.060 in. CL
Pipe Plug
(1.5 mm) Seat
CL3495.eps

Hex Socket Pipe Plug 4

228156 Rev. 1 27
 S ERVICE

5.3-3 Valve Service

IMPORTANT: Several different valves are used and
shown. Service the Valve in a clean work area.

1 Remove the Valve from the Clamp as described in

Section 5.3-1.
2
CLAMP
SIDESHIFT
Check Valve
2 Remove the SIDESHIFT and CLAMP check valve Check Valve Cartridge
SIDESHIFT Cartridge
cartridges. For reassembly, tighten cartridges to
Check Valve
50 ft.-lbs. (65 Nm). Poppet

4
Cartridge
3 Remove the special fitting and spool. NOTE: If regen- Relief Valve
eration circuit (fast arm opening) has been deactivated, Components
the spool is replaced with an orifice pipe plug.
4 Remove the SIDESHIFT and CLAMP relief valve car-
tridges (if equipped) and poppet valve relief compo-
nents.

STANDARD VALVE

Poppet
Relief Valve
Components 4 5
CL

OP

CL3494.eps
6
Special Fitting
and Spool
OR
Regeneration 3 WARNING: Special fitting must be
reinstalled in CLAMP (CL) port.
Flow Divider
Components
5 Elimination Plug Clamp arms will not function properly
without special fitting installed.

9
Bushing Clips Bushing
IMPORTANT: Trucks with flow less than
6 GPM (23 L/min.) require installation of
Service Kit Part No. 679846 on flow
divider spool as shown.
CL1036.ill

Flow Divider Spool

CLAMP Check SIDESHIFT Check O-rings (3)
O-rings (3)
Valve Cartridge Valve Cartridge

CL1011.eps Back-up rings (2) CL1012.eps

Back-up rings (3)

28 228156 Rev. 1
 S ERVICE

5.3-3 Valve Service (Continued)

5

6
Remove the flow divider components.
CAUTION: Do not disassemble flow divider spools.
Remove the remaining plugs and fittings.
2 CLAMP
SIDESHIFT
Check
Valve
SIDESHIFT
7 Remove the O-rings and back-up rings from the Check Adjustable
cartridge valves, fittings and plugs. Valve Relief Valve
8 Clean all parts with cleaning solvent or kerosene. SIDESHIFT Poppet
9 For reassembly, reverse the above procedures with
the following exceptions:
• Replace O-rings and back-up rings on cartridges
Check Valve
4 Relief Valve
Components

and fittings as shown below.

• Lubricate cartridges, fittings and plugs with
petroleum jelly prior to installation.
• If required for low-flow trucks, install bushings and
clips on flow divider spools as shown.

VALVE WITH OPTIONAL SIDESHIFT

AND CLAMP RELIEF CARTRIDGES 4
CLAMP
Adjustable
Poppet

4
Relief Valve
Relief Valve
Components

CL

OP

Low-Flow Kit
Components
CL3491.eps
6
Special Fitting

3
and Spool WARNING: Special fitting must be
Flow Divider
Components
5 OR
Regeneration
Elimination Plug
reinstalled in CLAMP (CL) port.
Clamp arms will not function properly
without special fitting installed.

9
Bushing Clips Bushing
IMPORTANT: Trucks with flow less than
6 GPM (23 L/min.) require installation of
Service Kit Part No. 679846 on flow
divider spool as shown.
CL1036.ill
Flow Divider Spool

CLAMP Adjustable O-rings (2) SIDESHIFT Adjustable O-rings (2)

Relief Cartridge Relief Cartridge

CL3492.eps CL3493.eps
Back-up rings (2) Back-up rings (2)

228156 Rev. 1 29
 S ERVICE

5.4 Cylinders
5.4-1 Cylinder Removal and
Installation
NOTE: The following procedures can be performed with
the Clamp mounted on the truck and the arms remaining .050 in. (1.3 mm)
on the Attachment. Clearance
1 Extend the arms outside the width of the frame.
2 Remove the bumper capscrews and nuts on each side
and remove the bumper from the Clamp. For reassem-
bly, screw the self-locking nut onto the capscrew to
leave .050–.080 in. (1.3–2.0 mm) end play for bumper
flex during operation..
2 Self-
Locking
Nut Bumper
3 Disconnect the cylinder rod end by removing the cotter
Mount
pin, locking cap and spherical nut. Frame
Lug
4 Retract the cylinder rods until they disengage from the
arm lugs.
CL1081.eps

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.

5 Disconnect the hydraulic lines from the cylinder ports.

Plug the lines and cap the cylinder ports. Tag lines for
reassembly (see Section 5.1 for hose connections).
6

7
Disconnect the cylinder head end from the frame lug
by removing cotter pin, locking cap and spherical nut.
Lift cylinders away from the Clamp frame.
1
8 For reassembly, reverse the above procedures with the
following exceptions for the cylinder anchors:
• Lubricate threads with chassis grease.
• Install hex beveled washer on cylinder rod end.
NOTE: Make sure 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. 3
2
Arm Lug Cotter Pin
8
Cylinder
5
Rod End

6
CL1062.eps

WARNING: After completing this service

procedure, test the Clamp through five
Spherical Nut, Hex washer (beveled
complete cycles. First test empty, then test
Locking Cap side toward arm lug)
with a load to make sure the Clamp operates
correctly before returning to the job.
CL0458.ill

30 228156 Rev. 1
 S ERVICE

Cylinder Disassembly
5.4-2
1 Clamp the cylinder in a soft-jawed vise at the extreme
1
head end only. Do not clamp on the shell.
2

3
Unscrew and remove the retainer using a claw-type
spanner wrench as shown. (Cascade Part No. 678598)
Remove the rod/piston assembly from the cylinder.
2
4 To remove the piston, clamp the rod assembly in a vise
on the wrench flats as shown. CAUTION: Do not
clamp on the cylinder rod sealing surface.
5 Remove the piston nut and remove the piston from the

6
cylinder rod.
Place the piston or retainer in a soft-jawed vise to
remove the seals. Pry the seals or O-rings up with a
4 CL1072.ill

brass seal removal tool (Cascade Part No. 674424)

and cut the seals to remove them. CAUTION: Do not
scratch seal grooves.

CL0173.ill
5
5.4-3 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.
• 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.
6
• Inspect the spherical nuts and hex washer for wear SS0062.ill
and replace as necessary.

Rod End
Piston Nut Rod Hex Washer
Spherical Nut, Spherical Nut,
Locking Cap Piston Shell Retainer Locking Cap

CL1063.ill

228156 Rev. 1 31
 S ERVICE

Cylinder Reassembly
5.4-4

1 Lubricate all new seals and O-rings with petroleum jelly.

4
2 Note the direction of the U-cup seals. Pressure seals
must be installed with the lip toward the high pres-
sure side of the cylinder. 3 Chamfer angle
CL1070.ill

3 Polish the piston and retainer chamfer angles with 400-

grit emery cloth to ease seal installation.
Stop
4 Install a new seal and O-ring on the piston. Install the Fins
piston seal from the rod end side of the piston by
Cylinder
hooking one side into the groove and carefully working
Shell
the seal over the piston as shown. IMPORTANT:
Loader must not
5 Install a new rod seal, back-up ring, and wiper seal in
contact thread
the retainer I.D., and a new O-ring and back-up ring on relief chamfer RC0320.ill
the retainer O.D. as shown. NOTE: Use internal seal
installation tool (Cascade Part No. 599512) to ease seal

6
installation. If installing by hand, form the seal into a
'kidney' shape and position into the internal groove. Use
finger pressure to smooth the seal into the groove.
Apply petroleum jelly to the piston internal O-ring and
7 Piston
Loader

install the piston on the rod. Tighten the nut as follows:

15D, 25D, 35D – 65 ft.-lbs. (85 Nm)
50D – 100 ft.-lbs. (135 Nm)
7 Place the piston loader into the cylinder shell.
IMPORTANT: The loader must cover all of the shell

8
Piston/Rod
threads but not contact the thread relief chamfer. If Assembly
necessary, trim the stop fins for a correct fit. The piston
will not enter the shell if the loader contacts the thread
relief chamfer.
8 Apply a thick film of petroleum jelly to the piston, shell
and loader. Using a rubber mallet, tap the piston/rod
assembly into the cylinder shell.
9 Place the retainer loader over the rod end threads.
Apply petroleum jelly to the retainer I.D. and slide it onto
the rod. Remove the loader and screw the retainer into
the shell. Tighten the retainer as follows:
9
15D, 25D, 35D – 75-125 ft.-lbs. (100-170 Nm) Retainer Loader
50D – 275-300 ft.-lbs. (370-400 Nm)
Retainer
CL1074.ill

Piston U-Cup

4 Pressure Seal
Note seal direction
Rod U-Cup
Pressure Seal
Note seal direction

6
Back-Up Rings
(if equipped)
O-Ring
Back-Up Ring

O-Ring 5 Back-Up Ring

(if equipped)

Wiper Seal

CL1304.ill

32 228156 Rev. 1
 S ERVICE

5.5 Base Unit Stabilizer

Pivot Pins,
5.5-1 Frame and Mounting Plate – Retainers

Disassembly and Reassembly

1 Remove the contact pads and stabilizers as described
1
in Section 5.2-3. NOTE: Pad and stabilizer can be
removed as a unit by removing the pivot pins as shown.
2 Remove the cylinders as described in Section 5.4-1.
3 Disconnect and plug the supply hoses to the Clamp.
Tag hoses for reassembly.
4 Remove the lower bumper. For reassembly, tighten the

4
capscrews to 40 ft.-lbs. (55 Nm).
Lower
5 Disconnect the lower hooks: Bumper
CL1087.ill
Quick-Change Hooks – Remove the locking pins and
drop the hooks into the unlocked position. Replace the
pins in the lower holes. For reassembly, remove the
pins and slide the hooks up to the locked position.
Replace the pins in the top holes.
Bolt-On Hooks – Remove the capscrews and mount-
ing hooks. For reassembly, tap the hooks tight against
the carriage bar and tighten the capscrews to
3
Sideshift Left Sideshift Right Open Clamp
110 ft.-lbs. (150 Nm).
6 Attach an overhead hoist to the backrest cutout holes
as shown and remove the Clamp from the truck.

5 QUICK-CHANGE LOWER HOOKS

Guide

RC0367.ill
®

a de
sc CL0901.ill
ca

-1
14
55
67
C-

Quick-Change
WARNING: Make sure hoist has a rated
Hook
capacity of at least 2500 lbs. (1150 kg.)
Locking Pin

BOLT-ON LOWER HOOKS

6
Lower
Carriage Bar

RC0368.ill

ST
JU Lower
AD
Hook

CL1089.ill

Lower Hooks

228156 Rev. 1 33
 S ERVICE

5.5-1 Frame and Mounting Plate –

Disassembly and Reassembly 8
(Continued)
7 Remove the Clamp from the truck carriage and set on a
pallet.
7
8 Remove the backrest. For reassembly, tighten the
backrest capscrews to 75 ft.-lbs. (100 Nm).
9 Disconnect and remove the four (4) tubes or hoses from
the bottom of the Attachment valve. Tag for reassembly.
10 Remove the capscrews fastening the valve mounting
plate to the frame and remove the valve. For reassembly,
tighten the capscrews to 15 ft.-lbs. (20 Nm).
11 Using the overhead hoist, lay the Clamp over on it's back CL1091.ill
with the mounting plates down.
12 Pull the arms out of the frames.
13 Inspect the arm bearings for wear and replace as
necessary (see Section 5.2-5).
14 Remove the capscrews fastening each frame to the

10
mounting plates and remove the frames. Tag frames for
reassembly in the same location.
15 For reassembly, reverse the above procedures with the
following exceptions for the aluminum frames:
• Use a straight edge as necessary to align top edges
(upper hook side) of mounting plates (see illustration). CL1014.ill

• Install upper aluminum frame on mounting plates and

lightly tighten capscrews. Assure frame is parallel to
edge of mounting plates within .030 in. (.8 mm).
NOTE: Apply Loctite 242 (blue) to frame capscrews.
9
• Tighten upper frame capscrews to 75 ft.-lbs. (100 Nm).
• Install lower aluminum frame on
mounting plates and lightly
tighten capscrews.
• Install arms into frames.
NOTE: Assure that arms move Arm
12 Lower

14
freely and have unrestricted
travel. Adjust lower frame if Aluminum
required. Frame
• Tighten lower frame capscrews
to 75 ft.-lbs. (100 Nm).
Mounting
Plates

Frame
Capscrews,
Washers

14
Upper
Aluminum
Frame

IMPORTANT: Use
straight edge to align
15
mounting plates, frames. CL1090.ill
13
Arm Bearings

34 228156 Rev. 1
 S ERVICE

5.6

5.6-1
Solenoid Valve
Coil Service
1 2
1 Disconnect the wires and diode from the coil terminals.
2 Remove the end cover capscrews. Remove the end

3
cover and coil.
Install the new coil and end cover. Assure that the
terminals are positioned correctly.
4
4 For reassembly, reverse the above procedures except RC0204.ill
as follows:
• Refer to the electrical schematic in Section 4.5 for
correct wire and diode installation.
Coil
5.6-2 Valve Service Solenoid Valve
• Check the plunger within the valve body for freedom of Assembly
movement. Press end button on coil to assure that valve
is not jammed or damaged. If problems are found,
replace the solenoid valve as a complete assembly.

228156 Rev. 1 35
 S PECIFICATIONS

6.1 Specifications
6.1-1 Hydraulics
Truck Relief Setting
2000 psi (140 bar) Recommended
2300 psi (160 bar) Maximum
Truck Flow Volume ➀
Min. ➁ Recommended Max. ➂

15D, 25D 4 GPM 7 GPM 7 GPM

35D, 50D (15 L/min.) (26 L/min.) (26 L/min.)

➀ Cascade D-Series Clamps are compatible with 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.
➂ Flow greater than maximum can result in excessive heating,
reduced system performance and reduced hydraulic system life.

Hoses and Fittings

GA0090.ill
CLAMP function – No. 8, minimum ID 13/32 in. (10 mm).
SIDESHIFT function – No. 6, minimum ID 9/32 in. (7 mm).

6.1-2 Auxiliary Valve Functions

Check for compliance
with ITA (ISO) standards: Tilt
Forward Release

Sideshift
Hoist Down Left

GA0082.ill
Hoist Up Sideshift
Right
Tilt Clamp
Back
6.1-3 Truck Carriage
GA0091.ill

Carriage Mount Dimension (A) ITA (ISO)

Minimum Maximum
A
Class II 14.94 in. (380.0 mm) 15.00 in. (381.0 mm)
Class III 18.68 in. (474.5 mm) 18.74 in. (476.0 mm)

GA0028.ill

36 228156 Rev. 1
 S PECIFICATIONS

6.1-4 Torque Values

Fastener torque values for D-Series Clamps are shown in
the table below in both U.S. and Metric units. All torque
values are also called out in each specific service proce-
dure section throughout the Manual.

Ref. Fastener Size Ft.-lbs. Nm

1 Frame-to-mounting plate (★) 1/2 UNC 75 100

2 Upper hook-to-mounting plate (4) M-20 235 320 ▲

3 Backrest-to-mounting plate (8) M-12 75 100 CL1105.ill

4
5
Centering tab-to-mounting plate

Valve mounting plate-to-frame (2)

M-16

M-10
165

15
225 ▲

20
1
6
7
Valve-to-mounting plate (2)

Quick-Change hook-to-baseplate (4)

M-10

M-16
15

110
20

150
Cylinder
17
Piston Nut

2 3 4 5 6
8 Lower bumper-to-mounting plate (4) M-12 75 100

9 Bolt-on lower hook-to-baseplate (4) M-16 110 150

10 Cylinder retainer (2), 15D, 25D, 35D – 100 135

50D – 290 386
11 Spring-to-arm (4) M-10 30 40 ■

12 Pin retainer-to-stabilizer (4) M-8 15 20 ■

13 Filler block-to-contact pad (12) M-10 18 25

14 Contact pad-to-stabilizer (12) M-12 50 65

15 Bumper-to-mounting lug (2) (see sec. 5.4-1)

16 Cylinder anchor nut (4) 3/4 UNF 160 220 CL1104.ill

10 9 8 7
17 Cylinder piston-to-rod 5/8 UNF 65 90 Cylinder
7/8 UNF 100 135 Retainer
★ Number of fasteners varies depending on Model
■ Use Loctite 242 (blue)
▲ Double-torque (tighten,
loosen 1/2-turn, retighten)

12 11
13 16

14 15
CL1106.ill

228156 Rev. 1 37
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
U.S. Headquarters 5570 Timberlea Blvd. Rua João Guerra, 134
2201 NE 201st Mississauga, Ontario Macuco, Santos - SP
Fairview, OR 97024-9718 Canada L4W-4M6 Brasil 11015-130
Tel: 800-CASCADE (227-2233) Tel: 905-629-7777 Tel: 55-13-2105-8800
Fax: 888-329-8207 Fax: 905-629-7785 Fax: 55-13-2105-8899

EUROPE-AFRICA
Cascade Italia S.R.L. Cascade (Africa) Pty. Ltd.
European Headquarters PO Box 625, Isando 1600
Via Dell’Artigianato 1 60A Steel Road
37050 Vago di Lavagno (VR) Sparton, Kempton Park
Italy South Africa
Tel: 39-045-8989111 Tel: 27-11-975-9240
Fax: 39-045-8989160 Fax: 27-11-394-1147

ASIA-PACIFIC
Cascade Japan Ltd. Cascade Korea Cascade-Xiamen Cascade India Material
2-23, 2-Chome, 121B 9L Namdong Ind. No. 668 Yangguang Rd. Handling Private Limited
Kukuchi Nishimachi Complex, 691-8 Gojan-Dong Xinyang Industrial Zone No 34, Global Trade Centre
Amagasaki, Hyogo Namdong-Ku Haicang, Xiamen City 1/1 Rambaugh Colony
Japan, 661-0978 Inchon, Korea Fujian Province Lal Bahadur Shastri Road,
Tel: 81-6-6420-9771 Tel: +82-32-821-2051 P.R. China 361026 Navi Peth, Pune 411 030
Fax: 81-6-6420-9777 Fax: +82-32-821-2055 Tel: 86-592-651-2500 (Maharashtra) India
Fax: 86-592-651-2571 Phone: +91 020 2432 5490
Fax: +91 020 2433 0881
Cascade Australia Pty. Ltd. Cascade New Zealand Sunstream Industries
1445 Ipswich Road 15 Ra Ora Drive 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

c Cascade Corporation 2006 3-2006 Part Number 228156 Rev. 1