ERVICE MANUAL. D-Series. Forward Bin Dumper. Manual Number cascade Cascade is a Registered Trademark of Cascade Corporation

Transcription

1 S ERVICE MANUAL D-Series Forward Bin Dumper Manual Number cascade Cascade is a Registered Trademark of Cascade Corporation

2 C ONTENTS Page INTRODUCTION, Section 1 Introduction, Special Definitions, INSTALLATION, Section 2 Truck System Requirements, Recommended Hydraulic Supply Options, Forward Bin Dumper Installation, PERIODIC MAINTENANCE, Section Hour Maintenance, Hour Maintenance, Hour Maintenance, Hour Maintenance, TROUBLESHOOTING, SECTION 4 General Procedures, Truck System Requirements, Tools Required, Troubleshooting Chart, Plumbing, Hosing Diagram, Hydraulic Schematic, Dump Function, Supply Circuit Test, Dump Circuit Test, Sideshift Function, Supply Circuit Test, Sideshift Circuit Test, Electrical (solenoid-equipped units), Page SERVICE, Section 5 Bin Dumper Removal, Frame, Bin Retainer, Pushrod Service, Safety Latch Service, Bearing Service Cylinder Rod Anchor, Bearing Service Sideshifter, Frame Pivot Pin, Bushing Service, Counterbalance Valve, Valve Removal, Installation, Valve Service, Dump Cylinders, Cylinder Removal, Cylinder Disassembly, Cylinder Inspection, Cylinder Reassembly, Sideshift Cylinder, Cylinder Removal & Disassembly, Cylinder Inspection, Cylinder Reassembly, Solenoid Valve, Coil Service, Valve Service, SPECIFICATIONS, Section 6 Specifications, Hydraulics, Auxiliary Valve Functions, Truck Carriage, Torque Values, i

3 I NTRODUCTION 1.1 Introduction This Manual provides the Installation, Periodic Maintenance, Troubleshooting, Service and Specifications for Cascade D-Series Forward Bin Dumpers. The Attachment is designed to handle agricultural and industrial bins of various sizes and capacities. In any communication about the Bin Dumper, 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 top of the RH corner of the lower frame. IMPORTANT: All hoses, tubes and fittings on D-Series Bin Dumpers are JIC. NOTE: Specifications are shown in both U.S. and (Metric) units. SERIAL NUMBER c cascade LIFT TRUCK ATTACHMENT 40D-BD-005 CATALOG WEIGHT NUMBER LBS. ADDITIONAL EQUIPMENT ADDITIONAL EQUIPMENT ADDITIONAL EQUIPMENT ATTACHMENT CAPACITY POUNDS INCH LOAD AT CENTER CAPACITY OF TRUCK AND ATTACHMENT COMBINATION MAY BE LESS THAN ATTACHMENT CAPACITY SHOWN ABOVE. CONSULT TRUCK NAMEPLATE. RECOMMENDED SYSTEM PRESSURE 2000 PSI MAXIMUM SYSTEM PRESSURE 2300 PSI cascade FOR TECHNICAL ASSISTANCE, PARTS AND SERVICE CONTACT: PORTLAND, OREGON USA BD0030.ill Nameplate S/N 40D-BD Special Definitions The following statements 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 Rev. 0 1

4 I NSTALLATION 2.1 Truck System Requirements D-Series Bin Dumpers will provide maximum operating capability when the following requirements are met. WARNING: Rated capacity of the truck/ attachment combination is a responsibility of the original truck manufacturer and may be less than that shown on the attachment nameplate. Consult the truck nameplate. Truck Relief Setting 2000 psi (140 bar) Recommended 2300 psi (160 bar) Maximum Truck Flow Volume ➀ Min. ➁ Recommended Max. ➂ 40D 5 GPM 7.5 GPM 10 GPM (19 L/min.) (28 L/min.) (38 L/min.) ➀ Cascade D-Series Bin Dumpers are compatible with SAE 10W petroleum base hydraulic fluid meeting Mil. Spec. MIL or MIL B. 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 slower than normal dumping speed. ➂ Flow greater than maximum can result in excessive heating, reduced system performance and reduced hydraulic system life. A GA0028.ill Carriage Mount Dimension (A) ITA (ISO) ➀ Minimum Maximum Class II in. (380.0 mm) in. (381.0 mm) Class III in. (474.5 mm) in. (476.0 mm) ➀ Minimum carriage width required = 36 in. (914 mm). GA0080.ill Carriage Clean carriage bars and inspect for damaged notches Auxiliary Valve Functions Check for compliance with ITA (ISO) standards: Tilt Forward Dumper Forward Hoist Down Sideshift Left GA0082.ill Hoist Up Tilt Back Sideshift Right Dumper Back Rev. 0

5 I NSTALLATION 2.2 Recommended Hydraulic Supply Options D-Series Forward Bin Dumpers can be operated with any of the hydraulic supply arrangements shown below. Refer to Cascade Hose and Cable Reel Selection Guide, Part No , to select the correct hose reel for the mast and truck. The hose and fitting requirements are: Hoses and fittings for dump and sideshift (if equipped) functions should be at least No. 6 with 9/32 in. (7 mm) minimum I.D. Non-Sideshifting A Mast Single Internal Reeving. OR B RH THINLINE 2-Port Hose Reel Group. B C A Sideshifting A Mast Double Internal Reeving. OR A and B Mast Single Internal Reeving and RH THINLINE 2-Port Hose Reel Group. OR B and C RH and LH THINLINE 2-Port Hose Reel Groups. GA0033.ill Solenoid Adaption A and B Mast Single Internal Reeving and RH Cable Reel Group. OR B RH 6-N-1 Cable/Hose Reel Group Rev. 0 3

6 I NSTALLATION 2.3 Installation Procedure 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 C Remove bolt-on lower mounting hooks. Tighten upper mounting hook capscrews to final torque value: Class II / III 120 ft.-lbs. (165 Nm) A C Class II / III Upper Hooks (Reversable Dual Mount) BD0014.ill B Bolt-on Lower Hooks 2 Unlock quick-change lower mounting hooks (if equipped) A B Remove pin and drop hooks into unlocked position. Reinstall pin in lower hole. Guide A NOTE: Guides can be reversed to reduce hook-to-carriage clearance (See lower hook installation, Step 6). cascade B Pin C LH Lower Hook 5/8-in. (16 mm) offset on top provides max. clearance Rev. 0 CL0097.ill Tighten Capscrews: Class II / III Mounting 120 ft.-lbs. (165 Nm)

7 I NSTALLATION 3 Prepare Hoses A Determine hose lengths required for hydraulic supply configuration of truck. B Cut hoses to length, install end fittings or quick-disconnect kits. SINGLE INTERNAL HOSE REEVING Non-sideshifting WARNING: Use No. 6 hoses with a minimum internal diameter of 9/32 in. (7 mm), working pressure rated at 3000 psi (20,700 kpa). Route hoses to avoid pinching between upper and lower frames during dumper operation. Dumper Back Dumper Forward BD0017.ill HOSE REEL Non-sideshifting DOUBLE INTERNAL HOSE REEVING Sideshifting Dumper Back Dumper Forward Sideshift Right Sideshift Left BD0071.ill Dumper Back Dumper Forward BD0070.ill Back (Driver's) Views 4 Flush hydraulic supply hoses A Install hoses to hose terminals. Connect using union fittings. B Operate auxiliary valves for 30 sec. C Remove union fittings. GA0092.ill Rev. 0 5

8 I NSTALLATION 5 Mount Bin Dumper on truck A Center truck behind Bin Dumper. B Tilt mast forward and raise carriage into position. C Engage upper mounting hooks with carriage. Make sure locater tab on left hook engages with a notch on upper carriage bar. D Lift Bin Dumper 2 in. (5 cm) off pallet. A B BD0018.il ITA Class II in. (15 17 mm) ITA Class III in. (18 20 mm) (Class III mounting shown) C Upper Hook Locater Tab C C ITA Class II in. (8 9 mm) ITA Class III in. (10 11 mm) BD0072.ill Truck Carriage (NOTE: Min. Width: 36 in. (91.5 cm) GA0079.ill 6 Install and engage lower hooks Tap tight into position. If sideshifting, back off 1 notch and check clearance: 3/32 in. (2.5 mm) Min. 3/16 in. (5 mm) Max. BOLT-ON TYPE ADJUST Lower Carriage Bar Slide hook up to engage bar, install pin in locked position. (upper hole.) F QUICK-CHANGE TYPE (Optional) cascade C Lower Carriage Bar F Inspect hooks for excessive clearance. (Reverse guides to reduce clearance See Step 2.) 3/16 in. (5 mm) Max. Tighten Capscrews: Class II / III Mounting 120 ft.-lbs. (165 Nm) SD0066.ill SD0065.ill Rev. 0

9 I NSTALLATION 7 Connect hoses prepared in Step 3 to Attachment fittings BD0074.ill BD0075.ill 8 Install solenoid control knob (solenoid-equipped units) Button toward driver PRESS BUTTON TO DUMP SIDESHIFT Adapter Truck control valve handle CL0240.ill 9 Install wiring (solenoid-equipped units) Control Lever Knob Diode Diode Solenoid Coil 7.5-Amp Fuse White Knob Button Black 7.5-Amp Fuse White Black CL0258.ill CL0257.ill User-supplied wire Solenoid Coil Rev. 0 7

10 I NSTALLATION 10 Cycle Attachment functions With no load, cycle dumper forward and back several times. Sideshift left and right several times (if equipped). Pick up and dump a maximum load, check for smooth operation. Check for operation in accordance with ITA (ISO) standards. Check for leaks at fittings, valve and cylinders. NON-SIDESHIFTING A Dumper Forward B Dumper Back C (not used) D (not used) SIDESHIFTING A Sideshift Left B Sideshift Right C Dumper Forward D Dumper Back SIDESHIFTING WITH SOLENOID VALVE A Sideshift Left A Dumper Forward (press knob button) B Sideshift Right B Dumper Back (press knob button) B A BD0007.ill B D A C BD0006.ill B B A A BD0006.ill AUXILIARY VALVE FUNCTIONS Hoist down Tilt forward A C B D GA0005.ill Hoist up Tilt back Rev. 0

11 T ROUBLESHOOTING ERIODIC MAINTENANCE P Hour Maintenance Every time the lift truck is serviced or every 100 hours of truck operation, whichever comes first, complete the following maintenance on the Forward Bin Dumper: Check for loose or missing bolts, worn or damaged hoses and hydraulic leaks. Tighten hoses. Inspect top and front bin retainers for damage and proper adjustment. WARNING: After completing any service procedure, always test each function through five complete cycles. First test with no load, then test with a load to make sure the Attachment operates correctly before returning it to the job Hour Maintenance After each 500 hours of truck operation, in addition to the 100-hour maintenance, perform the following procedures: Check clearance between lower mounting hooks and truck lower carriage bar: Quick-Change Hooks 3/16 in. (5 mm) max. Bolt-on hooks, non-sideshifting Tight against truck lower carriage bar. Bolt-on hooks, sideshifting 3/16 in. (5 mm) max. If adjustment is necessary, refer to Section 2, Step 6. Tighten lower hook capscrews to 120 ft.-lbs. (165 Nm). Tighten upper hook capscrews to 120 ft.-lbs. (165 Nm). Apply chassis grease to all grease fittings and lower sideshifter (if equipped) bearing areas. Check torque on bearing housing capscrews. Tighten to 150 ft.-lbs. (200 Nm) as necessary. Upper Hooks Lower Hooks Top Bin Retainers Back (Driver s) View BD0068.ill Sideshifter Lower Bearings (if equipped) Hour Maintenance After each 1000 hours of truck operation, in addition to the 100 and 500-hour maintenance, perform the following procedures: Inspect cylinder rod-end anchor bearing blocks for wear and replace as necessary (see Section 5.2-3). Inspect sideshifter (if equipped) upper and lower bearings for wear and replace as necessary (see Section 5.2-4). Pivot Pins Cylinder Rod-End Anchor Bearing Blocks (2 per side) Bearing Housing Capscrews (8) Sideshifter Upper Hook Grease Fittings (2) Hour Maintenance After each 2000 hours of truck operation, in addition to the 100, 500 and 1000-hour maintenance, perform the following procedures: Front Bin Retainer Frame Pivot Grease Fitting (1 per side) Left Side BD0021.ill Inspect all pivot pins and bushings for wear and replace as necessary (see Sections 5.2-1, 5.2-2, 5.2-5, 5.4-3). NOTE: Frame pivot grease fittings serviced from underneath Attachment Rev. 0 9

12 T ROUBLESHOOTING 4.1 General Procedures Truck System Requirements Truck hydraulic pressure should be within the range shown in Specifications, Section 6.1. PRESSURE TO THE FORWARD BIN DUMPER MUST NOT EXCEED 2300 psi (160 bar). Truck hydraulic flow should be within the volume range shown in Specifications, Section 6.1. Hydraulic fluid supplied to the Bin Dumper must meet the requirements shown in Specifications, Section 6.1. WARNING: Before servicing any hydraulic component, relieve pressure in the Attachment system. Turn the truck off and move the truck auxiliary control handle several times in both directions. After completing any service procedure, always 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 Tools Required In addition to a normal selection of hand tools, the following are required: 20 GPM (80 L/min) inline flow meter. (Cascade Flow Meter Kit, part no ) psi (200 bar) pressure gauge. (Cascade Pressure Gauge Kit, part no ). Quick-disconnect adapters and fittings. Flow Meter Kit (2) No JIC/ O-Ring (2) No. 6-8 JIC Reducer Flow Meter GA0013.ill 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 malfunction. Guidelines below can then be used as a starting point to begin troubleshooting. Dump Circuit Bin retainers do not close or hold bin properly. Attachment dumps or retracts slowly or not at all. To correct these problems, see Section 4.3. Sideshift Circuit Attachment will not sideshift. Attachment sideshifts slowly. To correct these problems, see Section psi (200 bar) Pressure Gauge Pressure Gauge Kit No. 4 6 Pipe/JIC No. 6-6 Hose GA0014.ill No. 6 8 JIC Reducer No. 6 and No. 8 JIC Swivel Tee Diagnostic Quick-Disconnects No. 4, No. 6 and No. 8 JIC/O-Ring Male Straight Thread O-Ring Coupler: No. 4 (Part No ) No. 5 (Part No ) No. 6 (Part No ) Female JIC Thread Coupler: No. 4 (Part No ) No. 6 (Part No ) AC0127.ill NOTE: Diagnostics Kit includes all of the above Rev. 0

13 T ROUBLESHOOTING 4.2 Plumbing Hosing Diagram SIDESHIFT RIGHT, DUMPER FORWARD Pressure: Return: SIDESHIFT LEFT, DUMPER BACK 2-Port Hose Reels or IHR Dump Cylinders (2) Dumper Forward Dumper Back Valve Hydraulic Schematic Sideshift Cylinder Dump Cylinders (2) SSR Hose Terminal Truck Auxiliary Valve (Sideshift) SSL BD0016.ill C2 C1 Counterbalance Valve Cartridges (2) Truck Auxiliary Valve (Dump) V2 Dumper Back V1 Dumper Forward SSR SSL Truck Auxiliary Valve (Sideshift) Truck Auxiliary Valve (Dump) Truck Pump Truck Relief Valve Truck Tank BD0025.ill Rev. 0 11

14 T ROUBLESHOOTING 4.3 Dump Function There are six potential problems that could affect the dumping function: Incorrect bin size or load handling. Refer to Operator s Guide for suggested procedures. Damaged front bin retainer or pushrod. Incorrect hydraulic pressure or flow from lift truck. External leaks. Defective solenoid coil or valve (if equipped). Defective counterbalance valve or cylinder seals 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 BIN DUMPER 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 Tilt the dumper fully forward, holding the lever in the FORWARD position for a few seconds. Release the lever and check for external leaks at fittings, hoses, valve and cylinders Dump 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. Assure that the valve is not jammed (see Sections 4.5 and 5.5). IMPORTANT: Solenoid-operated valves must be plumbed so that the solenoid is energized during the dumping function. 2 Tilt the dumper FORWARD. Turn the truck off and relieve Attachment system pressure. 3 Using a No. 4 tee fitting, connect a 3000 psi (200 bar) pressure gauge to either cylinder rod-end port, routing the gauge and hose out the bottom of the lower frame. 4 Start the truck and retract the dumper, holding the lever in the BACK position for a few seconds. 5 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 (2 bar) per minute, the problem is not hydraulic (see Section 4.3 above). If the pressure drop is more than 150 psi (10 bar), the counterbalance valve or the cylinders are at fault and must be serviced (see Sections and 5.4). NOTE: The Attachment must be removed from the truck in order to service the valve and the cylinders. Flow Meter 2 WARNING: Before removing hydraulic lines or components, relieve pressure in the Attachment hydraulic system. With the truck off, move the truck auxiliary control handle several times in both directions. 3 Pressure gauge on cylinder rodend port Back (Driver s) View 4 BD0031.ill BD0086.ill Rev. 0

15 T ROUBLESHOOTING 4.4 Sideshift Function There are six potential problems that could affect the sideshifting function: Inadequate upper bearing lubrication or worn bearings (see Section 3). Incorrect hydraulic pressure or flow from lift truck (see Section 6). External leaks. Lower mounting hooks installed incorrectly (see Section 2, Step 6). Worn or defective cylinder seals (see Section 4.4-2). Cylinder fittings or flow restrictors plugged, incorrect type, or not installed correctly (see Section 5.5) 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. PRES- SURE TO THE SIDESHIFTER 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 Sideshift left fully, holding the lever in the SIDESHIFT LEFT position for a few seconds. Release the lever and check for external leaks at fittings, hoses and cylinder Sideshift Circuit Test 1 Press the solenoid button (if equipped) and listen for a click at the solenoid valve. If no sound is heard, 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 not energized during the sideshifting function. 2 Sideshift fully to the left. Turn the truck off and relieve Attachment system pressure. Disconnect the SIDE- SHIFT RIGHT supply hose from the hose terminal and route the hose to a drain bucket. Cap the hose terminal supply. 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, check for plugged or incorrectly-installed flow restrictor 3 washers and fittings. If there is still no hydraulic flow, the problem is not hydraulic (see Section 4.4). Sideshift Right Hose 2 Hose end in drain bucket WARNING: Before removing hydraulic lines or components, relieve pressure in the Attachment hydraulic system. With the truck off, move the truck auxiliary control handle several times in both directions. Back (Driver s) View Cap Supply Fitting BD0076.ill Rev. 0 13

16 T ROUBLESHOOTING 4.5 Electrical Circuit (solenoid-equipped units) 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 terminals. 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 If there is no ohmmeter reading, the coil is defective and should be replaced. Refer to Section Control Lever Knob with Push-button Diode Diode Solenoid Coil 7.5-Amp Fuse White Knob Button Black 7.5-Amp Fuse White Black CL0258.ill CL0257.ill User-supplied wire Solenoid Coil Solenoid Coil Rev. 0

17 S ERVICE 5.1 Bin Dumper Removal 1 Retract the dumper fully rearward. WARNING: Before removing hydraulic lines, relieve pressure in the Attachment hydraulic system. With the truck off, move the truck auxiliary control handle(s) several times in both directions. Dumper Back 2 Dumper Forward 2 Disconnect and plug the hydraulic supply hoses at the Attachment fittings. Tag hoses for reassembly. 3 Disconnect the lower hooks: Quick-Change Hooks Remove locking pins and drop hooks into unlocked position. Replace pins in lower holes. For reassembly, remove pins and slide hooks up to locked position. Replace pins in top holes (locked). Bolt-On Hooks Remove lower hooks. For reassembly, tap tight against carriage bar and tighten the capscrews to 120 ft.-lbs. (165 Nm). Back (Driver s) View BD0017.ill After reassembly, check the lower hook clearances: Quick-Change Hooks 3/16 in. (5 mm) max. Bolt-on hooks, non-sideshifting Tight against truck lower carriage bar. Bolt-on hooks, sideshifting 3/16 in. (5 mm) max. If adjustment is necessary, refer to Section 2, Step 6. 4 Lower the Bin Dumper onto a pallet. Tilt the mast forward and lower the carriage to disengage the upper hooks. 5 For installation, reverse the above procedures with the following exceptions: 4 Refer to Installation, Section 2 for complete installation procedure. Lubricate the Bin Dumper as described in Periodic Maintenance, Section 3. BD0028.ill 3 BOLT-ON LOWER HOOKS QUICK-CHANGE LOWER HOOKS (Optional) Carriage Bar Guide BD0029.ill ADJUST Left Hook Baseplate cascade C BD0067.ill Left Hook Locking Pin (Unlocked Position) Rev. 0 15

18 S ERVICE 5.2 Frame Bin Retainer and Pushrod Service Bin Retainer Pivot Pin 2 Pushrod Pivot Pin 1 Upper Frame 1 Remove the pivot pin to disconnect the pushrod from the bin retainer. For reassembly, tighten the pin retainer to 15 ft.-lbs. (20 Nm). 2 Remove the bin retainer pivot pin from the frame and remove the bin retainer. Keep track of shim location. For reassembly, tighten the pin retainer to 15 ft.-lbs. (20 Nm). 3 Unscrew the pushrod from its inner spherical joint (NOTE: LH thread on inner spherical joint). For reassembly, screw the pushrod all the way in then back out 12 turns. 4 For reassembly, reverse the above procedures with the following exceptions: Inspect pivot pins and bushings for wear. Replace as necessary. CAUTION: Bushings may be damaged if installed without a proper bushing driver. Shim front bin retainer as required to center within frame. Inspect pushrod outer spherical joint for wear and replace as necessary. Adjust pushrod length to position bin retainer parallel to frame (pointing forward) when Bin Dumper is fully retracted. Tighten jam nut. Bushing Bin Retainer 4 Shims (as required) Spherical Joint, Jam Nut BD0046.ill 3 Pushrod Safety Latch Service 1 Tilt the dumper forward to the vertical position. 2 Attach a safety chain to the upper frame as shown. 3 Compress the safety latch spring by using a length of threaded rod, nuts and washers. 4 Remove the safety latch pivot pin. Keep track of shims. For reassembly, tighten the pin retainer to 15 ft.-lbs. (20 Nm). Remove the threaded rod compressing the safety latch spring. 5 Remove the safety latch assembly from the upper frame. 6 For reassembly, reverse the above procedures with the following exceptions: Inspect safety latch assembly and pivot pin for wear and replace as necessary. Make sure spring is seated on guide pin in upper frame. Shim as required to center safety latch on stubshafts of cylinder rod-end joint. Pivot Pin 4 Spring 3 NOTE: Make removal tool from 1/4-in. (6 mm) threaded rod, nuts and washers as shown. 5Safety Latch BD0073.ill Rev. 0

19 S ERVICE Bearing Service Cylinder Rod Anchor NOTE: The rod-end anchor bearings can be serviced with the Bin Dumper mounted on the truck. 1 Remove the bin retainer pushrod as described in Section Tilt the dumper forward to the vertical position 3 Attach a safety chain to the upper frame as shown. 4 Remove the safety latch assembly as described in Section Remove the bearing housing upper end-caps. For reassembly, apply Loctite 242 (blue) to the capscrews and tighten to 150 ft.-lbs. (200 Nm). 6 Disengage the cylinder rod-end/bearing block assembly by sliding it up and out of the bearing housing open end. Slide the bearing blocks off the stub shafts. 7 Disassemble the cylinder rod end joint by removing the roll pins that secure the pivot pin to the stubshafts. 8 For reassembly, reverse the above procedures with the following exceptions. Inspect and replace the following parts as necessary: Pushrod inner spherical joint (LH thread) Bearing blocks Stubshafts Pivot pin Safety latch Pushrod Inner Spherical Joint (LH thread) Roll Pins (2) BD0047.ill Bearing Blocks (2) 7 Pivot Pin 1 Stubshafts (2) BD0045.ill Rev. 0 17

20 S ERVICE Bearing Service Sideshifter NOTE: The Sideshifting Bin Dumper must be removed from the lift truck in order to service the sideshifter bearings or the cylinder/anchor bracket assembly. 1 Remove the Bin Dumper from the lift truck as described in Section 5.1 and set on a pallet. 2 Loosen or remove the sideshifting cylinder retainers. For reassembly, tighten the capscrews to 22 ft.-lbs. (30 Nm). 3 Lower the cylinder/anchor bracket assembly and bearings away from the upper hooks. 4 Inspect the upper bearing thickness. If either bearing is worn to less than 1/16 in. (1.5 mm), replace both bearings. 5 Inspect the lower bearing exposed thickness. If less than 1/16 in. (1.5 mm), replace both bearings. 6 For reassembly, reverse the above procedures with the following exceptions: Clean all parts with cleaning solvent. Inspect cylinder/anchor bracket assembly for damage that could impair performance or cause leaks under pressure. For sideshift cylinder service, see Section Make sure upper bearings are installed correctly in anchor bracket cutouts as shown. Sideshift Cylinder/Anchor Bracket Assembly 3 Upper Bearings (2) 4 Sideshifter Upper Hooks 6 Correct bearing location on anchor bracket 1/16 in. (1.5 mm) min. 2 Sideshifter Cylinder Retainers BD0066.ill 5 Bearings Sideshifter Lower (2) Rear (Driver s) View Rev. 0

21 S ERVICE Frame Pivot Pin and Bushing Service NOTE: The main pivot pins and bushings can be replaced with the Bin Dumper mounted on the truck. Replace the pins and bushings on each side of the frame if wear is found on either side. 2 Pin-only replacement: 3 Remove the retainer capscrews. Do one side at a time: Use a spare pin to drive old pin out of frame. Install new pin, displacing spare pin. Tighten pin retainer capscrews to 15 ft.-lbs. (20 Nm). Pin and Bushing replacement: 1 Tilt the dumper forward to the vertical position. 2 Attach a safety chain to the upper frame as shown. 3 Remove the pin retainer capscrews and drift the main pivot pins from the joints. For reassembly, tighten the pin retainer capscrews to 15 ft.-lbs. (20 Nm). 4 Carefully move the upper frame forward about 2 in. to provide access to the bushings in the lower frame. 5 Remove the pivot pin bushings from the lower frame. 6 For reassembly, reverse the above procedures with the following exceptions: Install new bushings in the lower frame. CAUTION: Bushings may be damaged if installed without a proper bushing driver. Install new pivot pins. Upper Frame 4 Bushings (2) 5 3 Pivot Pin Lower Frame BD0049.ill Rev. 0 19

22 S ERVICE 5.3 Counterbalance Valve Valve Removal, Installation The following procedure requires that the Bin Dumper be removed from the truck. 1 Remove the Attachment from the truck as described in Section Disconnect the six (6) hoses from the Valve fittings. Tag hoses for reassembly. 3 Remove the two capscrews fastening the Valve to the lower frame and remove the Valve. For reassembly, tighten the capscrews to 8 ft.-lbs. (10 Nm). 4 For reassembly, reverse the above procedures with the following exceptions: Service the Valve as described in Section Valve Service Top hoses connect to cylinder head end (Dumper Forward) 2 2 Bottom hoses connect to cylinder rod end (Dumper Back) 3 BD0050.ill IMPORTANT: Service the Valve in a clean work area. 1 Remove the Valve from the Bin Dumper as described in Section Remove the cartridges and fittings from the Valve. 3 Remove the O-rings and back-up rings from the cartridges and fittings. 4 Clean all parts with cleaning solvent or kerosene. 5 For reassembly, reverse the above procedures with the following exceptions: Replace O-rings and back-up rings on cartridges and fittings as shown below. Lubricate cartridges and fittings with petroleum jelly prior to installation. Tighten cartridges to 50 ft.-lbs. (65 Nm). 5 O-Ring O-Rings (2) 2 BD0027.ill Counterbalance Valve Cartridges (2) BD0026.ill Back-up Ring Back-up Rings (2) Counterbalance Valve Cartridge Rev. 0

23 S ERVICE 5.4 Dump Cylinders Cylinder Removal NOTE: Removing the dump cylinders requires that the Attachment be removed from the truck. (Cylinder supply hoses must be disconnected at the valve.) 1 Disengage the cylinder rod-end anchor from the bearing housing as described in Section 5.2-3, Steps 1 through 6. WARNING: Before servicing any hydraulic components or lines, relieve pressure in the Attachment system. With the truck off, move the truck auxiliary control handle several times in both directions. 2 Disconnect the cylinder hoses from the counterbalance valve as shown in Section Tag hoses for reassembly. 3 Remove the retainer and pivot pin from the cylinder head end and move the cylinder and hoses out of the lower frame. Keep track of shims. For reassembly, tighten the cylinder pivot pin retainer capscrew to 20 ft.-lbs. (30 Nm). 4 Service the cylinder as described in Section For reassembly, reverse the above procedures with the following exceptions: Clean any rust or paint from the pin bores in the frame before reinstalling the cylinder pivot pin. Shim as required to center the cylinder within the frame. 1 Cylinder Rod Anchor Dump Cylinder BD0065.ill Cylinder Head- End Pivot Pin and Retainer Rev. 0 21

24 S ERVICE Cylinder Disassembly 1 Clamp the cylinder at its head end in a soft-jawed vise. 2 Using a claw-type spanner, unscrew the retainer from the cylinder shell. 3 Remove the cylinder rod/retainer/piston assembly from the cylinder shell. 4 Clamp the rod assembly by its fork end in a softjawed vise. Remove the nut and piston from the rod. Slide the retainer from the rod. 5 Pry the seals out of the piston and retainer grooves using a brass seal removal tool (Part No ). Cut the seals to remove. CAUTION: Do not scratch seal grooves. 2 BD0034.ill 1 BD0035.ill 3 Retainer Locknut Cylinder Inspection Inspect the rod, piston and retainer for nicks or burrs. Minor nicks or burrs may be removed with 400-grit emery cloth. 4 Piston Retainer NOTE: Minor nicks are those that will not bypass oil under pressure. If the minor nicks cannot be removed, replace the part. Inspect the cylinder shell bore and remove any minor nicks or burrs with a butterfly. If nicks or burrs cannot be removed, replace the part. SS0061.ill Inspect the outside of the shell for any deformities or cuts that could impare performance or cause leaks under pressure. If necessary, replace the part. Inspect the bushings and pivot pins for wear and replace as necessary. CAUTION: Bushings may be damaged if installed without a proper bushing driver. 5 SS0088.ill Bushing Retainer Shell Rod Piston Bushing BD0078.ill Rev. 0

25 S ERVICE Cylinder Reassembly 1 Polish the piston and retainer chamfer angles with 400- grit emery cloth to prevent seal damage and ease installation. 2 Clean all parts with cleaning solvent. Lubricate new seals and O-rings with petroleum jelly. 3 Install new seals, O-rings and back-up rings on the piston and retainer. Hook one side of the seal in the groove and carefully work it over the piston or retainer. 4 Note the direction of the U-cup seals (see illustration below). Pressure seals are installed with the lip toward the high pressure side of the cylinder. The cylinder will not work properly if the seals are turned around. 5 Apply petroleum jelly to the retainer I.D. and install the retainer, then the piston on the cylinder rod. Use a new piston retaining nut and tighten to 125 ft.-lbs. (170 Nm). 6 Apply petroleum jelly to the piston and install the piston/ rod assembly into the cylinder shell. Use a rubber or plastic mallet as needed. 7 Screw the retainer into the shell and tighten to 250 ft.-lbs. (340 Nm). Assure that the piston moves freely. 1 3 BD0038.ill Exclusion Seal Rod U-Cup Pressure Seal 4 Piston Pressure Seal 6 Retainer 7 BD0077.ill Retainer O-Ring, Back-Up Ring 5 Piston Nut Rev. 0 23

26 S ERVICE 5.5 Sideshift Cylinder Cylinder Removal and Disassembly Class II NOTE: Remove the sideshift cylinder as described in Section Clamp the cylinder in a soft-jawed vise. Do not clamp on the cylinder shell. 2 Center the cylinder rod in the cylinder. Remove the spiral snap rings from the retainers (see illustration). 3 Tap the retainers into the shell approximately 2 in. (50 mm). Remove the circular snap rings by prying one end up and working the ring out of the groove. CAUTION: Do not scratch the cylinder bore. NOTE: Service Tool Kit includes two doubleended brass tools that make seal and retaining ring removal easy and won t damage the cylinder components with dents or scratches. 4 Remove the rod assembly and retainers from the cylinder (see illustration below). 5 Clamp the piston/rod assembly in a soft-jawed vise or between two blocks of wood to remove the seals. Pry the seals up with a brass tool. Cut seals to remove. CAUTION: Do not scratch the seal grooves. 3 SS0122.ill SS0039.ill Cylinder Inspection Class II Inspect all components for nicks or burrs. Minor nicks or burrs can be removed with 400-grit emery cloth. NOTE: Minor nicks are those that will not bypass hydraulic fluid under pressure. If nicks cannot be removed with emery cloth, replace the part. Inspect outside of shell for deformities that could weaken performance when under pressure. Replace if necessary. Inspect fittings and flow restrictor washers. SS0040.ill 5 Optional Spacers 3 2 SS0120.ill Restrictor Washers (1 per side) Rev. 0

27 S ERVICE Cylinder Reassembly Class II 1 Break any shart edges on the piston and retainer chamfer angles with 400-grit emery paper. 2 Wash all components with cleaning solvent. Lubricate the new seals and O-rings with petroleum jelly. 3 Note the direction of the U-cup seals (see illustration below). Pressure seals are installed with the lip toward the high pressure side of the cylinder. The cylinder will not work properly if the seals are turned around. 4 Install the new seals on the piston and retainer. Hook one side of the seal in the groove and push it over the piston or retainer. 5 Apply a thick film of petroleum jelly to the inside of the cylinder shell, piston seals and retainers. 6 Insert the rod assembly into the cylinder shell. If resistance is encountered, tap the rod end with a rubber mallet. 7 Tap the retainers into the shell far enough to install the retaining rings in their grooves. 8 Pull the rod out to one side to the fully extended position. This will position the retainer so the spiral snap ring can be installed. Repeat for the retainer on the other end. 9 Install the flow restrictor washers and fittings. IMPORTANT: Fitting must bottom against flow restrictor in cylinder port for proper hydraulic flow. SS0046.ill 1 3 Optional Spacers OR BD0079.ill SS0121.ill Retainer Shell Piston Restrictor Washer (1 per side) Rev. 0 25

28 S ERVICE 5.6 Solenoid Valve Coil Service 1 Remove the cover from the valve assembly. 2 Disconnect the wires and diode from the coil terminals. 3 Loosen the end cover capscrews. Remove the end cover and coil. 4 Install the new coil and end cover. Assure that the terminals are positioned correctly. 5 For reassembly, reverse the above procedures with the following exceptions: Refer to the electrical schematic in Section 4.5 for correct wire and diode installation Valve Service Check the valve plunger for freedom of movement. If jammed or damaged, replace the solenoid valve as a complete assembly RC0204.ill Solenoid coil Solenoid valve Rev. 0

29 S PECIFICATIONS 6.1 Specifications Hydraulics Truck Relief Setting 2000 psi (140 bar) Recommended 2300 psi (160 bar) Maximum Truck Flow Volume ➀ Min. ➁ Recommended Max. ➂ 40D 5 GPM 7.5 GPM 10 GPM (19 L/min.) (28 L/min.) (38 L/min.) ➀ Cascade Forward Bin Dumpers are compatible with SAE 10W petroleum base hydraulic fluid meeting Mil. Spec. MIL or MIL B. 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 slow dumping and sideshift speeds. ➂ Flow greater than maximum can result in excessive heating, reduced system performance and reduced hydraulic system life. Hoses and Fittings All supply hoses should be No. 6 minimum. All fittings should have an orifice size of 9/32 in. (7 mm) minimum. GA0090.ill Auxiliary Valve Functions Check for compliance with ITA (ISO) standards: Tilt Forward Dumper Forward Hoist Down Sideshift Left GA0082.ill Truck Carriage Hoist Up Tilt Back Sideshift Right Dumper Back Carriage Mount Dimension (A) ITA (ISO) ➀ GA0091.ill A GA0028.ill Minimum Maximum Class II in. (380.0 mm) in. (381.0 mm) Class III in. (474.5 mm) in. (476.0 mm) ➀ Minimum carriage width required = 36 in. (914 mm) Rev. 0 27

30 S PECIFICATIONS Torque Values Fastener torque values for the D-Series Forward Bin Dumper are shown in the table below in both U.S. and Metric units. All torque values are also called out in each service section throughout the Manual. Ref. Fastener Size Ft.-lbs. Nm 1 Upper hook-to-frame, Class II & III (4) 5/8 in Lower hook-to-frame, Class II & III (4) 5/8 in Bearing housing-to-frame (16) M Pivot pin retainer-to-frame (8) M Pivot pin retainer-to-frame (4) M Pivot pin retainer-to-foot (8) M Valve-to-frame (2) 5/16 in Cylinder piston nut-to-cylinder rod (2) 5/8 in Safety latch plate-to-frame (4) M Sideshifter upper hook-to-frame (6) 5/8 in SS lower bearing hangar-to-frame (4) M SS cyl. retainer bracket-to-frame (2) M Use Loctite 242 (Blue) BD0052.ill Rev. 0

31 Do you have questions you need answered right now? Call your nearest Cascade Service Department. Visit us online at AMERICAS Cascade Corporation U.S. Headquarters 2201 NE 201st Fairview, OR Tel: 800-CASCADE ( ) Fax: Cascade Canada Inc Timberlea Blvd. Mississauga, Ontario Canada L4W-4M6 Tel: Fax: Cascade do Brasil Rua João Guerra, 134 Macuco, Santos - SP Brasil Tel: Fax: EUROPE-AFRICA Cascade Italia S.R.L. European Headquarters Via Dell Artigianato Vago di Lavagno (VR) Italy Tel: Fax: Cascade (Africa) Pty. Ltd. PO Box 625, Isando A Steel Road Sparton, Kempton Park South Africa Tel: Fax: ASIA-PACIFIC Cascade Japan Ltd. 2-23, 2-Chome, Kukuchi Nishimachi Amagasaki, Hyogo Japan, Tel: Fax: Cascade Australia Pty. Ltd Ipswich Road Rocklea, QLD 4107 Australia Tel: Fax: Cascade Korea 121B 9L Namdong Ind. Complex, Gojan-Dong Namdong-Ku Inchon, Korea Tel: Fax: Cascade New Zealand 15 Ra Ora Drive East Tamaki, Auckland New Zealand Tel: Fax: Cascade-Xiamen No. 668 Yangguang Rd. Xinyang Industrial Zone Haicang, Xiamen City Fujian Province P.R. China Tel: Fax: Sunstream Industries Pte. Ltd. 18 Tuas South Street 5 Singapore Tel: Fax: Cascade India Material Handling Private Limited No 34, Global Trade Centre 1/1 Rambaugh Colony Lal Bahadur Shastri Road, Navi Peth, Pune (Maharashtra) India Phone: Fax: c Cascade Corporation Part Number