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Cascade F Series Service Manual

Fork positioner
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S
ERVICE MANUAL
F-Series
Fork Positioners
Manual Number 208743-R1
c sc de
corpor tion
Cascade is a Registered Trademark of Cascade Corporation

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  • Page 1 ERVICE MANUAL F-Series Fork Positioners Manual Number 208743-R1 c sc de  corpor tion Cascade is a Registered Trademark of Cascade Corporation...

  • Page 2: Table Of Contents

    ONTENTS Page INTRODUCTION, Secton 1 Special Definitions 1.1 INSTALLATION, Secton 2 Truck System Requirements, 2.1 Recommended Hydraulic Supply, 2.2 Installation Procedures, 2.3 PERIODIC MAINTENANCE, Secton 3 TROUBLESHOOTING, Secton 4 General Procedures, 4.1 Truck System Requirements, 4.1-1 Tools Required, 4.1-2 Troubleshooting Chart, 4.1-3 Plumbing, 4.2 Hosing Diagram, 4.2-1, 2-3, 2-5 Circuit Schematic, 4.2-2, 2-4, 2-6...
  • Page 3 NTRODUCTION This Manual provides the Installation, Periodic Maintenance, Troubleshooting, Service and Specifications for Cascade F-Series Fork Positioners. IMPORTANT: All hoses, tubes and fittings on F-Series attachments are JIC. NOTE: Specifications are shown in both U.S. and (Metric) units. Specal Defintons The statements shown appear throughout this Manual where special emphasis is required.

  • Page 4: Truck System Requirements

    NSTALLATION Truck System Requirements Truck Relief Setting Minimum – 2300 psi (160) bar Maximum – 2600 psi (180) bar Truck Flow Volume Minimum 3 GPM (11 L/min.) 4 GPM (15 L/min.) Recommended 4 GPM (15 L/min.) 5 GPM (19 L/min.) Maximum 5 GPM (19 L/min.) 6 GPM (23 L/min.) Dimension A − ITA (ISO) GA0023.eps Mounting Minimum Maximum 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) Clean carriage bars and inspect for damaged notches. Class IV 23.44 in. (595.5 mm) 23.50 in. (597.0 mm) Recommended...

  • Page 5: Installation Procedures

    NTRODUCTION Installation Procedures Attach overhead hoist Remove lower hooks 1000 lb. 450 Kg. FP0023.eps FP0007.eps Mount on truck carriage ITA Class II – .60-.66 in. (15-17 mm) ITA Class III – .72-.78 in. (18-20 mm) ITA Class IV – .72-.78 in. (18-20 mm) Center Notch ITA Class II – .32-.36 in. (7-9 mm) ITA Class III – .39-.43 in. (10-11 mm) FP0025.eps ITA Class IV –...
  • Page 6 NSTALLATION Install forks A Remove fork lock pins B Remove fork blocks C Install forks D Adjust blocks to provide 1/16 in. (1.5 mm) clearance with side of fork. WARNING: Customer supplied forks must have the fork lock pins removed for proper operation on the fork positioner. If the forks are removed to be used in Non-Fork Positioner applications, the fork 55F – 55-60 ft.-lbs.(75-80 Nm) lock pins must be reinstalled. 100F/120F – 110-118 ft.-lbs.(150-160 Nm) FP0008.eps Install backrest 115-125 ft.-lbs. (155-170 Nm) FP0009.eps Install solenoid control knob– Solenoid equipped units PRESS BUTTON TO POSITION SIDESHIFT...
  • Page 7 NTRODUCTION Install wiring – Solenoid equipped units Diode Knob Black 7.5 Amp White Button 7.5 Amp Fuse White Black Fuse Solenoid Coils User 18 gauge wire Solenoid Supplied 1/4 in. Terminals Coils Diode Wire FP0022.eps FP0021.eps Flush hydraulic supply hoses A Install hoses B Operate auxiliary valves (both directions)
  • Page 8 NSTALLATION Install hoses Forks Out/SSL Forks In/SSR Solenoid Fork Positioner with Cable Solenoid Valve Cable Reel and Internal Reeving Hydraulic Supply Installation Kit 224041 FP0011.eps Forks Out/SSL Forks In/SSR Solenoid Cable 6-N-1 Cable-Hose Reel Hydraulic Supply Installation Kit 224041 FP0012.eps 208743 Rev.
  • Page 9 NTRODUCTION Install hoses Forks Out/SSL Forks In/SSR Fork Positioner with Sequence Valve Internal Reeving Hydraulic Supply Installation Kit 224041 FP0014.eps FORK POSITIONER WITH SEQUENCE VALVE FORK POSITIONER WITH FORK POSITIONER WITH A Sideshift Left – Forks Out STANDARD VALVE SOLENOID VALVE B Sideshift Right – Forks In A Sideshift Left A Sideshift Left B Sideshift Right A Forks Out (press knob button)
  • Page 10 NSTALLATION Lubrication Points – 100 hours Grease fittings IMPORTANT: Prelubed at factory. Lube not necessary for installation. • Lubricate the grease fittings (sideshift to access) and lower bearings every 100 hours with chassis grease. • Lubricate the shaded areas on the fork bars with Slip Plate (Slix It) No. 8035 lubricant– Cascade part no. 599489. Fork Bars Lubricate full length FP0727.eps Lower Bearings Inspect Forks and Upper Carriage Lower Hook/Carriage Clearance Bar – 500 hours Repair or Replace Use wear gauge part no. 209508 (ITA Class II) or 209507 (ITA Class III) to inspect for carriage bar and fork hook wear every 500 hours of operation.
  • Page 11 Lower Hooks hoses and hydraulic leaks. Clearance ❏ Inspect the clearance between the truck lower carriage bar and the fork positioner lower hooks. Tighten the lower hook bolts to a torque of 115-125 ft.-lbs. (155-170 Nm). .09 in. FP0010.eps ❏ Lubricate the grease fittings (sideshift to access) and (2.3 mm) lower bearings with chassis grease. Upper Bearing Zerk Fittings ❏ Lubricate the shaded areas (refer to step 12 of Installation) on the fork bars with Slip Plate (Slix It) No. 8035 lubricant - Cascade part no. 599489. 500 Hour Maintenance After each 500 hours of truck operation, in addition to the 100 hour maintenance, perform the following procedures. ❏ Tighten the backrest capscrews to a torque of 115-125 ft.-lbs. (155-170 Nm). ❏ Check the forks and carriage for wear with wear gauge part no. 209509 (Class II) or 209507 (Class III). Refer to Installation step 13. ❏ Apply chassis grease to the upper bearing zerk fittings and fork carrier bearings. 1000 Hour FP0091.eps Maintenance Fork Carrier...

  • Page 12: General Procedures

    • An inline flow meter capable of measuring hydraulic flow to 20 GPM (80 L/min), Cascade part no. 671477 • A pressure gauge capable of measuring pressure to Flow meter Kit 671477 3500 psi (240 bar), Cascade part no. 671212.

  • Page 13: Plumbing

    ROUBLESHOOTING Flow Divider Plumbing Valve Manifold Hosing diagram– 4.2-1 Sideshift non-Flow divider and Cylinder Flow divider Valve POSITIOn FORKS OuTWARd and SIdeSHIFT RIGHT PReSSuRe Fork Position ReTuRn Cylinders nOTe: For Position Forks INWARD and Sideshift LEFT, reverse the shades shown. Internal Reeving Truck...
  • Page 14 ROUBLESHOOTING Sequence Hosing diagram– Valve 4.2-3 Flow Divider Sequence Valve Valve Sideshift Cylinder POSITIOn FORKS OuTWARd and SIdeSHIFT RIGHT PReSSuRe ReTuRn nOTe: For Position Forks INWARD Fork and Sideshift LEFT, reverse the shades Position shown. Cylinders Internal Reeving Truck Termination Auxiliary Valves FP0051.eps...
  • Page 15 ROUBLESHOOTING Solenoid Valve Hosing diagram– 4.2-5 Flow Solenoid Valve Divider Valve Sideshift Cylinder POSITIOn FORKS OuTWARd and SIdeSHIFT RIGHT PReSSuRe ReTuRn nOTe: For Position Forks INWARD Fork and Sideshift LEFT, reverse the shades Position shown. Cylinders Internal Reeving Truck Termination Auxiliary Valve FP0047.eps...

  • Page 16: Fork Position Circuit

    ROUBLESHOOTING Fork Position circuit There are six potential problems that could affect fork positioning operation. • Fork carriers binding in the carriage grooves. • Kinked supply hoses or air in the system. • External leaks. • Incorrect hydraulic pressure/volume from truck •...

  • Page 17: Sideshift Circuit

    ROUBLESHOOTING Flow divider Valve equipped attachments – Start fitting the truck. Position the forks in and out. If the forks do not position evenly, the flow divider valve cartridge or cylinders require service. Continue troubleshooting. Position the forks completely outward. Disconnect the opposite end of the hose connected to the flow divider valve CL (close) port from its fitting.

  • Page 18: Electrical Circuit

    ROUBLESHOOTING electrical circuit (Solenoid equipped attachments) Check for truck voltage at the solenoid coil terminals when the knob button is pushed. Check the solenoid coil to make sure it matches the truck voltage. The coil voltage is marked at the terminals.

  • Page 19: Attachment Removal

    ERVICE Attachment Removal Remove the backrest. For reassembly tighten the cap- screws to a torque of 145 ft.-lbs. (195 Nm) for Cascade backrests only. Consult the lift truck service manual if equipped with truck manufacturer’s backrest. Remove the fork stops from the fork carrier. Remove the forks.

  • Page 20: Bearings

    • Lubricate the grease fittings and lower bearings every Lubricate 500 hours with chassis grease. full length • Lubricate the shaded areas on the fork bars with Slip Plate (Slix It) No. 8035 lubricant– Cascade part no. 599489. FP0086.eps Lower bearings Fork Carrier Bearing 5.2-2...

  • Page 21: Carriage Bearing Service

    ERVICE 1000 lb Carriage Bearing Service (450 kg) 5.2-3 Remove the forks from the attachment. Remove the clevis pin from the base end of the sideshift cylinder. Disconnect the hose ends from the sideshift cyinder and anchor plate fittings. Tag hoses for reassembly. Remove the setscrew from the anchor plate.

  • Page 22: Valves

    ERVICE Valves Valve Removal 5.3-1 WARNING: Before removing any hoses, relieve pressure in the hydraulic system. Turn the truck off, then actuate the truck control valve several times in both directions. Remove the hoses from the valve. Tag the hoses for reassembly.

  • Page 23: Sequence Valve Service

    ERVICE Sequence Valve Service 5.3-3 IMPORTANT: Service the valve in a clean work area. Remove the cartridge valves. Remove the remaining plugs and fittings. Remove the O-rings and back-up rings from the cartridge valves. Clean all parts with kerosene or cleaning solvent. For reassembly, reverse the above procedures except as follows: •...

  • Page 24: Sideshift Cylinder

    ERVICE Sideshift Cylinder Cylinder Speed 5.4-1 Adjustment The sideshifting speed can be adjusted by modifying the restrictor washer in the cylinder base end port. WARNING: Before removing any hoses, FP0274.eps relieve pressure in the hydraulic system. Turn the truck off, then actuate the truck control valve several times in both directions.

  • Page 25: Cylinder Disassembly

    ERVICE Cylinder Disassembly 5.4-3 Clamp the cylinder in a soft-jawed vise. Clamp lightly on the base end only. Position the cylinder rod in the fully extended position. Remove the spiral snap rings from the retainer. See the illustration below. Tap the retainer into the shell approximately 2 in. SS0059.eps (50 mm).

  • Page 26: Cylinder Reassembly

    ERVICE Cylinder Reassembly 5.4-4 Polish the piston and retainer chamfer angle with emery cloth. This allows the seals to slide over the chamfer easier. Wash all components with cleaning solvent. Lubricate all new seals and rings with petroleum jelly or STP. Note the direction of the U-cup seals.

  • Page 27: Fork Position Cylinder

    ERVICE Fork Position Cylinders Cylinder Removal 5.5-1 WARNING: Before removing any hoses, relieve pressure in the hydraulic system. Turn the truck off, then actuate the truck control valve several times in both directions. Disconnect the hoses from the cylinder ports. Tag the hoses for reassembly.

  • Page 28: Cylinder Disassembly

    ERVICE Cylinder Disassembly 5.5-2 Clamp the cylinder in a soft-jawed vise. Clamp lightly on the base end only. Position the cylinder rod in the fully extended position. Remove the spiral snap ring from the retainer. See the illustration below. Tap the retainer into the shell approximately 2 in. (50 mm).

  • Page 29: Cylinder Reassembly

    ERVICE Cylinder Reassembly 5.5-4 Polish the piston and retainer chamfer angle with emery cloth. This allows the seals to slide over the chamfer easier. Wash all components with cleaning solvent. Lubricate all new seals and rings with petroleum jelly or STP. Note the direction of the U-cup seals.

  • Page 30: Specifications

    Recommended 4 GPM (15 L/min.) 5 GPM (19 L/min.) Maximum 5 GPM (19 L/min.) 6 GPM (23 L/min.) Hydraulic Oil Cascade attachments are compatible with SAE 10W petroleum base oil per Mil. Spec. MIL-0-5606 or MIL-0-2104B. Use of synthetic or aqueous base hydraulic oil is not recommended.

  • Page 31: Truck Carriage

    23.50 in. (597.0 mm) Class IV GA0028.eps Torque Values 6.1-4 FP0063.eps FP0275.eps Torque Values Ref. No. Ft.-lbs. (Nm) 29-37 40-50 ▲ 55-60 75-80 148-162 200-220 10-12 16-18 22-25 ▲ Cascade backrests only. For other backrests see OEM recommendations. 208743 Rev. 1...
  • Page 32 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...

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