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Summary of Contents for cascade corporation K Series
- Page 1 ERVICE MANUAL K-Series Integral Sideshifting Fork Positioner Manual Number 6083966-R4 cascade corporation Cascade is a Registered Trademark of Cascade Corporation...
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Page 2: Table Of Contents
ONTENTS Page INTRODUCTION, Section 1 Introduction Special Definitions PERIODIC MAINTENANCE, Section 2 100-Hour Maintenance 300-Hour Maintenance 1000-Hour Maintenance 2000-Hour Maintenance TROUBLESHOOTING, Section 3 General Procedures Truck System Requirements Tools Required Troubleshooting Chart Plumbing Hosing Diagram Hydraulic Schematic Fork Position Function Supply Circuit Test Fork Position Circuit Test Sideshift Function... -
Page 3: Introduction, Section
NTRODUCTION Introduction This Manual provides the Installation, Periodic Maintenance, Troubleshooting, Service and Specifications for Cascade K-Series Integral Fork Positioner. In any communication about the attachment, refer to the product ID Label. IMPORTANT: K-Series Integral Fork Positioner/ Sideshifter is metric. Supply fittings adapted as required for application. NOTE: Specifications are shown in both inch and (Metric) units. -
Page 4: 100-Hour Maintenance
ERIODIC MAINTENANCE WARNING: After completing any service procedure, always test the Fork Positioner/ Sideshifter through five complete cycles to make sure the attachment operates correctly before returning it to the job. Backrest 100-Hour Maintenance Cylinders Every time the lift truck is serviced or every 100 hours and hoses Cylinder Rod of truck operation, whichever comes first, complete the... -
Page 5: 2000-Hour Maintenance
ERIODIC MAINTENANCE 2000-Hour Maintenance After 2000 hours of truck operation, in addition to the 100, 300 and 1000-hour maintenance, forks in use shall be inspected at intervals of not more than 12 months (for single shift operations) or whenever any defect or permanent deformation is detected. -
Page 6: General Procedures
ROUBLESHOOTING General Procedures WARNING: Before servicing any hydraulic component, relieve pressure in the system. Turn the truck off and move Truck System Requirements 3.1-1 the truck auxiliary control valves several times in both directions. • Truck hydraulic pressure should be within the range After completing any service procedure, test the shown in Specifications, Section 5.1. -
Page 7: Plumbing
ROUBLESHOOTING Plumbing Fork Position Cylinders Hosing Diagram 3.2-1 Manifold OPEN Port CLOSE Port Truck Auxiliary Valve SIDESHIFT LEFT, SIDESHIFT CLOSE FORKS Sideshift Cylinder PRESSURE RETURN NOTE: For SIDESHIFT RIGHT, IHR Terminals OPEN FORKS reverse the Truck Auxiliary colors shown. Valve FORK POSITION FP0757.eps Hydraulic Schematic... -
Page 8: Fork Position Function
ROUBLESHOOTING Fork Position Function WARNING: Before removing any hoses, relieve pressure in the hydraulic Five potential problems can affect the fork positioning system. With the truck off, open the function: truck auxiliary control valve(s) several times in both directions. • Binding due to bending damage, wear, lack of lubrication. -
Page 9: Sideshift Function
ROUBLESHOOTING Sideshift Function WARNING: Before removing any hoses, relieve pressure in the hydraulic system. Six potential problems can affect the sideshifting function: With the truck off, open the truck auxiliary control valve(s) several times in both • Binding due to bending damage, wear, lack of directions. -
Page 10: Fork Positioner Removal
ERVICE Fork Positioner Removal and Replacement Fork Carrier 4.1-1 Outer Section Fork Carrier Fork Carrier Remove capscrews fastening inner fork carriers and Capscrews Inner Section remove forks. WARNING: Make sure locking pins are removed from the forks. Forks must slide freely on sideshifter frame or carriage bars. - Page 11 ERVICE Removal and Replacement (Continued) 4.1-1 Remove capscrews fastening Fork Positioner to sideshifter frame and remove unit through front. Keep track of shims. For reassembly, shim as necessary, with a maximum of 4 shims per side. Tighten mounting capscrews to 50 ft.-lbs. (65 Nm). CAUTION: Maximum difference in number of shims per side is 2 and the total allowable gap before tightening capscrews is 0.020 in.
- Page 12 ERVICE Removal and Replacement (Continued) 4.1-1 For installation, reverse the above procedures with the following exceptions: • Service fork positioner components. Refer to Section 4.2. • If necessary, adjust flow restrictors for equal fork movement as follows: Loosen jam nuts and screw both flow restrictors in until they bottom.
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Page 13: Fork Carrier Configuration
ERVICE Fork Carrier Configuration 4.1-2 WARNING: For forks longer than 60 in. (1500 mm) or load centers exceeding NOTE: Refer to the layouts below to position inner retainers 30 in. (760 mm), consult Cascade. for various fork widths. Tighten fork carrier inner retainer capscrews to 25 ft.-lbs. -
Page 14: Fork Positioner Service
ERVICE Fork Positioner Service Disassembly 4.2-1 Use C-clamps to clamp Fork Positioner face down onto a benchtop as shown. Use 2 x 4 in. (5 x 10 cm) wood blocks for clearance and to keep parts in alignment. Tool Anchor 6048031 Plug Cylinder... -
Page 15: Reassembly
ERVICE Reassembly 4.2-3 Lubricate new seals, O-rings and wear rings with O-ring lube, hydraulic fluid or petroleum jelly. INSTALLING RETAINER INTERNAL SEALS If necessary, use 400-grit emery cloth to break any sharp edges on the piston, retainer and cylinder shell Twist seal into 'figure 8' or chamfer angles and threads to prevent seal damage. -
Page 16: Sideshifter Frame Removal
ERVICE Sidesifter Frame Removal Lower Mounting Hooks NOTE: To remove the integral sideshifter carriage from the Minimum mast, refer to the OEM Service Manual procedures. 1-13/16 in. Wear (46 mm) Remove the forks and backrest from the Sideshifter Limit frame. For Cascade backrest reassembly, tighten the Mark capscrews to 145 ft.-lbs. -
Page 17: Bearing Lubrication
ERVICE Bearings Upper Bearings Grease Fittings Bearing Lubrication 4.4-1 Lubricate both the upper and lower Sideshifter bearings with chasis grease every 300 hours or 4 weeks of operation (whichever comes first). In contaminated environments, lubricate every week or as required. SS0443.eps Upper Bearings Grease Areas... -
Page 18: Sideshift Cylinder
ERVICE Sideshift Cylinder Removal, Inspection and 4.5-1 Replacement WARNING: Before removing any hoses, relieve pressure in the hydraulic system. With the truck off, open the truck auxiliary control valve(s) several times in both directions. SS0440.eps Sideshift LEFT Front View Sideshift RIGHT Disconnect the hoses from the cylinder and tag for reassembly. -
Page 19: Rod Seal Carrier
ERVICE Rod Seal Carrier 4.5-2 Rod Seal Carriers Replacement NOTE: The rod seal carriers are the only field servicable parts on the cylinder and are supplied with seals already loaded. The cylinder must be removed from the carriage to replace the seals. Remove the cylinder from the carriage as described in Section 4.5-1. -
Page 20: Hydraulics
PECIFICATIONS Specifications Hydraulics 5.1-1 Truck Relief Setting 2200 psi (152 bar) Recommended 3500 psi (241 bar) Maximum Truck Flow Volume ➀ Recommended ➁ ➂ Min. Max. 35K, 55K, 1 GPM 2 GPM 3 GPM (4 L/min.) (7.5 L/min.) (12 L/min.) ➀... -
Page 21: Torque Values
PECIFICATIONS Torque Values 5.1-3 Fastener torque values for the K-Series Integral Fork NOTE: All fasteners have a torque value Positioner are shown in the table below in both US and range of ±10% of stated value. Metric units. All torque values are also called out in each service section throughout this manual. - Page 22 Pte. Ltd. 18 Tuas South Street 5 Rocklea, QLD 4107 East Tamaki, Auckland Australia New Zealand Singapore 637796 Tel: +65-6795-7555 Tel: 1-800-227-223 Tel: +64-9-273-9136 Fax: +61 7 3373-7333 Fax: +64-9-273-9137 Fax: +65-6863-1368 © Cascade Corporation 2015 02-2015 Part Number 6083966-R4...
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