H-Series Fork Positioners

Transcription

1 I NSTLLTION INSTRUTIONS H-Series Fork Positioners Manual Number cascade ascade is a Registered Trademark of ascade orporation

2 ONTENTS Recommended Hydraulic Supply i Truck Requirements 1 Installation 2 Periodic Maintenance 7 This Manual provides instructions for installing ascade H-Series Fork Positioners. Follow the suggested installation procedures for best results. If you have any questions or need more information, contact your nearest ascade Service epartment (see back cover). Read the WRNING Statements placed throughout this Manual to emphasize safety during Fork Positioner installation. IMPORTNT: Field alterations may impair performance or capability and could result in loss of warranty. onsult ascade for any required modifications. R EOMMENE HYRULI SUPPLY OPTIONS H-Series Fork Positioners can be operated with any of the hydraulic supply arrangements shown below. Refer to ascade Hose & able Reel Selection Guide, Part No , to select the correct hose reel for the mast and truck. Hose and fitting requirements are as follows: ll hoses and fittings for the fork-positioning and sideshifting (if equipped) functions should be No. 6 with 9/32 in. (7 mm) minimum I.. Non-Sideshifting Mast Single Internal Reeving OR LH THINLINE 2-Port Hose Reel Group Sideshifting Mast ouble Internal Reeving OR and Mast Single Internal Reeving and RH THINLINE 2-Port Hose Reel Group OR and RH and LH THINLINE 2-Port Hose Reel Groups Solenoid daption and Mast Single Internal Reeving and RH able Reel Group OR RH 6-N-1 able/hose Reel Group G0033.ill i Rev. 0

3 T RUK REQUIREMENTS WRNING: 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. onsult the truck nameplate. Truck Relief Setting 2300 psi (160 bar) Recommended 2600 psi (180 bar) Maximum Truck Flow Volume ➀ 150H Min. ➁ Recommended Max. ➂ Fork 3 GPM 4 GPM 5 GPM Position (11 L/min.) (15 L/min.) (19 L/min.) Sideshift 1 GPM 6 GPM 12 GPM (4 L/min.) (23 L/min.) (45 L/min.) ➀ ascade H-Series Fork Positioners are compatible with SE 10W petroleum base hydraulic fluid meeting Mil. Spec. MIL or MIL Use of synthetic or aqueous base hydraulic fluid is not recommended. If fire resistant hydraulic fluid is required, special seals must be used. ontact ascade. ➁ Flow less than recommended can result in slow and unequal fork movement. ➂ Flow greater than maximum can result in excessive heating, reduced system performance and short hydraulic system life. G0095.ill arriage Mount imension () IT (ISO) G0028.ill Minimum Maximum lass II in. (380.0 mm) in. (381.0 mm) lass III in. (474.5 mm) in. (476.0 mm) lass IV in. (595.5 mm) in. (597.0 mm) arriage lean carriage bars and inspect for damaged notches. uxiliary Valve Functions heck for compliance with NSI standards: Tilt Forward Spread Forks Hoist own Sideshift Left G0082.ill Hoist Up Tilt ack Sideshift Right lose Forks Rev. 0 1

4 I NSTLLTION 1 ttach overhead hoist Remove banding. ttach hoist to top of backrest as shown and lift ttachment into vertical position. Remove bolt-on lower mounting hooks. WRNING: Make sure overhead hoist has a rated capacity of at least 2000 lbs. (910 kg.) FP0211.ill 2 Unlock quick-change lower mounting hooks (if equipped) Remove pin and drop hooks into unlocked position. Reinstall pin in lower hole. Guide NOTE: Guides can be reversed to reduce hook-to-carriage clearance (See lower hook installation, Step 4). cascade Pin LH lower Hook 5/8-in. (16 mm) offset on top provides max. clearance Rev. 0 L0097.ill Tighten apscrews: lass II, III Mounting 165 ft.-lbs. (225 Nm) lass IV Mounting 190 ft.-lbs. (255 Nm)

5 I NSTLLTION 3 Mount Fork Positioner on truck Lower ttachment onto truck carriage. Engage upper mounting hooks. If sideshifter equipped, make sure bearings are in place and centering tab engages center notch on truck carriage. IT lass II in. (15 17 mm) IT lass III in. (18 20 mm) IT lass IV in. (18 20 mm) enter Notch IT lass II in. (8 9 mm) IT lass III in. (10 11 mm) IT lass IV in. (12 13 mm) FP0209.ill Truck arriage SS0139.ill ack (river's) View Sideshifter Upper earings S0023.ill 4 Install or engage lower hooks Tap tight into position. If sideshifter, back off 1 notch and check clearance: 3/32 in. (2.4 mm) min. 3/16 in. (4.8 mm) max. OLT-ON TYPE JUST Lower arriage ar Slide hook up to engage bar, install pin in locked position. (upper hole.) QUIK-HNGE TYPE (optional) cascade Lower arriage ar Inspect hooks for excessive clearance. (Reverse guides to reduce clearance see Step 2.) 3/16 in. (4.8 mm) max. SS0140.ill SS0141.ill Tighten apscrews: lass II, III Mounting 120 ft.-lbs. (165 Nm) lass IV Mounting 190 ft.-lbs. (255 Nm) Rev. 0 3

6 I NSTLLTION 5 Install Forks ttach overhead hoist to backrest as shown. Remove capscrews fastening Fork Positioner frame to sideshifter or false carriage. Raise frame to install forks. E WRNING: Remove locking pins from forks. ssure that forks slide freely on carriage bars. Install forks, using bottom fork slot to engage forks with carriage. Line up forks with fork carriers on frame. Reinstall frame, engaging fork carriers with forks and top carriage bar. Tighten mounting capscrews to ft.-lbs. ( Nm). Fork Positioner Frame Mounting apscrews (4). Fork arriers FP0210.ill Forks Sideshifter or False arriage Rev. 0

7 I NSTLLTION 6 Prepare hoses etermine hose lengths required for hydraulic supply configuration of truck. ut hoses to length and install end fittings or quick-disconnect kits. INTERNL HOSE REEVING Sideshifting / Non-sideshifting lose Forks Spread Forks HOSE REELS Sideshifting / Non-Sideshifting lose Forks Spread Forks FP0207.ill FP0208.ill Sideshift Right Sideshift Left Sideshift Right Sideshift Left ack (river's) View 7 Flush hydraulic supply hoses Install hoses to hose terminals on carriage. onnect using union fittings. Operate auxiliary valves for 30 sec. Remove union fittings. G0092.ill Rev. 0 5

8 I NSTLLTION 8 onnect hoses prepared in Step 6 to ttachment fittings FP0219.ill 9 Install solenoid control knob (Solenoid equipped units) utton toward driver PRESS UTTON TO POSITION SIESHIFT dapter Truck control valve handle L0240.ill 10 Install wiring (Solenoid equipped units) ontrol Lever Knob iode iode Solenoid oil 7.5-mp Fuse White Knob utton lack 7.5-mp Fuse White lack L0258.ill L0257.ill User-supplied wire Solenoid oil Rev. 0

9 I NSTLLTION 11 ycle Fork Positioner functions Open and close forks several times. Sideshift (if equipped) left and right. heck for smoothness and equal movement. heck for operation in accordance with IT (ISO) standards. heck for leaks at fittings, valve, cylinders. UXILIRY VLVE FUNTIONS Tilt forward Hoist down G0005.ill Hoist up Tilt back NON-SIESHIFTING Spread Forks lose Forks (not used) (not used) SIESHIFTING Sideshift Left Sideshift Right Spread Forks lose Forks SIESHIFTING WITH SOLENOI VLVE Sideshift Left Spread Forks (press knob button) Sideshift Right lose Forks (press knob button) FP0164.ill FP0164.ill FP0164.ill 12 djust forks for equal movement (if required) Valve NOTE: ttachment is Factory-adjusted for equal fork movement when operated at recommended pressure and flow rate. Locate flow restrictor fittings below valve. Loosen jam nuts and screw both flow restrictors in until they bottom. Screw each restrictor out (W) three turns. Open forks fully, then close. Look for unequal fork movement. On faster fork (one that bottoms first), screw flow restrictor in (W) 1/2-turn. Repeat Steps and until fork movement is equal. Tighten jam nuts. Front View FP0176.ill Flow Restrictor Fittings Rev. 0 7

10 P ERIOI MINTENNE WRNING: fter 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. Fork arrier Grease Fittings (2) Sideshifter Upper earing Grease Fittings (2) (sideshift to expose fittings) 100-Hour Maintenance Every time the lift truck is serviced or every 100 hours of truck operation, whichever comes first, perform the following maintenance procedures: heck for loose or missing bolts, worn or damaged hoses and hydraulic leaks. 500-Hour Maintenance fter each 500 hours of truck operation, in addition to the 100-hour maintenance, perform the following procedures: Tighten fork positioner frame mounting capscrews to ft.-lbs. ( Nm). Tighten lower hook capscrews to: lass II, III 125 ft.-lbs. (165 Nm). lass IV 190 ft.-lbs. (255 Nm). pply chassis grease to fork carrier grease fittings. pply chassis grease to fork cylinder rod anchors. pply chassis grease to sideshifter (if equipped) upper bearing grease fittings, and lower flat bearings. Frame Mounting apscrews (4) Front View FP0206.ill Fork arrier earings (2) ylinder Rod nchors (2) 1000-Hour Maintenance fter each 1000 hours of truck operation, in addition to the 100 and 500-hour maintenance, perform the following procedures: Inspect fork carrier bearings for wear and replace if necessary. Inspect fork cylinder rod anchors for wear and replace if necessary. Inspect thickness of of sideshifter (if equipped) upper bearing sets. If either bearing segment is worn to less than 1/16-in. (1.5 mm) thick, replace the bearing set. Inspect exposed thickness of sideshifter (if equipped) lower bearings. If either has less than 1/16-in. (1.5 mm) showing, replace both bearings (see Service Manual). Sideshifter Lower earings (2) FP0205.ill Lower Mounting Hook apscrews (4) ack (river's) View Rev. 0

11 o you have questions you need answered right now? all your nearest ascade Service epartment. ascade orporation U.S. Headquarters 2201 NE 201st Fairview, OR Tel: 800-SE ( ) FX: ascade anada Inc Timberlea lvd. Mississauga, Ontario anada L4W-4M6 Tel: FX: ascade GmbH Monchengladbach Klosterhofweg 52 Germany Tel: FX: ascade Finland Vantas Finland Tel: FX: ascade N.V. European Headquarters P.O. ox El lmere amsluisweg E lmere The Netherlands Tel: FX: ascade N.V. enelux Sales and Service P.O. ox El lmere amsluisweg E lmere The Netherlands Tel: FX: ascade (UK) Ltd. 15, Orgreave rescent ore House Industrial Estate Handsworth Sheffield S13 9NQ England Tel: FX: ascade Scandinavia Hydraulik.. Muskötgatan 19, E8-9 S25466 Helsingborg Sweden Tel: FX: ascade Norway Østerliveien Oslo Norway Tel: FX: ascade France S..R.L. 11, Rue Jean harcot Zone Industrielle Sud or.p Morangis edex France Tel: FX: ascade Hispania S.. venida e La Fabregada, 7 Hospitalet e Llobregat arcelona Spain Tel: FX: ascade Japan Ltd , Torikai Kami Settsu, Osaka Japan, 566 Tel: FX: ascade Korea Room 508, Pum Yang ldg , ang ac-ong Se-ho Ku, Seoul Korea Tel: ext. 512 FX: HYO-ascade Pty. Ltd. 87 ntimony Street arole Park, risbane 4300 ustralia Tel: FX: HYO-ascade (NZ) Ltd. 15 Ra Ora rive, East Tamaki P.O. ox Howick, uckland New Zealand Tel: FX: ascade (frica) Pty. Ltd. P.O. ox 625, Isando Steel Road Sparton, Kempton Park South frica Tel: FX: ascade-xiamen Wanshan No. 1 Workshop Huli Road Xiamen Fujian, PR Tel: FX: ascade (Singapore) Trading o. Four Seasons Park utumn lock - pt ascaden Walk Singapore Tel: FX: c ascade orporation Part Number