ERVICE MANUAL. F-Series. Fork Positioners. Manual Number R1. cascade. corporation. Cascade is a Registered Trademark of Cascade Corporation

Transcription

1 S ERVICE MNUL F-Series Fork Positioners Manual Number R1 cascade corporation Cascade is a Registered Trademark of Cascade Corporation

2 C ONTENTS INTRODUCTION, Section 1 1 Special Definitions INSTLLTION, Section 2 2 System Requirements, Recommended Hydraulic Supply, Installation Procedures, PERIODIC MINTENNCE, Section 3 9 TROULESHOOTING, Section 4 10 General Procedures, System Requirements, Tools Required, Troubleshooting Chart, Plumbing, Hosing Diagram, 4.2-1, 2-3, Circuit Schematic, 4.2-2, 2-4, Fork Position Circuit, Sideshift Circuit, Electrical Circuit, SERVICE, Section 5 17 ttachment Removal, earings, earing Lubrication, Fork Carrier earing Service, Carriage earing Service, s, Removal, Flow Divider Service, Sequence Service, Solenoid Service, Sideshift Cylinder, Cylinder Speed djustment, Cylinder Removal, Cylinder Disassembly, Cylinder Inspection, Cylinder Reassembly Fork Position Cylinder, Cylinder Removal, Cylinder Disassembly, Cylinder Inspection, Cylinder Reassembly, SPECIFICTIONS, Section 6 28 Specifications, Hydraulics, uxiliary Functions, Carriage, Torque Values, Page

3 I NTRODUCTION This Manual provides the Installation, Periodic Maintenance, Troubleshooting, Service and Specifications for Cascade F-Series Fork Positioners. IMPORTNT: ll hoses, tubes and fittings on F-Series attachments are JIC. NOTE: Specifications are shown in both U.S. and (Metric) units. 1.1 Special Definitions The statements shown appear throughout this Manual where special emphasis is required. Read all WRNINGS and CUTIONS before proceeding with any work. Statements labeled IMPORTNT and NOTE are provided as additional information of special significance or to make your job easier. WRNING - statement preceded by WRNING is information that should be acted upon to prevent bodily injury. WRNING is always inside a ruled box. CUTION - statement preceded by CUTION is information that should be acted upon to prevent machine damage. IMPORTNT - statement preceded by IMPORTNT is information that possesses special significance. NOTE - statement preceded by NOTE is information that is handy to know and may make your job easier. 1

4 I NSTLLTION 2.1 System Requirements Relief Setting Minimum 2300 psi (160) bar Maximum 2600 psi (180) bar Flow Volume Minimum Recommended Maximum 55F 100F/120F 3 GPM (11 L/min.) 4 GPM (15 L/min.) 4 GPM (15 L/min.) 5 GPM (19 L/min.) 5 GPM (19 L/min.) 6 GPM (23 L/min.) Dimension IT (ISO) Mounting Minimum Maximum Class II in. (380.0 mm) in. (381.0 mm) Class III in. (474.5 mm) in. (476.0 mm) Class IV in. (595.5 mm) in. (597.0 mm) G0023.eps Clean carriage bars and inspect for damaged notches. 2.2 Recommended Hydraulic Supply Fork Positioner with Standard Non-Sideshifting Mast Single Internal Reeving OR RH THINLINE 2-Port Hose Reel Group Sideshifting Mast Double Internal Reeving OR and Mast Single Internal Reeving and RH THINLINE 2-Port Hose Reel Group OR and C RH and LH THINLINE 2-Port Hose Reel Groups Fork Positioner with Sequence Mast Single Internal Reeving OR RH THINLINE 2-Port Hose Reel Group Fork Positioner with Solenoid and Mast Single Internal Reeving and RH Cable Reel Group OR RH 6-N-1 Cable/Hose Reel Group G0032.eps C 2

5 I NTRODUCTION 2.3 Installation Procedures 1ttach overhead hoist 2 Remove lower hooks 1000 lb. 450 Kg. FP0023.eps FP0007.eps 3 Mount on truck carriage IT Class II in. (15-17 mm) IT Class III in. (18-20 mm) IT Class IV in. (18-20 mm) Center Notch IT Class II in. (7-9 mm) IT Class III in. (10-11 mm) IT Class IV in. (12-13 mm) FP0025.eps Carriage G0035.eps Upper earings FP0521.eps 4 Install lower hooks FP0520.eps ft.-lbs ( Nm).09 in. (2.3 mm) FP0010.eps 3

6 I NSTLLTION 5 Install forks Remove fork lock pins Remove fork blocks C Install forks D djust blocks to provide 1/16 in. (1.5 mm) clearance with side of fork. C WRNING: 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 lock pins must be reinstalled.,d 55F ft.-lbs.(75-80 Nm) 100F/120F ft.-lbs.( Nm) FP0008.eps 6 Install backrest ft.-lbs. ( Nm) FP0009.eps 7 Install solenoid control knob Solenoid equipped units PRESS UTTON TO POSITION FORKS SIDESHIFT utton toward driver c dapter control valve handle G0049.eps 4

7 I NTRODUCTION 8 Install wiring Solenoid equipped units 7.5 mp Fuse White Knob utton lack 7.5 mp Fuse White lack Diode 18 gauge wire 1/4 in. Terminals Solenoid Coils Diode User Supplied Wire Solenoid Coils FP0021.eps FP0022.eps 9 Flush hydraulic supply hoses Install hoses Operate auxiliary valves (both directions) C Remove hoses G0034.eps 10 Install hoses SSR SSL Fork Positioner with Standard Single Internal Reeving Hydraulic Supply Non-Sideshifting Installation Kit (2 Hoses) Forks Out Forks In Double Internal Reeving Hydraulic Supply Sideshifting Installation Kit (4 Hoses) FP0026.eps 5

8 I NSTLLTION 10 Install hoses Forks Out/SSL Forks In/SSR Fork Positioner with Solenoid Solenoid Cable Cable Reel and Internal Reeving Hydraulic Supply Installation Kit FP0011.eps Forks Out/SSL Forks In/SSR Solenoid Cable 6-N-1 Cable-Hose Reel Hydraulic Supply Installation Kit FP0012.eps 6

9 I NTRODUCTION 10 Install hoses Forks Out/SSL Forks In/SSR Fork Positioner with Sequence Internal Reeving Hydraulic Supply Installation Kit FP0014.eps FORK POSITIONER WITH STNDRD VLVE Sideshift Left Sideshift Right C Forks Out D Forks In FORK POSITIONER WITH SEQUENCE VLVE Sideshift Left Forks Out Sideshift Right Forks In FORK POSITIONER WITH SOLENOID VLVE Sideshift Left Forks Out (press knob button) Sideshift Right Forks In (press knob button) D C FP0016.eps D C FP0016.eps FP0016.eps 11 uxiliary Functions Hoist down Tilt forward C D G0005.eps Hoist up Tilt back 7

10 I NSTLLTION 12 Lubrication Points 100 hours Grease fittings IMPORTNT: 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 lubricant Cascade part no Fork ars Lubricate full length FP0727.eps Lower earings 13 Inspect Forks and Upper Carriage ar 500 hours Use wear gauge part no (IT Class II) or (IT Class III) to inspect for carriage bar and fork hook wear every 500 hours of operation. Inspect for excessive clearance between the lower hooks and carriage bar. If the gauge fits between the carriage bar and lower hook, repair or replacement is needed. Inspect the upper carriage bar. If the gauge arrow touches the carriage bar, repair or replacement is needed. Inspect the fork upper hooks. If the gauge arrow touches the hook, repair or replacement is needed. Lower Hook/Carriage Clearance OK Fork Upper Hooks Repair or Replace FP0102.eps Upper Carriage ar OK Repair or Replace OK Repair or Replace FP0100.eps FP0101.eps 8

11 P ERIODIC MINTENNCE 100 Hour Maintenance Every time the lift truck is serviced or every 100 hours of truck operation, whichever comes first, complete the following maintenance procedures. Check for loose or missing bolts, worn or damaged hoses and hydraulic leaks. Inspect the clearance between the truck lower carriage bar and the fork positioner lower hooks. Tighten the lower hook bolts to a torque of ft.-lbs. ( Nm). Lubricate the grease fittings (sideshift to access) and lower bearings with chassis grease. Lubricate the shaded areas (refer to step 12 of Installation) on the fork bars with Slip Plate (Slix It) No lubricant - Cascade part no IMPORTNT: fter completing any service procedure, always test each function through 5 complete cycles. First test the attachment empty, then test with a load to make sure the attachment operates correctly before returning it to the job. Lower Hooks Clearance.09 in. (2.3 mm) FP0010.eps Upper earing Zerk Fittings 500 Hour Maintenance fter 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 ft.-lbs. ( Nm). Check the forks and carriage for wear with wear gauge part no (Class II) or (Class III). Refer to Installation step 13. pply chassis grease to the upper bearing zerk fittings and fork carrier bearings Hour Maintenance fter each 1000 hours of truck operation, in addition to the 100 and 500 hour maintenance, perform the following procedures. Inspect the thickness of the upper bearings. If either of the bearings are worn to less than 1/16 in. (1.5 mm) thick, they should be replaced. Inspect the exposed thickness of the lower bearings. If the exposed thickness is less than 1/16 in. (1.5 mm), they should be replaced. Inspect the fork carrier bearings. If the exposed thickness is less than 1/16 in. (1.5 mm), they should be replaced Hour Maintenance fter each 2000 hours of truck operation, in addition to the 100, 500 and 1000 hour maintenance, perform the following procedures. Replace the upper and lower bearing sets and fork carrier bearings. Fork Carrier earings Upper earings Lower earings FP0091.eps FP0092.eps 9

12 T ROULESHOOTING 4.1 General Procedures System Requirements The lift truck must supply sufficient hydraulic pressure to handle the heaviest load. Pressure must not exceed 2600 (180 bar). Hydraulic flow should be within the volume range shown. The truck hydraulic system must supply hydraulic oil to the attachment that meets the specifications shown Tools Required WRNING: efore servicing any hydraulic component, relieve system pressure in the system. Turn the truck off, and open the truck auxiliary valve(s) several times in both directions. fter completing any service procedure, always test the function through several cycles. First test the attachment empty to bleed air trapped in the system to the truck system. Then test the attachment with a load to be sure it operates correctly before returning it to the job. Stay clear of the load while testing. Do not raise the load more than 3 in. (75 cm) off floor while testing. In addition to a normal selection of hand tools, you will need: n inline flow meter capable of measuring hydraulic flow to 20 GPM (80 L/min), Cascade part no pressure gauge capable of measuring pressure to 3500 psi (240 bar), Cascade part no Troubleshooting Chart Relief Setting Minimum 2300 psi (160) bar Maximum 2600 psi (180) bar Flow Volume 55F 100F/120F 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.) Hydraulic Oil Cascade attachments are compatible with SE 10W petroleum base oil per Mil. Spec. MIL or MIL Use of synthetic or aqueous base hydraulic oil is not recommended. Contact Cascade if fire resistant hydraulic oil must be used. Flow Meter Kit (2) No JIC/ O-Ring Flow Meter Get all the Facts - It is important that you gather all the facts regarding the problem before you begin service procedures. The best way is to talk with the operator. sk for a complete description of the malfunction. (2) No. 6-8 JIC Reducer G0013.eps Fork Position Circuit Forks will not move. Forks move slowly. Normal speed is 4 in. (100 mm) per second. To correct one of these problems, see Section 4.3 Sideshift Circuit ttachment will not sideshift. ttachment sideshifts slowly. To correct one of these problems, see Section 4.4 Pressure Gauge Kit Pressure Gauge No. 4-6 Pipe/JIC No. 6-6 Hose G0014.eps No. 6-8 JIC Reducer No. 6 and No. 8 JIC Swivel Tee *No. 6 JIC/ O-Ring * Not included in Pressure Gauge Kit part no

13 T ROULESHOOTING 4.2 Plumbing Hosing Diagram Non-Flow Divider and Flow Divider Flow Divider OR Manifold Sideshift Cylinder POSITION FORKS OUTWRD and SIDESHIFT RIGHT PRESSURE RETURN NOTE: For Position Forks INWRD and Sideshift LEFT, reverse the shades shown. Fork Position Cylinders uxiliary s Internal Reeving Termination Circuit Schematic Non-Flow Divider and Flow Divider Fork Position Cylinders FP0049.eps Non-Flow Divider Manifold Flow Divider OPEN CLOSE Sideshift Cylinder Internal Reeving Terminations uxiliary Relief Hydraulic Pump Tank FP0050.eps 11

14 T ROULESHOOTING Hosing Diagram Sequence Flow Divider Sequence POSITION FORKS OUTWRD and SIDESHIFT RIGHT PRESSURE RETURN NOTE: For Position Forks INWRD and Sideshift LEFT, reverse the shades shown. Fork Position Cylinders Sideshift Cylinder uxiliary s Internal Reeving Termination Circuit Schematic Sequence Fork Position Cylinders FP0051.eps Flow Divider Sideshift Cylinder OPEN TT CLOSE TT SS Sequence TRUCK uxiliary Internal Reeving Termination FP0052.eps 12 Pump Relief Hydraulic Tank

15 T ROULESHOOTING Hosing Diagram Solenoid Flow Divider Solenoid POSITION FORKS OUTWRD and SIDESHIFT RIGHT PRESSURE RETURN NOTE: For Position Forks INWRD and Sideshift LEFT, reverse the shades shown. Fork Position Cylinders Sideshift Cylinder uxiliary Internal Reeving Termination Circuit Schematic Solenoid Fork Position Cylinders FP0047.eps Sideshift Cylinder OPEN Flow Divider CLOSE Solenoid uxiliary Reeving Termination Relief Hydraulic Pump Tank FP0048.eps 13

16 T ROULESHOOTING 4.3 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 Faulty electrical connection or defective solenoid coils (solenoid equipped attachments). cartridge malfunctions. 1 ctuate the fork position and sideshift functions eight time in each direction and hold the truck valve actuated for 10 seconds at the end of each cycle to remove air from the system. 2 Check the pressure delivered by the truck. Refer to the truck service manual. The recommended truck pressure is 2000 psi (140 bar). TRUCK PRESSURE MUST NOT EXCEED 2300 PSI (160 R), measured at the carriage hose terminal. 3 Check the flow volume at the carriage hose terminal. The recommended flow volume is: 55F 100F/120F 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.) Solenoid WRNING: efore removing any hoses or tubes, relieve pressure in the hydraulic system. With the truck off, open the truck auxiliary control valve(s) several times in both directions. 4 Solenoid equipped attachments Press the control knob position forks button. If the solenoid coils "click", they are working correctly. Continue troubleshooting. If one or both of the solenoid coils do not "click", troubleshoot the electrical circuit as described in Section Sequence equipped attachments Start the truck. Sideshift to one side to activate the fork position function. If the forks move while sideshifting (prior to the end of the sideshift stroke), the check valves in the sequence valve assembly need servicing. Refer to section If after sideshifting completely to one side to activate the fork position function, the forks do not position, adjust the sequence valve cartridge s inner screws. Remove the end plug from the cartridges and adjust the inner screw CW to lower the sequence pressure or CCW to increase sequence pressure. djust each cartridge a similar small amount at a time until the forks position correctly. ctute the fork position function to test the settings. If the forks still do not position, the sequence cartridges require service. See section Sequence FP0088.eps FP0087.eps Solenoid Coils Sequence Cartridges 14

17 T ROULESHOOTING 6 Flow Divider equipped attachments Start 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. 7 Position the forks completely outward. Disconnect the opposite end of the hose connected to the flow divider valve CL (close) port from its fitting. Cap the fitting and place the hose end in a bucket. ctuate the truck handle to position the forks outward. If oil flows out of the hose, the cylinder seals require service. See section 5.5. If oil does not flow out of the hose, the flow divider valve cartridge requires service. See section Cap fitting CLOSE Port Flow Divider FP0090.eps 4.4 Sideshift Circuit There are six potential problems that could affect sideshifting operation. Inadequate upper bearing lubrication or worn bearings. See sections and Lower mounting hooks installed incorrectly. See section 5.1 step 6. Kinked supply hoses. External leaks. Incorrect hydraulic pressure/volume from the truck. Worn or defective cylinder seals. 1 Check the pressure delivered by the truck. Refer to the truck service manual. The minimum recommended truck pressure is 2000 psi (140 bar). TRUCK PRESSURE MUST NOT EXCEED 3500 PSI (245 R), measured at the carriage hose terminal. 2 Check the flow volume at the carriage hose terminal. The recommended flow volume is 2 GPM (7.5 L/min). 3 Sideshift completely to the left and hold the control handle in this position for 5 seconds. Check for external leaks at the cylinder, fittings and hoses. 4 Sideshift completely to the right and hold the control handle in this position for 5 seconds. Check for external leaks at the cylinder, fittings and hoses. 5 Disconnect the LH cylinder hose from the hose terminal or internal reeving fitting. Cap the supply fitting. Place the hose end in a bucket. Start the truck. ctuate the sideshift left control handle for 5 seconds. If there is oil flow out of the hose, the cylinder seals are defective and require service. Refer to Section If there is no oil flow out of the hose, the problem is not hydraulic. WRNING: efore removing any hoses or tubes, relieve pressure in the hydraulic system. With the truck off, open the truck auxiliary control valve(s) several times in both directions. FP0078.eps 15

18 T ROULESHOOTING 4.5 Electrical Circuit (Solenoid equipped attachments) 1 Check for truck voltage at the solenoid coil terminals when the knob button is pushed. 2 Check the solenoid coil to make sure it matches the truck voltage. The coil voltage is marked at the terminals. Test the coils by checking for resistance with a Volt Ohm Meter across the terminals with the wires disconnected. If there is no ohmmeter reading shown, the solenoid coil is defective and requires replacing. 3 Check the control knob circuit fuse. Replace if necessary. 4 Check for loose electrical connections at the truck ignition switch, control knob button(s), solenoid valve terminals and diodes. 5 Remove the diode(s) from the solenoid valve 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. 7.5 mp Fuse White Knob utton lack 7.5 mp Fuse White lack Diode 18 Gauge Wire 1/4 in. Terminals FP0021.eps Solenoid s Diode User Supplied Wire Solenoid s FP0022.eps 16

19 S ERVICE 5.1 ttachment Removal 1 Remove the backrest. For reassembly tighten the capscrews 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. 2 Remove the fork stops from the fork carrier. Remove the forks. WRNING: efore removing any hoses, relieve pressure in the hydraulic system. Turn the truck off, then actuate the truck control valve several times in both directions. 2 FP0083.eps 1 3 Disconnect the attachment supply hoses. Tag the hoses for reassembly. 4 Remove the lower mounting hooks. 5 ttach a 1000 lb. (450 kg) capacity overhead hoist. Remove the attachment from the truck carriage lb (450 kg) 6 For installation, reverse the above procedures except for the following special instructions: Clean the upper bearings and upper hook bearing areas. Locate the upper bearings in the anchor bracket cutouts. Install the lower mounting hooks up tight against the carriage bar then back off on rib position. Tighten the capscrews to a torque of ft.-lbs. ( Nm). 6 FP0084.eps 4 FP0072.eps FP0085.eps Torque to ft.-lbs. ( Nm) 6 Clearance.09 in. (2.3 mm) FP0010.eps 17

20 S ERVICE 5.2 earings earing Lubrication Grease fittings Lubricate the grease fittings and lower bearings every 500 hours with chassis grease. Lubricate the shaded areas on the fork bars with Slip Plate (Slix It) No lubricant Cascade part no Lubricate full length FP0086.eps Lower bearings Fork Carrier earing Service 1 Remove the fork stop blocks from the fork carrier. Remove the fork. For reassembly, adjust the stop blocks to provide 1/16 in. (1.5 mm) clearance with the side of the fork and tighten the capscrews to a torque of ft.-lbs. (75-80 Nm). 2 Remove the cylinder anchor pin from the carrier lug. For reassembly, tighten the capscrew to a torque of 7-9 ft.-lbs. (10-12 Nm). 3 Remove the cylinder anchor lug from the carrier. For reassembly, tighten the capscrew to a torque of ft.-lbs. (22-25 Nm). 4 Slide the carrier out the side to remove the bearings. 5 For reassembly, reverse the above procedures except for the following special instructions: Clean the carriage bars of any built-up grease. Clean all parts prior to reassembly FP0069.eps 18

21 S ERVICE Carriage earing Service 1 Remove the forks from the attachment. 2 Remove the clevis pin from the base end of the sideshift cylinder. 3 Disconnect the hose ends from the sideshift cyinder and anchor plate fittings. Tag hoses for reassembly. 4 Remove the setscrew from the anchor plate. 5 Remove the lower mounting hooks. 6 ttach a suitable overhead hoist to the fork positioner carriage. Remove the carriage from the truck. The anchor bracket will remain on the truck carriage. 7 Measure the exposed thickness of the upper and lower bearings. If the thickness is less than 1/16 in. (1.5 mm), replace as required. 8 For reassembly, reverse the above procedures except for the following special instructions: Clean the upper hook and lower bearing pockets of any built-up grease. Clean all parts prior to reassembly. Install the lower mounting hooks as described in section 5.1 step 6. fter the fork positioner is reassembled and mounted on the truck, apply chassis grease to the bearing grease fittings. See section lb (450 kg) 5 FP0053.eps 3 4 nchor racket 7 1/16 in. (1.5 mm) Minimum Upper earings FP0074.eps FP0071.eps 2 7 FP0072.eps Upper earings 19

22 S ERVICE 5.3 s Removal 1 WRNING: efore removing any hoses, relieve pressure in the hydraulic system. Turn the truck off, then actuate the truck control valve several times in both directions. 1 Remove the hoses from the valve. Tag the hoses for reassembly. 2 Solenoid s Remove the wires connected to the solenoid coil terminals. Tag the wires for reassembly. 3 Remove the capscrews fastening the valve to the mounting. For reassembly, tighten the capscrews to a torque of ft.-lbs. 3 3 FF0068.eps Flow Divider Service IMPORTNT: Service the valve in a clean work area. 1 Remove the cartridge valve. 2 Remove the remaining plugs and fittings. 3 Remove the O-rings and back-up rings from the cartridge valve. 4 Clean all parts with kerosene or cleaning solvent. 5 For reassembly, reverse the above procedures except as follows: The cartridge valve back-up rings and O-rings must be installed as shown for proper operation. Lubricate the cartridge and seals with hydraulic oil prior to reassembly FP0065.eps O-Ring and ack-up Ring Installation O-Rings G0060.eps ack-up Rings SEQUENCE VLVE 20

23 S ERVICE Sequence Service IMPORTNT: Service the valve in a clean work area. 1 Remove the cartridge valves. 2 Remove the remaining plugs and fittings. 3 Remove the O-rings and back-up rings from the cartridge valves. 4 Clean all parts with kerosene or cleaning solvent. 5 For reassembly, reverse the above procedures except as follows: The cartridge valve back-up rings and O-rings must be installed as shown for proper operation. Lubricate the cartridge and seals with hydraulic oil prior to reassembly FP0064.eps O-Ring and ack-up Ring Installation O-Rings O-Rings O-Rings G0058.eps G0057.eps ack-up Rings ack-up Ring G0059.eps ack-up Rings SEQUENCE VLVE CHECK VLVE SOLENOID VLVE Solenoid Service IMPORTNT: Service the valve in a clean work area. 1 Remove the solenoid valves. 2 Remove the remaining plugs and fittings. 3 Remove the O-rings and back-up rings from the cartridge valve. 4 Clean all parts with kerosene or cleaning solvent. 5 For reassembly, reverse the above procedures except as follows: The solenoid valve back-up rings and O-rings must be installed as shown for proper operation. Lubricate the valve and seals with hydraulic oil prior to reassembly. Refer to the electrical schematic in Section 4.5 to connect wires to the solenoid coils FP0067.epss 21

24 S ERVICE 5.4 Sideshift Cylinder Cylinder Speed djustment The sideshifting speed can be adjusted by modifying the restrictor washer in the cylinder base end port. 2 WRNING: efore removing any hoses, relieve pressure in the hydraulic system. Turn the truck off, then actuate the truck control valve several times in both directions. FP0274.eps 1 Disconnect the hose or tube, fitting and restrictor from the cylinder base end port. 2 Increase Speed Enlarge the restrictor washer orifice to no greater than.100 in. (2.5 mm) dia. NOTE: Completely removing the washer may result in excessive sideshift speed. Decrease Speed raze the restrictor washer orifice closed, then drill the orifice less than.080 in. (2 mm) diameter. FP0042.eps Cylinder Removal WRNING: efore 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 or tubes from the cylinder ports. Tag the hoses for reassembly. 2 Remove the clevis pins from the cylinder ends. 3 For reassembly, reverse the above procedures except for the following special instructions: Operate the sideshifter through several full cycles to force air in the system to the truck hydraulic tank. Check for leaks at all fittings. FP0080.eps 22

25 S ERVICE Cylinder Disassembly 1 Clamp the cylinder in a soft-jawed vise. Clamp lightly on the base end only. 2 Position the cylinder rod in the fully extended position. Remove the spiral snap rings from the retainer. See the illustration below. 3 Tap the retainer into the shell approximately 2 in. (50 mm). Remove the retaining ring by prying one end up and working the ring out of the groove. Service Tool Kit includes two double-ended brass tools that make seal and ring removal easy and won t damage the cylinder components with dents or scratches. CUTION: Do not scratch the cylinder bore. 4 Remove the rod assembly from the cylinder. See the illustration below. 5 Clamp the rod assembly in a soft-jawed vise or between two blocks of wood. Never clamp directly on the rod sealing surface. Remove the nut fastening the piston to the rod. Remove the piston and retainer. 6 Place the piston or retainer in the vise to remove the seals. Pry the seals up with a brass tool. Cut the seals to remove. CUTION: Do not scratch the seal grooves. 3 SS0089.eps 5 1 SS0059.eps Cylinder Inspection 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 oil under pressure. If nicks cannot be removed with emery cloth, replace the part. Inspect the outside of the shell for deformities that could weaken the shell s performance when under pressure. Replace if necessary. 6 SS0255.eps SS0088.eps 2 4 Restrictor Washer SS0057.eps 23

26 S ERVICE Cylinder Reassembly 1 Polish the piston and retainer chamfer angle with emery cloth. This allows the seals to slide over the chamfer easier. 2 Wash all components with cleaning solvent. Lubricate all new seals and rings with petroleum jelly or STP. 3 Note the direction of the U-cup seals. If the seals are installed backward they will not work properly. For proper seal placement see the illustration below. 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 Install the retainer and piston on the rod and tighten the piston retaining nut to the torque value below: 55F ft.-lbs. 100F/120F ft.-lbs. 6 pply a thick film of petroleum jelly or STP to the inside of the cylinder shell, piston seals and retainers. 7 Insert the rod assembly into the cylinder shell. If resistance is encountered, tap the rod end with a rubber mallet. 8 Tap the retainer into the shell far enough to install the retaining ring in its groove. 9 Pull the rod out to the fully extended position. This will position the retainer so the spiral snap ring can be installed. 1 SS0063.eps 3 OR 9 SS0256.eps SS0084.eps 8 7 Retainer Shell Piston 5 24

27 S ERVICE 5.5 Fork Position Cylinders Cylinder Removal WRNING: efore removing any hoses, relieve pressure in the hydraulic system. Turn the truck off, then actuate the truck control valve several times in both directions. 1 Disconnect the hoses from the cylinder ports. Tag the hoses for reassembly. 2 Remove the clevis pins from the cylinder base end. 3 Remove the cylinder anchor pins from the carrier lug. For reassembly, tighten the capscrew to a torque of ft.-lbs. (22-25 Nm). 4 For reassembly, reverse the above procedures except for the following special instructions: Operate the fork position function through several full cycles to force air in the system to the truck hydraulic tank. Check for leaks at all fittings FP0070.eps 25

28 S ERVICE Cylinder Disassembly 1 Clamp the cylinder in a soft-jawed vise. Clamp lightly on the base end only. 2 Position the cylinder rod in the fully extended position. Remove the spiral snap ring from the retainer. See the illustration below. 3 Tap the retainer into the shell approximately 2 in. (50 mm). Remove the retaining ring by prying one end up and working the ring out of the groove. 1 Service Tool Kit includes two double-ended brass tools that make seal and ring removal easy and won t damage the cylinder components with dents or scratches. CUTION: Do not scratch the cylinder bore. 4 Remove the rod assembly from the cylinder. See the illustration below. 5 Clamp the rod assembly in a soft-jawed vise or between two blocks of wood. Never clamp directly on the rod sealing surface. Remove the nut fastening the piston to the rod. Remove the piston and retainer. 6 Place the piston or retainer in the vise to remove the seals. Pry the seals up with a brass tool. Cut the seals to remove. 3 FP0094.eps 5 FP0075.eps CUTION: Do not scratch the seal grooves Cylinder Inspection 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 oil under pressure. If nicks cannot be removed with emery cloth, replace the part. Inspect the outside of the shell for deformities that could weaken the shell s performance when under pressure. Replace if necessary. 6 FP0077.eps SS0088.eps 2 4 FP0045.eps 26

29 S ERVICE Cylinder Reassembly 1 Polish the piston and retainer chamfer angle with emery cloth. This allows the seals to slide over the chamfer easier. 2 Wash all components with cleaning solvent. Lubricate all new seals and rings with petroleum jelly or STP. 3 Note the direction of the U-cup seals. If the seals are installed backward they will not work properly. For proper seal placement see the illustration below. 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 Install the retainer and piston on the rod and tighten the piston retaining nut to the torque value below: 55F ft.-lbs. (58-64 Nm) 100F/120F ft.-lbs. (75-82 Nm) 6 pply a thick film of petroleum jelly or STP to the inside of the cylinder shell, piston seals and retainer. 7 Insert the rod assembly into the cylinder shell. If resistance is encountered, tap the rod end with a rubber mallet. 8 Tap the retainer into the shell far enough to install the retaining ring in its groove. 9 Pull the rod out to the fully extended position. This will position the retainer so the spiral snap ring can be installed. 1 SS0063.eps 9 3 FP0046.eps Retainer Shell Piston FP0082.eps 27

30 S PECIFICTIONS Hydraulics Relief Setting Minimum 2300 psi (160) bar Maximum 2600 psi (180) bar Flow Volume Minimum Recommended Maximum 55F 100F/120F 3 GPM (11 L/min.) 4 GPM (15 L/min.) 4 GPM (15 L/min.) 5 GPM (19 L/min.) 5 GPM (19 L/min.) 6 GPM (23 L/min.) Hydraulic Oil Cascade attachments are compatible with SE 10W petroleum base oil per Mil. Spec. MIL or MIL Use of synthetic or aqueous base hydraulic oil is not recommended. Contact Cascade if fire resistant hydraulic oil must be used. G0073.eps uxiliary Functions FORK POSITIONER WITH STNDRD VLVE Sideshift Left Sideshift Right C Forks Out D Forks In FORK POSITIONER WITH SEQUENCE VLVE Sideshift Left Forks Out Sideshift Right Forks In FORK POSITIONER WITH SOLENOID VLVE Sideshift Left Forks Out (press knob button) Sideshift Right Forks In (press knob button) D C FP0016.eps D C FP0016.eps FP0016.eps Hoist down Tilt forward C D G0005.eps Hoist up Tilt back 28

31 S PECIFICTIONS Carriage The truck carriage must conform to ISO dimensional standard 2328, equivalent to Industrial ssociation (IT) dimensions shown. Make sure the truck carriage is clean and the notches are undamaged. G0028.eps Dimension IT (ISO) Mounting Minimum Maximum Class II in. (380.0 mm) in. (381.0 mm) Class III in. (474.5 mm) in. (476.0 mm) Class IV in. (595.5 mm) in. (597.0 mm) Torque Values FP0063.eps 2 1 FP0275.eps Ref. No. Torque Values Ft.-lbs. (Nm) Cascade backrests only. For other backrests see OEM recommendations. 29

32 Do you have questions you need answered right now? Call your nearest Cascade Service Department. Visit us online at MERICS Cascade Corporation U.S. Headquarters 2201 NE 201st Fairview, OR Tel: 800-CSCDE ( ) Fax: Cascade Canada Inc Timberlea lvd. Mississauga, Ontario Canada L4W-4M6 Tel: Fax: Cascade do rasil Rua João Guerra, 134 Macuco, Santos - SP rasil Tel: Fax: EUROPE-FRIC Cascade Italia S.R.L. European Headquarters Via Dell rtigianato Vago di Lavagno (VR) Italy Tel: Fax: Cascade (frica) Pty. Ltd. PO ox 625, Isando Steel Road Sparton, Kempton Park South frica Tel: Fax: SI-PCIFIC Cascade Japan Ltd. 2-23, 2-Chome, Kukuchi Nishimachi magasaki, Hyogo Japan, Tel: Fax: Cascade ustralia Pty. Ltd Ipswich Road Rocklea, QLD 4107 ustralia Tel: Fax: Cascade Korea 121 9L Namdong Ind. Complex, Gojan-Dong Namdong-Ku Inchon, Korea Tel: Fax: Cascade New Zealand 15 Ra Ora Drive East Tamaki, uckland 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 ahadur Shastri Road, Navi Peth, Pune (Maharashtra) India Phone: Fax: c Cascade Corporation Part Number R1