F-Series. Fork Positioners NSTALLATION INSTRUCTIONS. cascade. and PERIODIC MAINTENANCE. corporation. Manual Number R4

Transcription

1 NSTLLTON NSTRUCTONS and PERODC MNTENNCE F-Series Fork Positioners Manual Number R4 cascade corporation Cascade is a Registered Trademark of Cascade Corporation

2 T RUCK REQUREMENTS Truck Relief Setting Minimum 2300 psi (160) bar Maximum 2600 psi (180) bar Truck 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 T (SO) Mounting Minimum Maximum Class in. (380.0 mm) in. (381.0 mm) Class in. (474.5 mm) in. (476.0 mm) Class V in. (595.5 mm) in. (597.0 mm) G0023.eps Clean carriage bars and inspect for damaged notches. R ECOMMENDED HYDRULC SUPPLY Fork Positioner with Standard Valve Non-Sideshifting Mast Single nternal Reeving OR RH THNLNE 2-Port Hose Reel Group Sideshifting Mast Double nternal Reeving OR and Mast Single nternal Reeving and RH THNLNE 2-Port Hose Reel Group OR and C RH and LH THNLNE 2-Port Hose Reel Groups Fork Positioner with Sequence Valve Mast Single nternal Reeving OR RH THNLNE 2-Port Hose Reel Group Fork Positioner with Solenoid Valve and Mast Single nternal Reeving and RH Cable Reel Group OR RH 6-N-1 Cable/Hose Reel Group G0032.eps C Rev.4

3 NSTLLTON 1ttach overhead hoist 2 Remove lower hooks 1000 lb. 450 Kg. FP0023.eps FP0007.eps 3 Mount on truck carriage T Class in. (15-17 mm) T Class in. (18-20 mm) T Class V in. (18-20 mm) Center Notch T Class in. (7-9 mm) T Class in. (10-11 mm) T Class V in. (12-13 mm) FP0025.eps Truck Carriage G0035.eps Upper earings FP0521.eps 4 nstall lower hooks FP0520.eps ft.-lbs ( Nm).09 in. (2.3 mm) FP0010.eps Rev.4 2

4 NSTLLTON 5 nstall forks Remove fork lock pins Remove fork blocks C nstall forks D djust blocks to provide 1/16 in. (1.5 mm) clearance with side of fork. C WRNNG: Customer supplied forks must have the fork lock pins removed for proper operation on the fork positioner. f 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 nstall backrest ft.-lbs. ( Nm) FP0009.eps 7 nstall solenoid control knob Solenoid equipped units PRESS UTTON TO POSTON FORKS SDESHFT utton toward driver c dapter Truck control valve handle G0049.eps Rev.4

5 NSTLLTON 8 nstall 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 nstall hoses Operate auxiliary valves (both directions) C Remove hoses G0034.eps 10 nstall hoses SSR SSL Fork Positioner with Standard Valve Single nternal Reeving Hydraulic Supply Non-Sideshifting nstallation Kit (2 Hoses) Forks Out Forks n Double nternal Reeving Hydraulic Supply Sideshifting nstallation Kit (4 Hoses) FP0026.eps Rev.4 4

6 NSTLLTON 10 nstall hoses Forks Out/SSL Forks n/ssr Fork Positioner with Solenoid Valve Solenoid Cable Cable Reel and nternal Reeving Hydraulic Supply nstallation Kit FP0011.eps Forks Out/SSL Forks n/ssr Solenoid Cable 6-N-1 Cable-Hose Reel Hydraulic Supply nstallation Kit FP0012.eps Rev.4

7 NSTLLTON 10 nstall hoses Forks Out/SSL Forks n/ssr Fork Positioner with Sequence Valve nternal Reeving Hydraulic Supply nstallation Kit FP0014.eps FORK POSTONER WTH STNDRD VLVE Sideshift Left Sideshift Right C Forks Out D Forks n FORK POSTONER WTH SEQUENCE VLVE Sideshift Left Forks Out Sideshift Right Forks n FORK POSTONER WTH SOLENOD VLVE Sideshift Left Forks Out (press knob button) Sideshift Right Forks n (press knob button) D C FP0016.eps D C FP0016.eps FP0016.eps 11 uxiliary Valve Functions Hoist down Tilt forward C D G0005.eps Hoist up Tilt back Rev.4 6

8 NSTLLTON 12 Lubrication Points 100 hours Grease fittings MPORTNT: 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 t) No lubricant Cascade part no Fork ars Lubricate full length FP0727.eps Lower earings 13 nspect Forks and Upper Carriage ar 500 hours Use wear gauge part no (T Class ) or (T Class ) to inspect for carriage bar and fork hook wear every 500 hours of operation. nspect for excessive clearance between the lower hooks and carriage bar. f the gauge fits between the carriage bar and lower hook, repair or replacement is needed. nspect the upper carriage bar. f the gauge arrow touches the carriage bar, repair or replacement is needed. nspect the fork upper hooks. f 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 Rev.4

9 P ERODC MNTENNCE 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. nspect 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 nstallation) on the fork bars with Slip Plate (Slix t) No lubricant - Cascade part no 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 ) or (Class ). Refer to nstallation 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. nspect the thickness of the upper bearings. f either of the bearings are worn to less than 1/16 in. (1.5 mm) thick, they should be replaced. nspect the exposed thickness of the lower bearings. f the exposed thickness is less than 1/16 in. (1.5 mm), they should be replaced. nspect the fork carrier bearings. f 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. MPORTNT: 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 Fork Carrier earings Upper earings Lower earings FP0091.eps FP0092.eps Rev.4 8

10 Do you have questions you need answered right now? Call your nearest Cascade Service Department. Visit us online at MERCS Cascade Corporation U.S. Headquarters 2201 NE 201st Fairview, OR Tel: 800-CSCDE ( ) Fax: Cascade Canada nc Timberlea lvd. Mississauga, Ontario Canada L4W-4M6 Tel: Fax: Cascade do rasil Rua João Guerra, 134 Macuco, Santos - SP rasil Tel: Fax: EUROPE-FRC Cascade talia S.R.L. European Headquarters Via Dell rtigianato Vago di Lavagno (VR) taly Tel: Fax: Cascade (frica) Pty. Ltd. PO ox 625, sando Steel Road Sparton, Kempton Park South frica Tel: Fax: S-PCFC Cascade Japan Ltd. 2-23, 2-Chome, Kukuchi Nishimachi magasaki, Hyogo Japan, Tel: Fax: Cascade ustralia Pty. Ltd pswich Road Rocklea, QLD 4107 ustralia Tel: Fax: Cascade Korea 121 9L Namdong nd. Complex, Gojan-Dong Namdong-Ku nchon, Korea Tel: Fax: Cascade New Zealand 15 Ra Ora Drive East Tamaki, uckland New Zealand Tel: Fax: Cascade-Xiamen No. 668 Yangguang Rd. Xinyang ndustrial Zone Haicang, Xiamen City Fujian Province P.R. China Tel: Fax: Sunstream ndustries Pte. Ltd. 18 Tuas South Street 5 Singapore Tel: Fax: Cascade ndia Material Handling Private Limited No 34, Global Trade Centre 1/1 Rambaugh Colony Lal ahadur Shastri Road, Navi Peth, Pune (Maharashtra) ndia Phone: Fax: c Cascade Corporation Part Number R4