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7/29/2019 208743R1 F ForkPosServ
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Cascade is a Registered Trademark of Cascade Corporatio
ERVICE MANUAL
S
cascadecorporation
Manual Number 208743-R1
F-SeriesFork Positioners
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ONTENTSC
Page
INTRODUCTION, Secton 1 1
Special Defnitions 1.1 1
INSTALLATION, Secton 2 2
Truck System Requirements, 2.1 2
Recommended Hydraulic Supply, 2.2 3Installation Procedures, 2.3 4
PERIODIC MAINTENANCE, Secton 3 9
TROUBLESHOOTING, Secton 4 10
General Procedures, 4.1 10
Truck System Requirements, 4.1-1 10
Tools Required, 4.1-2 10
Troubleshooting Chart, 4.1-3 10
Plumbing, 4.2 11
Hosing Diagram, 4.2-1, 2-3, 2-5 11
Circuit Schematic, 4.2-2, 2-4, 2-6 11
Fork Position Circuit, 4.3 14
Sideshit Circuit, 4.4 15
Electrical Circuit, 4.5 16
SERVICE, Secton 5 17
Attachment Removal, 5.1 17
Bearings, 5.2 18
Bearing Lubrication, 5.2-1 18
Fork Carrier Bearing Service, 5.2-2 18
Carriage Bearing Service, 5.2-3 19
Valves, 5.3 20
Valve Removal, 5.3-1 20
Flow Divider Valve Service, 5.3-2 20
Sequence Valve Service, 5.3-3 21
Solenoid Valve Service, 5.3-4 21
Sideshit Cylinder, 5.4 22
Cylinder Speed Adjustment, 5.4-1 22
Cylinder Removal, 5.4-2 22
Cylinder Disassembly, 5.4-3 23
Cylinder Inspection, 5.4-4 23
Cylinder Reassembly. 5.4-5 24
Fork Position Cylinder, 5.5 25
Cylinder Removal, 5.5-1 25
Cylinder Disassembly, 5.5-2 26
Cylinder Inspection, 5.5-3 26
Cylinder Reassembly, 5.5-4 27SPECIFICATIONS, Secton 6 28
Specifcations, 6.1 28
Hydraulics, 6.1-1 28
Auxiliary Valve Functions, 6.1-2 28
Truck Carriage, 6.1-3 29
Torque Values, 6.1-4 29
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NTRODUCTIONI
This Manual provides the Installation, PeriodicMaintenance, Troubleshooting, Service and Specifcationsor Cascade F-Series Fork Positioners.
IMPORTANT: All hoses, tubes and fttings on F-Seriesattachments are JIC.
NOTE: Specifcations are shown in both U.S. and (Metric)
units.
1.1 Specal DefntonsThe statements shown appear throughout this Manualwhere special emphasis is required. Read all WARNINGSand CAUTIONS beore proceeding with any work.Statements labeled IMPORTANT and NOTE are providedas additional inormation o special signifcance or to makeyour job easier.
CAUTION - A statement preceded by CAUTION isinormation that should be acted upon to prevent machinedamage.
IMPORTANT - A statement preceded by IMPORTANT isinormation that possesses special signifcance.
NOTE - A statement preceded by NOTE is inormation thatis handy to know and may make your job easier.
WARNING - A statement preceded byWARNING is inormation that should beacted upon to prevent bodly njury. A
WARNING is always inside a ruled box.
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NSTALLATIONI
2
GA0032.eps
BC
A
2.1 Truck SystemRequirements
2.2 RecommendedHydraulic Supply
Fork Positioner with Standard Valve
Non-Sideshifting A MastSingleInternalReeving
ORB RHTHINLINE2-PortHoseReelGroup
Sideshifting A MastDoubleInternalReeving
OR
A and B MastSingleInternalReevingand RHTHINLINE2-PortHoseReelGroupOR
B and C RHandLHTHINLINE2-PortHoseReelGroups
Fork Positioner with Sequence Valve A MastSingleInternalReeving
ORB RHTHINLINE2-PortHoseReelGroup
Fork Positioner with Solenoid Valve
A and B MastSingleInternalReevingandRHCableReelGroupOR
B RH6-N-1Cable/HoseReelGroup
A
GA0023.eps
Cleancarriagebarsandinspectordamagednotches.
Truck Relief SettingMinimum2300psi(160)bar
Maximum2600psi(180)bar
Truck Flow Volume
55F 100F/120F
Minimum 3GPM(11L/min.) 4GPM(15L/min.)
Recommended 4GPM(15L/min.) 5GPM(19L/min.)
Maximum 5GPM(19L/min.) 6GPM(23L/min.)
Dimension A ITA (ISO)
Mounting Minimum Maximum
Class II 14.94in.(380.0mm) 15.00in.(381.0mm)
Class III 18.68in.(474.5mm) 18.74in.(476.0mm)
Class IV 23.44in.(595.5mm) 23.50in.(597.0mm)
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NTRODUCTIONI2.3 Installation Procedures
1000 lb.
450 Kg.
FP0007.eps
FP0010.ep
FP0023.eps
FP0025.eps
FP0520.eps
GA0035.eps FP0521.eps
1
Attach overhead hoist
2
Remove lower hooks
3Mount on truck carriage
4Install lower hooks
115-125t.-lbs(155-170Nm)
ITA Class II .32-.36in.(7-9mm)ITA Class III .39-.43in.(10-11mm)ITA Class IV .47-.51in.(12-13mm)
TruckCarriage
CenterNotch
UpperBearings
ITA Class II .60-.66in.(15-17mm)ITA Class III .72-.78in.(18-20mm)ITA Class IV .72-.78in.(18-20mm)
.09in.(2.3mm)
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NSTALLATIONI
4
5Install forks
A Removeorklockpins
B Removeorkblocks
C Installorks
D Adjustblockstoprovide 1/16in.(1.5mm)clearance withsideoork.
6Install backrest
55F 55-60t.-lbs.(75-80Nm)
100F/120F 110-118t.-lbs.(150-160Nm)
WARNING:Customersuppliedorksmusthavetheorklockpinsremovedorproperoperationontheorkpositioner.ItheorksareremovedtobeusedinNon-ForkPositionerapplications,theorklockpinsmustbereinstalled.
7c
GA0049.eps
PRESS BUTTONTO POSITION
FORKSSIDESHIFT
Adapter
Button towarddriver
Truck controlvalve handle
Install solenoid control knobSolenoid equipped units
FP0008.eps
A
C
B,D
FP0009.eps
115-125 ft.-lbs.(155-170 Nm)
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NTRODUCTIONIInstall wiring Solenoid equipped units
AInstallhosesBOperateauxiliaryvalves (bothdirections)
CRemovehoses
8
9Flush hydraulic supply hoses
GA0034.eps
Install hoses
10SSR SSL
Forks
Out
Forks
In
FP0026.eps
Fork Positioner with
Standard Valve
Double InternalReeving Hydraulic SupplySideshifting
Installation Kit 224042(4 Hoses)
Single Internal
Reeving Hydraulic SupplyNon-SideshiftingInstallation Kit 224041
(2 Hoses)
FP0021.epsFP0022.eps
7.5 Amp
Fuse
Knob
Button
SolenoidCoils
Diode
18 gauge wire1/4 in. Terminals
White Black7.5 AmpFuse
White
Black
UserSuppliedWire
SolenoidCoils
Diode
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NSTALLATIONI
6
10Install hoses
6-N-1 Cable-Hose ReelHydraulic Supply
Installation Kit 224041
Cable Reel andInternal ReevingHydraulic Supply
Installation Kit 224041
Fork Positioner withSolenoid Valve
FP0011.eps
Forks In/SSRForks Out/SSL
Solenoid
Cable
FP0012.eps
Forks In/SSRForks Out/SSL
Solenoid
Cable
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NTRODUCTIONI
B D
CA
GA0005.eps
Tilt backHoist up
Hoist down
Tilt forward
Auxiliary Valve Functions
11
Internal ReevingHydraulic Supply
Installation Kit 224041
Fork Positioner withSequence Valve
FORK POSITIONER WITHSOLENOID VALVE
A SideshitLet
A ForksOut(pressknobbutton)B SideshitRightB ForksIn(pressknobbutton)
FP0016.eps
A
B
A
AB
B
FORK POSITIONER WITHSTANDARD VALVE
A SideshitLet
B SideshitRightC ForksOutD ForksIn
FP0016.eps
A
B
C
CD
D
10Install hoses
FP0016.eps
B
FORK POSITIONER WITHSEQUENCE VALVE
A SideshitLetForksOutB SideshitRightForksIn
A
A
AB
B
FP0014.eps
Forks In/SSRForks Out/SSL
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NSTALLATIONI
8
FP0727.eps
LowerBearings
ForkBars
Lubricateulllength
Greasefttings
Lubrication Points 100 hours
12IMPORTANT: Prelubedatactory.Lubenotnecessaryorinstallation.
Lubricatethegreasefttings(sideshittoaccess)andlowerbearingsevery100hourswithchassisgrease.
LubricatetheshadedareasontheorkbarswithSlipPlate(SlixIt)No.8035lubricantCascadepartno.599489.
FP0100.eps FP0101.eps
OK
Lower Hook/Carriage Clearance
Repair orReplace13
Inspect Forks and Upper CarriageBar 500 hours
Useweargaugepartno.209508(ITAClassII)or209507(ITAClassIII)toinspectorcarriagebarandorkhookwearevery500hoursooperation.
Inspectorexcessiveclearancebetweenthelowerhooksandcarriagebar.Ithegaugeftsbetweenthecarriagebarandlowerhook,repairorreplacementisneeded.
Inspecttheuppercarriagebar.Ithegaugearrowtouchesthecarriagebar,repairorreplacementisneeded.
Inspecttheorkupperhooks.Ithegaugearrowtouchesthehook,repairorreplacementisneeded.
FP0102.eps
Fork Upper Hooks
OK Repair orReplace
Upper Carriage Bar
OK Repair orReplace
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ERIODIC MAINTENANCEP100 HourMaintenanceEverytimethelittruckisservicedorevery100hoursotruckoperation,whichevercomesfrst,completethe
ollowingmaintenanceprocedures. Checkorlooseormissingbolts,wornordamaged
hosesandhydraulicleaks.
Inspecttheclearancebetweenthetrucklowercarriagebarandtheorkpositionerlowerhooks.Tightenthelowerhookboltstoatorqueo115-125t.-lbs.
(155-170Nm).
Lubricatethegreasefttings(sideshittoaccess)andlowerbearingswithchassisgrease.
Lubricatetheshadedareas(reertostep12oInstallation)ontheorkbarswithSlipPlate(SlixIt)No.8035lubricant-Cascadepartno.599489.
500 HourMaintenanceAtereach500hoursotruckoperation,inadditiontothe100hourmaintenance,perormtheollowingprocedures.
Tightenthebackrestcapscrewstoatorqueo115-125t.-lbs.(155-170Nm).
Checktheorksandcarriageorwearwithweargaugepartno.209509(ClassII)or209507(ClassIII).ReertoInstallationstep13.
Applychassisgreasetotheupperbearingzerkfttingsandorkcarrierbearings.
1000 HourMaintenanceAtereach1000hoursotruckoperation,inadditiontothe100and500hourmaintenance,perormtheollowingprocedures.
Inspectthethicknessotheupperbearings.Ieitherothebearingsareworntolessthan1/16in.(1.5mm)thick,theyshouldbereplaced.
Inspecttheexposedthicknessothelowerbearings.Itheexposedthicknessislessthan1/16in.(1.5mm),theyshouldbereplaced.
Inspecttheorkcarrierbearings.Itheexposedthicknessislessthan1/16in.(1.5mm),theyshouldbereplaced.
2000 HourMaintenanceAtereach2000hoursotruckoperation,inadditiontothe100,500and1000hourmaintenance,perormtheollowingprocedures.
Replacetheupperandlowerbearingsetsandorkcarrierbearings.
IMPORTANT: Atercompletinganyserviceprocedure,alwaystesteachunctionthrough5completecycles.Firsttesttheattachmentempty,thentestwithaloadtomakesuretheattachmentoperatescorrectlybeorereturningittothejob.
FP0010.eps.09in.(2.3mm)
FP0091.eps
UpperBearingZerkFittings
ForkCarrierBearings
FP0092.eps
UpperBearings
LowerBearings
LowerHooks
Clearance
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ROUBLESHOOTINGT
10 208743 Rv. 1
Hyrali OilCascade attachments are compatible with SAE 10Wpetroleum base oil per Mil. Spec. MIL-0-5606 or MIL-0-2104B.
Use o synthetic or aqueous base hydraulic oil is notrecommended. Contact Cascade i re resistanthydraulic oil must be used.
4.1 Gral Prors
4.1-1 Trk Syst Rqirts
The lit truck must supply sucient hydraulic pressureto handle the heaviest load. PReSSuRe muST nOTexceed 2600 (180 bar).
Hydraulic fow should be within the volume rangeshown.
The truck hydraulic system must supply hydraulic oil tothe attachment that meets the specications shown.
4.1-2 Tools RqirIn addition to a normal selection o hand tools, you willneed:
An inline fow meter capable o measuring hydraulic
fow to 20 GPM (80 L/min), Cascade part no. 671477
A pressure gauge capable o measuring pressure to3500 psi (240 bar), Cascade part no. 671212.
4.1-3 Troblshootig chart
Gt all th Fats - It is important that you gather allthe acts regarding the problem beore you beginservice procedures. The best way is to talk withthe operator. Ask or a complete description o themalunction.
Fork Positio cirit
Forks will not move.
Forks move slowly. Normal speed is 4 in. (100 mm)per second.
To correct one o these problems, see Section 4.3
Sishift cirit
Attachment will not sideshit.
Attachment sideshits slowly.
To correct one o these problems, see Section 4.4
WARnInG: Beore servicing anyhydraulic component, relieve systempressure in the system. Turn the truck
o, and open the truck auxiliary valve(s)several times in both directions.
Ater completing any service procedure, always testthe unction through several cycles. First test theattachment empty to bleed air trapped in the systemto the truck system. Then test the attachment with aload to be sure it operates correctly beore returningit to the job.
Stay clear o the load while testing. Do not raise theload more than 3 in. (75 cm) o foor while testing.
Trk Flow Vol55F 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.)
Trk Rlif Sttig
Minimum 2300 psi (160) bar
Maximum 2600 psi (180) bar
GA0013.eps
Flow mtr Kit 671477
(2) No. 6-8 JIC Reducer
Flow Meter(2) No. 8-12 JIC/
O-Ring
GA0014.eps
Prssr Gag Kit 671212
* Not included in Pressure Gauge Kit part no. 671212.
PressureGauge
No. 6 and No. 8JIC Swivel Tee
No. 4-6 Pipe/JIC
No. 6-6 Hose
*No. 6 JIC/O-Ring
No. 6-8 JICReducer
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ROUBLESHOOTINGT
1208743 Rv. 1
4.2 Plbig4.2-1 Hosig diagra
no-Flow divir a
Flow divir Valv
POSITIOn FORKS OuTWARd aSIdeSHIFT RIGHT
PReSSuRe
ReTuRn
nOTe: For Position Forks INWARDand Sideshit LEFT, reverse the shadesshown.
4.2-2 cirit Shatino-Flow divir aFlow divir Valv
FP0049.eps
FP0050.eps
Non-Flow DividerManiold
Fork PositionCylinders
Flow DividerValve
OPEN CLOSE
InternalReeving
Terminations
SideshitCylinder
TruckAuxiliaryValve
TruckRelieValve
TruckHydraulic
Pump
TruckTank
SideshitCylinder
FlowDividerValveORManiold
ForkPositionCylinders
TruckAuxiliaryValves
InternalReevingTermination
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ROUBLESHOOTINGT
12 208743 Rv. 1
POSITIOn FORKS OuTWARd aSIdeSHIFT RIGHT
PReSSuRe
ReTuRn
nOTe: For Position Forks INWARDand Sideshit LEFT, reverse the shadesshown.
4.2-3 Hosig diagraSq Valv
4.2-4 cirit ShatiSq Valv
FP0051.eps
SideshitCylinder
FlowDividerValve
ForkPositionCylinders
TruckAuxiliaryValves
InternalReevingTermination
SequenceValve
FP0052.eps
Sequence
Valve
Fork PositionCylinders
Flow DividerValve
OPEN CLOSE
Internal ReevingTermination
SideshitCylinder
TruckAuxiliaryValve
TruckRelieValve
Truck
HydraulicPump
TruckTank
ATT
ATT
SS
TRUCK
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ROUBLESHOOTINGT
1208743 Rv. 1
POSITIOn FORKS OuTWARd aSIdeSHIFT RIGHT
PReSSuRe
ReTuRn
nOTe: For Position Forks INWARDand Sideshit LEFT, reverse the shadesshown.
4.2-5 Hosig diagraSoloi Valv
4.2-6 cirit ShatiSoloi Valv
FP0047.eps
FP0048.eps
SideshitCylinder
ForkPositionCylinders
TruckAuxiliaryValve
InternalReevingTermination
SolenoidValve
FlowDividerValve
SideshitCylinder
Fork PositionCylinders
TruckAuxiliaryValve
TruckReevingTermination
SolenoidValve
Flow DividerValve
TruckTank
Truck
HydraulicPump
TruckRelieValve
OPEN CLOSE
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ROUBLESHOOTINGT
14 208743 Rv. 1
WARnInG: Beore removing any hosesor tubes, relieve pressure in the hydraulicsystem. With the truck o, open the truckauxiliary control valve(s) several times inboth directions.
4.3 Fork Positio ciritThere are six potential problems that could aect orkpositioning operation.
Fork carriers binding in the carriage grooves.
Kinked supply hoses or air in the system. External leaks.
Incorrect hydraulic pressure/volume rom truck
Faulty electrical connection or deective solenoid coils(solenoid equipped attachments).
Valve cartridge malunctions.
1 Actuate the ork position and sideshit unctions eighttime in each direction and hold the truck valve actuatedor 10 seconds at the end o each cycle to remove airrom the system.
2 Check the pressure delivered by the truck. Reer to thetruck service manual. The recommended truck pressureis 2000 psi (140 bar). TRucK PReSSuRe muST nOTexceed 2300 PSI (160 BAR), measured at the carriagehose terminal.
3 Check the fow volume at the carriage hose terminal.The recommended fow volume is:
SqValv
SoloiValv
FP0088.eps
FP0087.eps
SolenoidValveCoils
Sequence
ValveCartridges
55F 100F/120FMinimum 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.)
4 Soloi Valv qipp attahts Press thecontrol knob position orks button.
I the solenoid coils "click", they are working correctly.Continue troubleshooting.
I one or both o the solenoid coils do not "click",troubleshoot the electrical circuit as described inSection 4.5.
5 Sq Valv qipp attahts Start thetruck. Sideshit to one side to activate the ork positionunction.
I the orks move while sideshiting (prior to the end othe sideshit stroke), the check valves in the sequencevalve assembly need servicing. Reer to section 5.3-3
I ater sideshiting completely to one side to activatethe ork position unction, the orks do not position,adjust the sequence valve cartridges inner screws.Remove the end plug rom the cartridges and adjustthe inner screw CW to lower the sequence pressure
or CCW to increase sequence pressure. Adjust eachcartridge a similar small amount at a time until the orksposition correctly. Actute the ork position unction totest the settings.
I the orks still do not position, the sequencecartridges require service. See section 5.3-4.
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ROUBLESHOOTINGT
1208743 Rv. 1
WARnInG: Beore removing any hosesor tubes, relieve pressure in the hydraulicsystem. With the truck o, open the truckauxiliary control valve(s) several times inboth directions.
4.4 Sishift ciritThere are six potential problems that could aectsideshiting operation.
Inadequate upper bearing lubrication or worn bearings.See sections 5.2-1 and 5.2-2.
Lower mounting hooks installed incorrectly. See section5.1 step 6.
Kinked supply hoses.
External leaks. Incorrect hydraulic pressure/volume rom the truck.
Worn or deective cylinder seals.
1 Check the pressure delivered by the truck. Reer tothe truck service manual. The minimum recommendedtruck pressure is 2000 psi (140 bar). TRucKPReSSuRe muST nOT exceed 3500 PSI (245 BAR) ,measured at the carriage hose terminal.
2 Check the fow volume at the carriage hose terminal.The recommended fow volume is 2 GPM (7.5 L/min).
3 Sideshit completely to the let and hold the controlhandle in this position or 5 seconds. Check or externalleaks at the cylinder, ttings and hoses.
4 Sideshit completely to the right and hold the controlhandle in this position or 5 seconds. Check or externalleaks at the cylinder, ttings and hoses.
5 Disconnect the LH cylinder hose rom the hose terminalor internal reeving tting. Cap the supply tting. Placethe hose end in a bucket. Start the truck. Actuate thesideshit let control handle or 5 seconds.
I there is oil fow out o the hose, the cylinder sealsare deective and require service. Reer to Section5.4-2.
I there is no oil fow out o the hose, the problem isnot hydraulic.
6 Flow divir Valv qipp attahts Startthe truck. Position the orks in and out. I the orks donot position evenly, the fow divider valve cartridge orcylinders require service. Continue troubleshooting.
7 Position the orks completely outward. Disconnect theopposite end o the hose connected to the fow divider
valve CL (close) port rom its tting. Cap the ttingand place the hose end in a bucket. Actuate the truckhandle to position the orks outward.
I oil fows out o the hose, the cylinder seals requireservice. See section 5.5.
I oil does not fow out o the hose, the fow dividervalve cartridge requires service. See section 5.3-2.
FP0090.eps
CLOSEPort
Captting
Flow DividerValve
FP0078.eps
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ROUBLESHOOTINGT
16 208743 Rv. 1
FP0022.eps
FP0021.eps
4.5 eltrial cirit(Soloi qipp attahts)
1 Check or truck voltage at the solenoid coil terminalswhen the knob button is pushed.
2 Check the solenoid coil to make sure it matchesthe truck voltage. The coil voltage is marked at theterminals. Test the coils by checking or resistance with
a Volt Ohm Meter across the terminals with the wiresdisconnected.
I there is no ohmmeter reading shown, the solenoidcoil is deective and requires replacing.
3 Check the control knob circuit use. Replace inecessary.
4 Check or loose electrical connections at the truckignition switch, control knob button(s), solenoid valveterminals and diodes.
5 Remove the diode(s) rom the solenoid valve terminals.Test with an ohmmeter or high resistance in onedirection and no resistance in the other direction. I
there is no resistance in both directions, replace the
diode.
Diode
BlackWhite
7.5 AmpFuse
UserSupplied
Wire
SolenoidValves
White Black
KnobButton
7.5 AmpFuse
Diode
SolenoidValves
18 Gauge Wire1/4 in. Terminals
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ERVICES
1208743 Rev. 1
FP0083.eps
FP0084.eps
FP0085.eps
FP0072.eps
FP0010.eps
Torque to
115-125 t.-lbs.
(155-170 Nm)
5.1 Attachment Removal1 Remove the backrest. For reassembly tighten the cap-
screws to a torque o 145 t.-lbs. (195 Nm) or Cascadebackrests only. Consult the lit truck service manual iequipped with truck manuacturers backrest.
2 Remove the ork stops rom the ork carrier. Remove theorks.
6
Clearance
.09 in. (2.3 mm)
WARNING: Beore removing any hoses,relieve pressure in the hydraulic system.Turn the truck o, then actuate thetruck control valve several times in bothdirections.
3 Disconnect the attachment supply hoses. Tag thehoses or reassembly.
4 Remove the lower mounting hooks.5 Attach a 1000 lb. (450 kg) capacity overhead hoist.
Remove the attachment rom the truck carriage.
6 For installation, reverse the above procedures exceptor the ollowing special instructions:
Clean the upper bearings and upper hook bearingareas.
Locate the upper bearings in the anchor bracketcutouts.
Install the lower mounting hooks up tight against thecarriage bar then back o on rib position. Tightenthe capscrews to a torque o 115-125 t.-lbs.(155-169 Nm).
6
4
3
12
1000 lb(450 kg)
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ERVICES
18 208743 Rev. 1
FP0069.eps
FP0086.eps
5.2 Bearings5.2-1 Bearing Lubrication
Lubricate the grease fttings and lower bearings every
500 hours with chassis grease. Lubricate the shaded areas on the ork bars with Slip
Plate (Slix It) No. 8035 lubricant Cascade part no.599489.
Grease fttings
Lowerbearings
Lubricateull length
5.2-2 Fork Carrier BearingService1 Remove the ork stop blocks rom the ork carrier.
Remove the ork. For reassembly, adjust the stopblocks to provide 1/16 in. (1.5 mm) clearance with theside o the ork and tighten the capscrews to a torque o55-60 t.-lbs. (75-80 Nm).
2 Remove the cylinder anchor pin rom the carrier lug.For reassembly, tighten the capscrew to a torque o7-9 t.-lbs. (10-12 Nm).
3 Remove the cylinder anchor lug rom the carrier. For
reassembly, tighten the capscrew to a torque o 16-18t.-lbs. (22-25 Nm).
4 Slide the carrier out the side to remove the bearings.5 For reassembly, reverse the above procedures except
or the ollowing special instructions:
Clean the carriage bars o any built-up grease.
Clean all parts prior to reassembly.
31
2
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ERVICES
1208743 Rev. 1
FP0071.e
FP0074.eps
FP0072.eps
Anchor
Bracket
Upper
Bearings
1/16 in.(1.5 mm)Minimum
Upper
Bearings
7
5.2-3 Carriage Bearing Service1 Remove the orks rom the attachment.2 Remove the clevis pin rom the base end o the sideshit
cylinder.
3Disconnect the hose ends rom the sideshit cyinderand anchor plate fttings. Tag hoses or reassembly.
4 Remove the setscrew rom the anchor plate.
5 Remove the lower mounting hooks.6 Attach a suitable overhead hoist to the ork positioner
carriage. Remove the carriage rom the truck. Theanchor bracket will remain on the truck carriage.
7 Measure the exposed thickness o the upper and lowerbearings. I the thickness is less than 1/16 in. (1.5 mm),replace as required.
8 For reassembly, reverse the above procedures exceptor the ollowing special instructions:
Clean the upper hook and lower bearing pockets o
any built-up grease. Clean all parts prior to reassembly.
Install the lower mounting hooks as described insection 5.1 step 6.
Ater the ork positioner is reassembled and mountedon the truck, apply chassis grease to the bearinggrease fttings. See section 5.2-1.
1000 lb(450 kg)
FP0053.eps
5
6
3 4
27
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ERVICES
20 208743 Rev. 1
5.3 Valves5.3-1 Valve Removal
SEQUENCE VALVE
O-Rings
Back-up Rings
O-Ring and Back-up Ring Installation
5.3-2 Flow Divider Valve ServiceIMPORTANT: Service the valve in a clean work area.
1 Remove the cartridge valve.
2 Remove the remaining plugs and fttings.3 Remove the O-rings and back-up rings rom the
cartridge valve.
4 Clean all parts with kerosene or cleaning solvent.5 For reassembly, reverse the above procedures except
as ollows:
The cartridge valve back-up rings and O-rings mustbe installed as shown or proper operation.
Lubricate the cartridge and seals with hydraulic oilprior to reassembly.
1 Remove the hoses rom the valve. Tag the hoses orreassembly.
2 Solenoid Valves Remove the wires connected to thesolenoid coil terminals. Tag the wires or reassembly.
3 Remove the capscrews astening the valve to themounting. For reassembly, tighten the capscrews to atorque o 13-15 t.-lbs.
WARNING: Beore removing any hoses,
relieve pressure in the hydraulic system.Turn the truck o, then actuate the truckcontrol valve several times in both directions.
FP0065.eps
FF0068.eps
GA0060.eps
3 21
3
1
3
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ERVICES
2208743 Rev. 1
GA0057.epsGA0058.eps
GA0059.eps
5.3-3 Sequence Valve Service IMPORTANT: Service the valve in a clean work area.
1 Remove the cartridge valves.2 Remove the remaining plugs and fttings.
3 Remove the O-rings and back-up rings rom thecartridge valves.
4 Clean all parts with kerosene or cleaning solvent.5 For reassembly, reverse the above procedures except
as ollows:
The cartridge valve back-up rings and O-rings mustbe installed as shown or proper operation.
Lubricate the cartridge and seals with hydraulic oilprior to reassembly.
O-Ring and Back-up Ring Installation
O-Rings O-Rings O-Rings
Back-up Rings Back-up Ring Back-up Rings
SOLENOID VALVECHECK VALVESEQUENCE VALVE
5.3-4 Solenoid Valve Service IMPORTANT: Service the valve in a clean work area.
1 Remove the solenoid valves.2 Remove the remaining plugs and fttings.3 Remove the O-rings and back-up rings rom the
cartridge valve.
4 Clean all parts with kerosene or cleaning solvent.5 For reassembly, reverse the above procedures except
as ollows:
The solenoid valve back-up rings and O-rings mustbe installed as shown or proper operation.
Lubricate the valve and seals with hydraulic oil priorto reassembly.
Reer to the electrical schematic in Section 4.5 toconnect wires to the solenoid coils.
sFP0067.eps
FP0064.eps
3
21
2
3
3
1
1
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ERVICES
22 208743 Rev. 1
FP0042.eps
FP0274.eps
FP0080.eps
5.4 Sideshift Cylinder5.4-1 Cylinder Speed
AdjustmentThe sideshiting speed can be adjusted by modiying therestrictor washer in the cylinder base end port.
5.4-2 Cylinder Removal
2WARNING: Beore removing any hoses,relieve pressure in the hydraulic system.Turn the truck o, then actuate the truckcontrol valve several times in both directions.
WARNING: Beore removing any hoses,relieve pressure in the hydraulic system.Turn the truck o, then actuate the truckcontrol valve several times in both directions.
1 Disconnect the hose or tube, ftting and restrictor romthe cylinder base end port.
2 Increase Speed Enlarge the restrictor washer orifceto no greater than .100 in. (2.5 mm) dia.
NOTE: Completely removing the washer may result in
excessive sideshit speed.
Decrease Speed Braze the restrictor washer orifceclosed, then drill the orifce less than .080 in. (2 mm)diameter.
1 Disconnect the hoses or tubes rom the cylinder ports.Tag the hoses or reassembly.
2 Remove the clevis pins rom the cylinder ends.3 For reassembly, reverse the above procedures except
or the ollowing special instructions:
Operate the sideshiter through several ull cyclesto orce air in the system to the truck hydraulic tank.Check or leaks at all fttings.
2 1
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ERVICES
2208743 Rev. 1
SS0089.eps
SS0088.eps
SS0255.ep
SS0059
SS0057.eps
5.4-4 Cylinder Inspection Inspect all components or nicks or burrs. Minor nicks
or burrs can be removed with 400 grit emery cloth.
NOTE: Minor nicks are those that will not bypass oilunder pressure. I nicks cannot be removed with emerycloth, replace the part.
Inspect the outside o the shell or deormities that couldweaken the shells perormance when under pressure.Replace i necessary.
5.4-3 Cylinder Disassembly1 Clamp the cylinder in a sot-jawed vise. Clamp lightly
on the base end only.
2 Position the cylinder rod in the ully extended position.Remove the spiral snap rings rom the retainer. See theillustration below.
3 Tap the retainer into the shell approximately 2 in.(50 mm). Remove the retaining ring by prying one endup and working the ring out o the groove.
Service Tool Kit 674424 includes two double-endedbrass tools that make seal and ring removal easy andwont damage the cylinder components with dents orscratches.
CAUTION: Do not scratch the cylinder bore.
4 Remove the rod assembly rom the cylinder. See theillustration below.
5 Clamp the rod assembly in a sot-jawed vise or betweentwo blocks o wood. Never clamp directly on the rod
sealing surace. Remove the nut astening the piston tothe rod. Remove the piston and retainer.
6 Place the piston or retainer in the vise to remove theseals. Pry the seals up with a brass tool. Cut the sealsto remove.
CAUTION: Do not scratch the seal grooves.
2 4RestrictorWasher
6
1
5
3
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ERVICES
24 208743 Rev. 1
SS0063.eps
SS0084.eps
SS0256.eps
5.4-4 Cylinder Reassembly1 Polish the piston and retainer chamer angle with emery
cloth. This allows the seals to slide over the chamereasier.
2 Wash all components with cleaning solvent. Lubricateall new seals and rings with petroleum jelly or STP.
3 Note the direction o the U-cup seals. I the seals areinstalled backward they will not work properly. Forproper seal placement see the illustration below.
4 Install the new seals on the piston and retainer. Hookone side o the seal in the groove and push it over thepiston or retainer.
5 Install the retainer and piston on the rod and tighten thepiston retaining nut to the torque value below:
55F 70-75 t.-lbs. 100F/120F 100-120 t.-lbs.
6 Apply a thick flm o petroleum jelly or STP to the insideo the cylinder shell, piston seals and retainers.
7 Insert the rod assembly into the cylinder shell. Iresistance is encountered, tap the rod end with a rubbermallet.
8 Tap the retainer into the shell ar enough to install theretaining ring in its groove.
9 Pull the rod out to the ully extended position. Thiswill position the retainer so the spiral snap ring can beinstalled.
1
3
9
8 7 5Retainer Shell Piston
OR
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ERVICES
2208743 Rev. 1
FP0070.eps
5.5 Fork Position Cylinders5.5-1 Cylinder Removal
WARNING: Beore removing any hoses,relieve pressure in the hydraulic system.Turn the truck o, then actuate the truckcontrol valve several times in both directions.
1 Disconnect the hoses rom the cylinder ports. Tag thehoses or reassembly.
2 Remove the clevis pins rom the cylinder base end.3 Remove the cylinder anchor pins rom the carrier lug.
For reassembly, tighten the capscrew to a torque o16-18 t.-lbs. (22-25 Nm).
4 For reassembly, reverse the above procedures exceptor the ollowing special instructions:
Operate the ork position unction through several ullcycles to orce air in the system to the truck hydraulictank. Check or leaks at all fttings.
2
3
1
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ERVICES
26 208743 Rev. 1
sFP0045.ep
FP0075.eps
FP0077.eps
FP0094.eps
SS0088.eps
5.5-2 Cylinder Disassembly1 Clamp the cylinder in a sot-jawed vise. Clamp lightly
on the base end only.
2 Position the cylinder rod in the ully extended position.Remove the spiral snap ring rom the retainer. See theillustration below.
3 Tap the retainer into the shell approximately 2 in.(50 mm). Remove the retaining ring by prying one endup and working the ring out o the groove.
Service Tool Kit 674424 includes two double-endedbrass tools that make seal and ring removal easy andwont damage the cylinder components with dents orscratches.
CAUTION: Do not scratch the cylinder bore.
4 Remove the rod assembly rom the cylinder. See theillustration below.
5 Clamp the rod assembly in a sot-jawed vise or betweentwo blocks o wood. Never clamp directly on the rod
sealing surace. Remove the nut astening the piston tothe rod. Remove the piston and retainer.
6 Place the piston or retainer in the vise to remove theseals. Pry the seals up with a brass tool. Cut the sealsto remove.
CAUTION: Do not scratch the seal grooves.
5.5-3 Cylinder Inspection Inspect all components or nicks or burrs. Minor nicks
or burrs can be removed with 400 grit emery cloth.
NOTE: Minor nicks are those that will not bypass oilunder pressure. I nicks cannot be removed with emerycloth, replace the part.
Inspect the outside o the shell or deormities that couldweaken the shells perormance when under pressure.Replace i necessary.
6
2 4
1
5
3
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ERVICES
2208743 Rev. 1
FP0082.e
FP0046.eps
5.5-4 Cylinder Reassembly1 Polish the piston and retainer chamer angle with emery
cloth. This allows the seals to slide over the chamereasier.
2 Wash all components with cleaning solvent. Lubricateall new seals and rings with petroleum jelly or STP.
3 Note the direction o the U-cup seals. I the seals areinstalled backward they will not work properly. Forproper seal placement see the illustration below.
4 Install the new seals on the piston and retainer. Hookone side o the seal in the groove and push it over thepiston or retainer.
5 Install the retainer and piston on the rod and tighten thepiston retaining nut to the torque value below:
55F 43-47 t.-lbs. (58-64 Nm) 100F/120F 55-60 t.-lbs. (75-82 Nm)
6 Apply a thick flm o petroleum jelly or STP to the insideo the cylinder shell, piston seals and retainer.
7 Insert the rod assembly into the cylinder shell. Iresistance is encountered, tap the rod end with a rubbermallet.
8 Tap the retainer into the shell ar enough to install theretaining ring in its groove.
9 Pull the rod out to the ully extended position. Thiswill position the retainer so the spiral snap ring can beinstalled.
1
SS0063.eps
3
9
8 7 5Retainer Shell Piston
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PECIFICATIONSS
28 208743 Rev. 1
GA0073.eps
6.1-1 Hydraulics
6.1-2 Auxiliary Valve Functions
Truck Relief Setting
Minimum 2300 psi (160) barMaximum 2600 psi (180) bar
Hydraulic OilCascade attachments are compatible with SAE 10Wpetroleum base oil per Mil. Spec. MIL-0-5606 orMIL-0-2104B.
Use o synthetic or aqueous base hydraulic oil is notrecommended. Contact Cascade i fre resistanthydraulic oil must be used.
B D
CA
GA0005.eps
Tilt backHoist up
Hoist down
Tilt forward
FORK POSITIONER WITH
SOLENOID VALVE
A Sideshit LetA Forks Out (press knob button)B Sideshit RightB Forks In (press knob button)
FP0016.eps
A
B
A
AB
B
FORK POSITIONER WITH
STANDARD VALVE
A Sideshit LetB Sideshit RightC Forks OutD Forks In
FP0016.eps
A
B
C
CD
D
FP0016.eps
B
FORK POSITIONER WITH
SEQUENCE VALVE
A Sideshit Let Forks OutB Sideshit Right Forks In
A
A
AB
B
Truck Flow Volume55F 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.)
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PECIFICATIONSS
2208743 Rev. 1
FP0063.eps FP0275.
A
GA0028.eps
6.1-3 Truck Carriage
The truck carriage must conorm to ISO dimensional
standard 2328, equivalent to Industrial Truck Association(ITA) dimensions shown.
Make sure the truck carriage is clean and the notches areundamaged.
6.1-4 Torque Values
Dimension A ITA (ISO)
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)
Class IV 23.44 in. (595.5 mm) 23.50 in. (597.0 mm)
1
12
3
4 5Ref. No.
Torque Values
Ft.-lbs. (Nm)
1 29-37 40-50
2 55-60 75-80
3 148-162 200-220
4 7-9 10-12
5 16-18 22-25
Cascade backrests only.For other backrests see OEMrecommendations.
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c
Do you have questions you need answered right now?Call your nearest Cascade Service Department.Visit us online at www.cascorp.com
AMERICAS
Cascade CorporationU.S. Headquarters2201 NE 201stFairview, OR 97024-9718
Tel: 800-CASCADE (227-2233)Fax: 888-329-8207
Cascade Canada Inc.5570 Timberlea Blvd.Mississauga, OntarioCanada L4W-4M6
Tel: 905-629-7777Fax: 905-629-7785
Cascade do BrasilRua Joo Guerra, 134Macuco, Santos - SPBrasil 11015-130
Tel: 55-13-2105-8800Fax: 55-13-2105-8899
EUROPE-AFRICA
Cascade Italia S.R.L.European HeadquartersVia DellArtigianato 137050 Vago di Lavagno (VR)ItalyTel: 39-045-8989111Fax: 39-045-8989160
Cascade (Africa) Pty. Ltd.PO Box 625, Isando 160060A Steel RoadSparton, Kempton ParkSouth AfricaTel: 27-11-975-9240Fax: 27-11-394-1147
ASIA-PACIFIC
Cascade Japan Ltd.2-23, 2-Chome,Kukuchi NishimachiAmagasaki, HyogoJapan, 661-0978Tel: 81-6-6420-9771Fax: 81-6-6420-9777
Cascade Korea121B 9L Namdong Ind.Complex, 691-8 Gojan-DongNamdong-KuInchon, KoreaTel: +82-32-821-2051Fax: +82-32-821-2055
Cascade-XiamenNo. 668 Yangguang Rd.Xinyang Industrial ZoneHaicang, Xiamen CityFujian ProvinceP.R. China 361026Tel: 86-592-651-2500Fax: 86-592-651-2571
Cascade India MaterialHandling Private LimitedNo 34, Global Trade Centre1/1 Rambaugh ColonyLal Bahadur Shastri Road,Navi Peth, Pune 411 030(Maharashtra) IndiaPhone: +91 020 2432 5490Fax: +91 020 2433 0881
Cascade Australia Pty. Ltd.1445 Ipswich RoadRocklea, QLD 4107AustraliaTel: 1-800-227-223
Fax: +61 7 3373-7333
Cascade New Zealand15 Ra Ora DriveEast Tamaki, AucklandNew ZealandTel: +64-9-273-9136
Fax: +64-9-273-9137
Sunstream IndustriesPte. Ltd.18 Tuas South Street 5Singapore 637796Tel: +65-6795-7555
Fax: +65-6863-1368