208743r1 f forkposserv

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


2/32208743 Rev. 1

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


3/32208743 Rev. 1

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.


4/32208743 Rev. 1

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)


5/32208743 Rev. 1

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)


6/32208743 Rev. 1

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)


7/32208743 Rev. 1

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


8/32208743 Rev. 1

NSTALLATIONI

6

10Install hoses

6-N-1 Cable-Hose ReelHydraulic Supply

Installation Kit 224041

Cable Reel andInternal ReevingHydraulic Supply


Fork Positioner withSolenoid Valve

FP0011.eps

Forks In/SSRForks Out/SSL

Solenoid

Cable

FP0012.eps


Solenoid

Cable


9/32208743 Rev. 1

NTRODUCTIONI

B D

CA

GA0005.eps

Tilt backHoist up

Hoist down

Tilt forward

Auxiliary Valve Functions

11

Internal ReevingHydraulic Supply


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



10/32208743 Rev. 1

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


11/32208743 Rev. 1

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


12/32

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


13/32

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


14/32

ROUBLESHOOTINGT

12 208743 Rv. 1


PReSSuRe

ReTuRn


4.2-3 Hosig diagraSq Valv

4.2-4 cirit ShatiSq Valv

FP0051.eps

SideshitCylinder

FlowDividerValve


TruckAuxiliaryValves


SequenceValve

FP0052.eps

Sequence

Valve


Flow DividerValve

OPEN CLOSE

Internal ReevingTermination

SideshitCylinder

TruckAuxiliaryValve

TruckRelieValve

Truck

HydraulicPump

TruckTank

ATT

ATT

SS

TRUCK


15/32

ROUBLESHOOTINGT

1208743 Rv. 1


PReSSuRe

ReTuRn


4.2-5 Hosig diagraSoloi Valv

4.2-6 cirit ShatiSoloi Valv

FP0047.eps

FP0048.eps

SideshitCylinder


TruckAuxiliaryValve


SolenoidValve

FlowDividerValve

SideshitCylinder


TruckAuxiliaryValve

TruckReevingTermination

SolenoidValve

Flow DividerValve

TruckTank

Truck

HydraulicPump

TruckRelieValve

OPEN CLOSE


16/32

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.


17/32

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


18/32

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


19/32

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)


20/32

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


21/32

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


22/32

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


23/32

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.


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.


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


24/32

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


25/32

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


26/32

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


27/32

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


28/32

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


29/32

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


30/32

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


STANDARD VALVE

A Sideshit LetB Sideshit RightC Forks OutD Forks In

FP0016.eps

A

B

C

CD

D

FP0016.eps

B


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.)


31/32

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.


32/32

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

208743r1 f forkposserv

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