Cascade F Series Manuale utente
Cascade is a Registered Trademark of Cascade Corporation
ERVICE MANUAL
S
cascade
corporation
Manual Number 208743-R1
F-Series
Fork Positioners
208743 Rev. 1
ONTENTS
C
i
Page
INTRODUCTION, Section 1 1
Special Definitions 1.1 1
INSTALLATION, Section 2 2
Truck System Requirements, 2.1 2
Recommended Hydraulic Supply, 2.2 3
Installation Procedures, 2.3 4
PERIODIC MAINTENANCE, Section 3 9
TROUBLESHOOTING, Section 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
Sideshift Circuit, 4.4 15
Electrical Circuit, 4.5 16
SERVICE, Section 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
Sideshift 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 27
SPECIFICATIONS, Section 6 28
Specifications, 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
208743 Rev. 1
NTRODUCTION
I
1
This Manual provides the Installation, Periodic
Maintenance, Troubleshooting, Service and Specifications
for Cascade F-Series Fork Positioners.
IMPORTANT: All 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 WARNINGS
and CAUTIONS before proceeding with any work.
Statements labeled IMPORTANT and NOTE are provided
as additional information of special significance or to make
your job easier.
CAUTION - A statement preceded by CAUTION is
information that should be acted upon to prevent machine
damage.
IMPORTANT - A statement preceded by IMPORTANT is
information that possesses special significance.
NOTE - A statement preceded by NOTE is information that
is handy to know and may make your job easier.
WARNING - A statement preceded by
WARNING is information that should be
acted upon to prevent bodily injury. A
WARNING is always inside a ruled box.
208743 Rev. 1
NSTALLATION
I
2
GA0032.eps
BC
A
2.1 Truck System
Requirements
2.2 Recommended
Hydraulic Supply
Fork Positioner with Standard Valve
Non-Sideshifting
A Mast Single Internal Reeving
OR
B RH THINLINE2-Port Hose Reel Group
Sideshifting
A Mast Double Internal Reeving
OR
A and B Mast Single Internal Reeving and
RH THINLINE2-Port Hose Reel Group
OR
B and C RH and LH THINLINE2-Port Hose Reel Groups
Fork Positioner with Sequence Valve
A Mast Single Internal Reeving
OR
B RH THINLINE2-Port Hose Reel Group
Fork Positioner with Solenoid Valve
A and B Mast Single Internal Reeving and RH Cable Reel Group
OR
B RH 6-N-1 Cable/Hose Reel Group
A
GA0023.eps
Clean carriage bars and inspect for
damaged notches.
Truck Relief Setting
Minimum – 2300 psi (160) bar
Maximum – 2600 psi (180) bar
Truck Flow Volume
55F100F/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.)
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)
208743 Rev. 1
NTRODUCTION
I
3
2.3 Installation Procedures
1000 lb.
450 Kg.
FP0007.eps
FP0010.eps
FP0023.eps
FP0025.eps
FP0520.eps
GA0035.eps
FP0521.eps
1
Attach overhead hoist 2
Remove lower hooks
3
Mount on truck carriage
4
Install lower hooks
115-125 ft.-lbs
(155-170 Nm)
ITA Class II – .32-.36 in. (7-9 mm)
ITA Class III – .39-.43 in. (10-11 mm)
ITA Class IV – .47-.51 in. (12-13 mm)
Truck
Carriage
Center
Notch
Upper
Bearings
ITA Class II – .60-.66 in. (15-17 mm)
ITA Class III – .72-.78 in. (18-20 mm)
ITA Class IV – .72-.78 in. (18-20 mm)
.09 in.
(2.3 mm)
208743 Rev. 1
NSTALLATION
I
4
5
Install forks
ARemove fork lock pins
BRemove fork blocks
C Install forks
DAdjust blocks to provide
1/16 in. (1.5 mm) clearance
with side of fork.
6
Install backrest
55F – 55-60 ft.-lbs.(75-80 Nm)
100F/120F – 110-118 ft.-lbs.(150-160 Nm)
WARNING: 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.
7
c
GA0049.eps
PRESS BUTTON
TO POSITION
FORKS
SIDESHIFT
Adapter
Button toward
driver
Truck control
valve handle
Install solenoid control knob–
Solenoid equipped units
FP0008.eps
A
C
B,D
FP0009.eps
115-125 ft.-lbs.
(155-170 Nm)
208743 Rev. 1
NTRODUCTION
I
5
Install wiring –
Solenoid equipped units
AInstall hoses
BOperate auxiliary valves
(both directions)
CRemove hoses
8
9
Flush hydraulic supply hoses
GA0034.eps
Install hoses
10
SSR SSL
Forks
Out
Forks
In
FP0026.eps
Fork Positioner with
Standard Valve
Double Internal
Reeving Hydraulic Supply
Sideshifting
Installation Kit 224042
(4 Hoses)
Single Internal
Reeving Hydraulic Supply
Non-Sideshifting
Installation Kit 224041
(2 Hoses)
FP0021.eps
FP0022.eps
7.5 Amp
Fuse
Knob
Button
Solenoid
Coils
Diode
18 gauge wire
1/4 in. Terminals
White Black
7.5 Amp
Fuse
White Black
User
Supplied
Wire
Solenoid
Coils
Diode
208743 Rev. 1
NSTALLATION
I
6
10
Install hoses
6-N-1 Cable-Hose Reel
Hydraulic Supply
Installation Kit 224041
Cable Reel and
Internal Reeving
Hydraulic Supply
Installation Kit 224041
Fork Positioner with
Solenoid Valve
FP0011.eps
Forks In/SSRForks Out/SSL
Solenoid
Cable
FP0012.eps
Forks In/SSRForks Out/SSL
Solenoid
Cable
208743 Rev. 1
NTRODUCTION
I
7
BD
C
A
GA0005.eps
Tilt back
Hoist up
Hoist down
Tilt forward
Auxiliary Valve Functions
11
Internal Reeving
Hydraulic Supply
Installation Kit 224041
Fork Positioner with
Sequence Valve
FORK POSITIONER WITH
SOLENOID VALVE
A Sideshift Left
A Forks Out (press knob button)
B Sideshift Right
B Forks In (press knob button)
FP0016.eps
A
B
A
A
B
B
FORK POSITIONER WITH
STANDARD VALVE
A Sideshift Left
B Sideshift Right
C Forks Out
D Forks In
FP0016.eps
A
B
C
C
D
D
10
Install hoses
FP0016.eps
B
FORK POSITIONER WITH
SEQUENCE VALVE
A Sideshift Left – Forks Out
B Sideshift Right – Forks In
A
A
A
B
B
FP0014.eps
Forks In/SSRForks Out/SSL
208743 Rev. 1
NSTALLATION
I
8
FP0727.eps
Lower Bearings
Fork
Bars
Lubricate
full length
Grease fittings
Lubrication Points – 100 hours
12
IMPORTANT: 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. 8035 lubricant–
Cascade part no. 599489.
FP0100.eps
FP0101.eps
OK
Lower Hook/Carriage Clearance
Repair or
Replace
13
Inspect Forks and Upper Carriage
Bar – 500 hours
Use wear gauge part no. 209508 (ITA Class II) or
209507 (ITA 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.
FP0102.eps
Fork Upper Hooks
OK
Repair or
Replace
Upper Carriage Bar
OK
Repair or
Replace
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