cascade corporation 55H User manual

Cascade is a Registered Trademark of Cascade Corporation
NSTALLATION MANUAL
I
cascade姞
corporation
Manual Number 6039153
55H Fork Positioner

Non-Sideshifting
A Mast Single Internal Reeving
OR
C LH THINLINE姠2-Port Hose Reel Group
Sideshifting
A Mast Double Internal Reeving
OR
A and C Mast Single Internal Reeving and
LH THINLINE姠2-Port Hose Reel
Group
OR
B and C RH and LH THINLINE姠2-Port Hose
Reel Groups
Solenoid Adaption
A and B Mast Single Internal Reeving and
RH Cable Reel Group
OR
B RH 6-N-1 Cable/Hose Reel Group
ONTENTS
C
ECOMMENDED HYDRAULIC SUPPLY OPTIONS
R
Recommended Hydraulic Supply i
Truck Requirements 1
Installation 2
Periodic Maintenance 8
i 6039153 Rev. 0
C
B
The 55H Fork Positioner requires one of the hydraulic
supply arrangements shown below. Refer to Cascade
Hose & Cable Reel Selection Guide, Part No. 212199, to
select the correct hose reel for the mast and truck. Hose
and fitting requirements are as follows:
•All hoses and fittings for fork-positioning and sideshift-
ing (if equipped) functions should be at least No. 4
with 3/16 in. (5 mm) minimum I.D.
This Manual provides instructions for installing the
Cascade 55H Sideshifting Fork Positioner.
Follow the suggested installation procedures for best
results. If you have any questions or need more informa-
tion, contact your nearest Cascade Service Department
(see back cover).
Read the WARNING Statements placed throughout this
Manual to emphasize safety during Fork Positioner
installation.
IMPORTANT: Field alterations may impair performance
or capability and could result in loss of warranty. Consult
Cascade for any required modifications.
GA0033.ill
A

6039153 Rev. 0 1
TRUCK REQUIREMENTS
GA0082.ill
GA0095.ill
Close
Forks
Sideshift
Right
Tilt
Forward
Hoist Up
Auxiliary Valve Functions
Check for compliance with ANSI standards:
WARNING: Rated capacity of the truck/
attachment combination is a responsibility of the
original truck manufacturer and may be less
than that shown on the attachment nameplate.
Consult the truck nameplate.
Carriage – Clean and inspect carriage
bars. Assure that bars are parallel and ends
are flush. Grind smooth any protruding
welds that may affect Sideshifter lower
bearings. Repair any damaged notches.
Tilt
Back
Hoist Down
Spread
Forks
Sideshift
Left
GA0028.ill
Carriage Mount Dimension (A) ITA (ISO)
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)
A
Truck Relief Setting
2300 psi (160 bar) Recommended
2600 psi (180 bar) Maximum
Truck Flow Volume ➀
55H Min. ➁Recommended Max. ➂
Fork 3 GPM 4 GPM 5 GPM
Position (11 L/min.) (15 L/min.) (19 L/min.)
Sideshift 1 GPM 2 GPM 3 GPM
(4 L/min.) (7.5 L/min.) (12 L/min.)
➀Cascade H-Series Fork Positioners are compatible with SAE
10W petroleum base hydraulic fluid meeting Mil. Spec. MIL-0-
5606 or MIL-0-2104B. Use of synthetic or aqueous base
hydraulic fluid is not recommended. If fire resistant hydraulic
fluid is required, special seals must be used. Contact Cascade.
➁Flow less than recommended can result in slow and unequal
fork movement.
➂Flow greater than maximum can result in excessive heating,
reduced system performance and short hydraulic system life.
Fork
Position

26039153 Rev. 0
NSTALLATION
I
Attach overhead hoist
ARemove banding.
BAttach hoist and lift into vertical position.
CRemove bolt-on lower mounting hooks.
1
2Unlock quick-change lower
mounting hooks (if equipped)
ARemove pin and drop hooks into
unlocked position.
BReinstall pin in lower hole (unlocked).
WARNING: Make sure overhead hoist
has a rated capacity of at least
2000 lbs. (910 kg.)
FP0601.ill
cascade
®
C-675514-1
CL0097.ill
Tighten Capscrews:
Class II, III Mounting – 165 ft.-lbs. (225 Nm)
A
Pin
LH lower
Hook
NOTE: Guides can be reversed to
change hook-to-carriage clearance
(See lower hook installation, Step 4).
Guide
5/8-in. (16 mm)
offset on top
provides max.
clearance.
B
B
C

6039153 Rev. 0 3
cascade
®
C-675514-1
SS0141.ill
NSTALLATION
3Mount Fork Positioner on truck
ALower Attachment onto truck carriage.
BEngage upper mounting hook. If sideshifter
equipped, make sure bearings are in place
and centering tab engages center notch on
truck carriage.
I
BOLT-ON TYPE QUICK-CHANGE TYPE
(optional)
Tighten Capscrews:
Class II, III Mounting – 120 ft.-lbs. (165 Nm)
4Install or engage lower hooks
Inspect hooks for
excessive clear-
ance. (Reverse
guides to change
clearance – see
Step 2.)
Slide hook up
to engage
bar, install
pin in locked
position.
(upper hole.)
ADJUST
SS0140.ill
Lower
Carriage
Bar
Lower
Carriage
Bar
3/16 in.
(4.8 mm)
max.
Tap tight into position.
If sideshifter, back off
1 notch and check
clearance:
3/32 in. (2.4 mm) min.
3/16 in. (4.8 mm) max.
ITA Class II – 0.32–0.36 in. (8–9 mm)
ITA Class III – 0.39–0.43 in. (10–11 mm)
ITA Class II – 0.60–0.66 in. (15–17 mm)
ITA Class III – 0.72–0.78 in. (18–20 mm)
Back (Driver's) View
FP0609.ill
SD0023.ill
SS0139.ill
B
A
Sideshifter
Upper Bearings
Sideshifter
Lower Bearings
Center
Notch
Truck Upper
Carriage

46039153 Rev. 0
5Install Forks
ADisconnect cylinder rod-end anchors from
fork carriers and retract cylinder rods.
BRotate fork carriers up to provide clearance
for fork installation.
CInstall forks using bottom fork slot to
engage forks with sideshifter carriage.
DLine up forks with fork carriers on frame and
rotate fork carriers down into position over
forks. Assure fork spacer plates are in
place if required.
EReconnect cylinder rod anchors using two
hardened washers and self-locking nut (see
illustration below). Adjust nut to provide
1/32 in. (1 mm) clearance in joint. Use flats
on cylinder rod end to prevent turning.
IMPORTANT: Joint must function with a
loose operating clearance. Lubricate with
chassis grease.
WARNING: Remove locking pins
from forks. Assure that forks slide
freely on sideshifter carriage bars.
NSTALLATION
I
FP0608.ill
FP0603.ill
Hardened Washers (2)
E
Fork Positioner Frame
Fork Carrier
D
Sideshifter
Assembly
Forks
Self-Locking Nut
Wrench Flat
B
C
Backrest
Cylinder Rod End
FP0610.ill
Fork Spacer Plate
(if required) D
1/32 in. (1 mm)

6039153 Rev. 0 5
NSTALLATION
I
Prepare hoses
ADetermine hose lengths required for
hydraulic supply configuration of truck.
BCut hoses to length and install end fittings
or quick-disconnect kits.
6
INTERNAL HOSE REEVING HOSE REELS
Sideshift Right Sideshift Left
FP0604.ill
Sideshift Right Sideshift Left
7Flush hydraulic supply hoses
AInstall hoses to hose terminals on carriage.
Connect together using union fittings.
BOperate auxiliary valves for 30 sec.
CRemove union fittings.
GA0092.ill
Back (Driver's) View
FP0602.ill
Close Forks Spread Forks
Close Forks Spread Forks

66039153 Rev. 0
10 Install wiring
(solenoid-equipped)
9
CL0258.ill
CL0257.ill
Solenoid Coil
User-supplied wire
7.5-Amp
Fuse
White Black
7.5-Amp Fuse
White Black
Solenoid Coil
Diode
Diode
Knob
Button
(normally
open)
Control Lever Knob
8Connect hoses prepared in
Step 6 to Attachment fittings
FP0605.ill
INSTALLATION
SIDESHIFT
PRESS
BUTTON
TO POSITION
FP0624.ill
Button
toward
driver
Adapter
Nut
Plate
Snap Ring
Install solenoid control knob or
pushbutton switch (solenoid-equipped)
AC0898.ill
Pushbutton
Switch
NOTE: Shrink tubing
may be removed around
button as desired
Cable
Ties
Foam Tape
Heat-Shrink Tubing
3 in. (60 mm)
Typical
SIDESHIFT Control Lever

6039153 Rev. 0 7
INSTALLATION
BD
C
A
GA0005.ill
Tilt back
Hoist up
Hoist down Tilt forward
Cycle Fork Positioner functions
11
SIDESHIFTING WITH
SOLENOID VALVE
ASideshift Left
ASpread Forks
(press knob button)
BSideshift Right
BClose Forks
(press knob button)
NON-SIDESHIFTING
ASpread Forks
BClose Forks
C (not used)
D (not used)
•Open and close forks several times.
Sideshift (if equipped) left and right.
Check for smoothness and equal move-
ment.
•Check for operation in accordance with
ITA (ISO) standards.
•Check for leaks at fittings, valve, cylinders.
FP0164.ill
A
B
A
B
FP0164.ill
BA
C
C
D
D
FP0164.ill
A
B
A
A
B
B
SIDESHIFTING
ASideshift Left
BSideshift Right
CSpread Forks
DClose Forks
AUXILIARY VALVE FUNCTIONS

86039153 Rev. 0
12
Back (Driver's) View
Adjust forks for equal movement
(if required)
NOTE: Attachment is Factory-adjusted for equal
fork movement when operated at recommended
pressure and flow rate at normal operating
temperature.
ALocate flow restrictor fitting on RH cylinder
(1 flow restrictor only used).
BOpen and close forks fully and look for
unequal fork movement.
CLoosen jam nut and adjust until RH fork
moves equally with LH fork. Tighten jam nut.
FP0625.ill
Flow
Restrictor
Fitting
A
INSTALLATION
13 Inspect fork hooks and
carriage bar clearance
NOTE: Use go/no-go Wear Gauge Part No.
209560 (Class II) or 209561 (Class III).
AInspect the fork lower hooks and
carriage bar. If the gauge fits between
the carriage bar and lower hook, repair
or replacement is needed.
BInspect the upper carriage bar. If the
gauge arrow touches the carriage bar,
repair or replacement is needed.
CInspect the fork upper hooks. If the
gauge arrow touches the hook, repair or
replacement is needed.
FP0631.ill
FORK LOWER HOOKS, CARRIAGE
OK
OK
OK
UPPER CARRIAGE BAR
FORK UPPER HOOKS
Wear
Gauge

6039153 Rev. 0 9
PERIODIC MAINTENANCE
100-Hour Maintenance
Every time the lift truck is serviced or every 100 hours of
truck operation, whichever comes first, perform the
following maintenance procedures:
•Check for loose or missing bolts, worn or damaged
hoses and hydraulic leaks.
500-Hour Maintenance
After each 500 hours of truck operation, in addition to the
100-hour maintenance, perform the following procedures:
•Tighten frame and backrest mounting capscrews to
115-125 ft.-lbs. (155-170 Nm).
•Tighten lower hook capscrews:
Class II, III Bolt-On – 120 ft.-lbs. (165 Nm).
Class II, III Quick-Change – 165 ft.-lbs. (225 Nm).
•Apply graphite dry lube to fork carrier bearings ('Slip
Plate', 'GraphoKote' or equivalent).
•Apply chassis grease to fork cylinder rod anchors.
•Apply chassis grease to sideshifter upper bearing
grease fittings, and lower flat bearings.
•Check fork hooks and carriage bars for wear using a
wear gauge (Cascade Part No. 209509 for Class II,
209507 for Class III).
1000-Hour Maintenance
After each 1000 hours of truck operation, in addition to
the 100 and 500-hour maintenance, perform the following
procedures:
•Inspect fork carrier bearings for wear and replace if
necessary.
•Inspect fork cylinder rod anchor washers for wear and
replace if necessary.
•Inspect thickness of sideshifter (if equipped) upper
and lower bearing sets. If any bearing in the set is
worn to less than 3/32 in. (2.5 mm) thickness, replace
entire bearing set (see Service Manual).
WARNING: After completing any service
procedure, always test each function
through five complete cycles. First test
with no load, then test with a load to
make sure the attachment operates
correctly before returning it to the job.
FP0606.ill
Front View
Back (Driver's) View
Frame and Backrest Mounting Capscrews (4)
Cylinder Rod
Anchors (2)
Fork Carrier
Bearings (2)
Sideshifter
Lower Bearings (2)
Lower Mounting Hook
Capscrews (4)
FP0607.ill
Sideshifter
Grease Fittings (2)

c
Do you have questions you need
answered right now? Call your
nearest Cascade Service Department.
Visit us online at www.cascorp.com
3519306rebmuNtraP4002-34002noitaroproCedacsaC
AMERICAS
Cascade Corporation
Parts Sales
2501 Sheridan Ave.
Springfield, OH 45505
Tel: 888-CASCADE (227-2233)
Fax: [phone]
Cascade Canada Inc.
5570 Timberlea Blvd.
Mississauga, Ontario
Canada L4W-4M6
Tel: [phone]
Fax: [phone]
Cascade do Brasil
Rua João Guerra, 134
Macuco, Santos - SP
Brasil 11015-130
Tel: [phone]
Fax: [phone]
EUROPE-AFRICA
Cascade Italia S.R.L.
European Headquarters
Via Dell’Artigianato 1
37050 Vago di Lavagno (VR)
Italy
Tel: [phone]
Fax: [phone]
Cascade (Africa) Pty. Ltd.
PO Box 625, Isando 1600
60A Steel Road
Sparton, Kempton Park
South Africa
Tel: [phone]
Fax: [phone]
ASIA-PACIFIC
Cascade Japan Ltd.
2-23, 2-Chome,
Kukuchi Nishimachi
Amagasaki, Hyogo
Japan, 661-0978
Tel: [phone]
Fax: [phone]
Cascade Korea
121B 9L Namdong Ind.
Complex, 691-8 Gojan-Dong
Namdong-Ku
Inchon, Korea
Tel: [phone]
Fax: [phone]
Cascade-Xiamen
No. 668 Yangguang Rd.
Xinyang Industrial Zone
Haicang, Xiamen City
Fujian Province
P.R. China 361026
Tel: [phone]
Fax: [phone]
Cascade India Material
Handling Private Limited
No 34, Global Trade Centre
1/1 Rambaugh Colony
Lal Bahadur Shastri Road,
Navi Peth, Pune 411 030
(Maharashtra) India
Phone: [phone]
Fax: [phone]
Cascade Australia Pty. Ltd.
1445 Ipswich Road
Rocklea, QLD 4107
Australia
Tel: [phone]
Fax: [phone]
Cascade New Zealand
15 Ra Ora Drive
East Tamaki, Auckland
New Zealand
Tel: [phone]
Fax: [phone]
Sunstream Industries
Pte. Ltd.
18 Tuas South Street 5
Singapore 637796
Tel: [phone]
Fax: [phone]