Cascade C Series User manual

Cascade is a Registered Trademark of Cascade Corporation
cascadeT
Manual Number 219990
NSTALLATION INSTRUCTIONS
C-Series
Fork Positioners
I

Non-Sideshifting
A Mast Single Internal Reeving
OR
C LH THINLINEE2-Port Hose Reel Group
Sideshifting
A Mast Double Internal Reeving
OR
A and C Mast Single Internal Reeving and
RH THINLINEE2-Port Hose Reel
Group
OR
B and C RH and LH THINLINEE2-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 7
i
C
B
C-Series Fork Positioners can be operated with any 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 the fork-positioning and
sideshifting (if equipped) functions should be at least
No. 6 with 9/32 in. (7 mm) minimum I.D.
This Manual provides instructions for installing Cascade
C-Series Fork Positioners.
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 installa-
tion.
IMPORTANT: Field alterations may impair performance or
capability and could result in loss of warranty. Consult
Cascade for any required modifications.
GA0033.ill
A

1
T
RUCK REQUIREMENTS
GA0082.ill
GA0080.ill
Close Forks
Sideshift
Right
Tilt
Forward
Hoist Up
Auxiliary Valve Functions
Check for compliance with ITA (ISO) 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 carriage bars and inspect for
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 III18.68 in. (474.5 mm) 18.74 in. (476.0 mm)
Class IV23.44 in. (595.5 mm) 23.50 in. (597.0 mm)
Truck Relief Setting
2000 psi (140 bar) Recommended
2300 psi (160 bar) Maximum
Truck Flow Volume ➀
Min. ➁Recommended Max. ➂
55C, 100C, 5 GPM 7 GPM 10 GPM
120C, 150C(19 L/min.) (26 L/min.) (38 L/min.)
➀Cascade C-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.
A

2
NSTALLATION
I
Attach overhead hoist
ARemove banding.
BAttach hoist to top of backrest as shown
and lift Attachment into vertical position
on pallet. Use wood blocking as required
to stabilize Attachment.
CRemove bolt-on lower mounting hooks
(if equipped).
1
2Unlock quick-change lower
mounting hooks (if equipped)
ARemove pin and drop hooks into
unlocked position.
BReinstall pin in lower hole.
WARNING: Make sure overhead hoist
has a rated capacity of at least
2000 lbs. (910 kg.)
cascade
®
C-675514-1
CL0097.ill
Tighten Capscrews:
Class II, III Mounting – 165 ft.-lbs. (225 Nm)
Class IV Mounting – 190 ft.-lbs. (255 Nm)
A
Pin
LH lower
Hook
NOTE: Guides can be reversed to
reduce hook-to-carriage clearance
(See lower hook installation, Step 4).
Guide
5/8-in. (16 mm)
offset on top
provides max.
clearance.
B
FP0202.ill
B
C
Bolt-on
Lower Hooks
Wood Blocking

3
FP0213.ill
cascade
®
C-675514-1
SS0141.ill
NSTALLATION
3Mount Fork Positioner on truck
ACenter truck behind Attachment.
BHang Attachment onto truck carriage.
CEngage upper mounting hooks. On
sideshifting units, make sure upper bearings
are in place and centering tab engages
center notch on truck carriage.
I
QUICK-CHANGE TYPE
(optional)
Tighten Capscrews:
Class II, III Mounting – 120 ft.-lbs. (165 Nm)
Class IV Mounting – 190 ft.-lbs. (255 Nm)
4Install or engage lower hooks
Inspect hooks for
excessive clearance.
(Reverse guides to
reduce clearance –
see Step 2.)
Slide hook up
to engage
bar, install
pin in locked
position.
(upper hole.)
SS0139.ill
ADJUST
SS0140.ill
Lower
Carriage
Bar
Lower
Carriage
Bar
3/16 in.
(4.8 mm)
max.
C
ITA Class II – 0.32–0.36 in. (8–9 mm)
ITA Class III – 0.39–0.43 in. (10–11 mm)
ITA Class IV –0.47–0.51 in. (12–13 mm)
ITA Class II – 0.60–0.66 in. (15–17 mm)
ITA Class III – 0.72–0.78 in. (18–20 mm)
ITA Class IV – 0.72–0.78 in. (18–20 mm)
Center
Notch
Truck
Carriage
Back (Driver's) View
B
Upper Bearings
SD0023.ill
Upper Hook
(Full-length
Sideshifter
type shown)
BOLT-ON TYPE
Tap tight into position.
If sideshifting, back off
1 notch and
check clearance:
3/32 in. (2.4 mm) min.
3/16 in. (4.8 mm) max.

4219990 Rev. 0
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.
5
INTERNAL HOSE REEVING
Sideshifting / Non-sideshifting SOLENOID – 6-N-1 CABLE/HOSE REEL
Sideshifting
SSR SSL
SSR SSL
Back (Driver's) Views
FP0198.ill
FP0200.ill
Close Forks
Spread Forks
FP0199.ill
SSL / Spread Forks
(TANK port) SSR / Close Forks
(PRESSURE port)
FP0221.ill
Close Forks
Spread Forks
SSR SSL Spread Forks Close Forks
HOSE REELS
55C – Sideshifting / Non-sideshifting HOSE REELS
100, 120, 150C – Sideshifting / Non-sideshifting

219990 Rev. 0 5
9Install wiring –
(Solenoid equipped units)
PRESS
BUTTON
TO POSITION SIDESHIFT
CL0240.ill
Button
toward
driver
Truck control
valve handle
Adapter
8Install solenoid control knob –
(Solenoid equipped units)
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
Control Lever Knob
7Connect hoses prepared in
Step 5 to Attachment fittings
INSTALLATION
FP0214.ill
6Flush hydraulic supply hoses
AInstall hoses to hose terminals on
carriage. Connect using union fittings.
BOperate auxiliary valves for 30 sec.
CRemove union fittings.
GA0092.ill

6
I
NSTALLATION
BD
CA
GA0005.ill Tilt backHoist up
Hoist down Tilt forward
Cycle Fork Positioner functions
10
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)
•Spread forks and close forks several times.
Sideshift (if equipped) left and right. Check
for smoothness and equal movement.
•Check for operation in accordance with ITA
(ISO) standards.
•Check for leaks at fittings, valve, cylinders.
A
B
A
BBA
C
C
D
DA
B
A
A
B
B
SIDESHIFTING
ASideshift Left
BSideshift Right
CSpread Forks
DClose Forks
Adjust forks for equal movement
(if required)
NOTE: Attachment is Factory-adjusted for equal
fork movement when operated at recommended
pressure and flow rate.
ALocate cylinder 'T' fittings with flow restrictor
adjustment. Loosen jam nuts and screw
both flow restrictors in until they bottom.
Screw each restrictor out (CCW) three turns.
BSpread forks fully, then close. Look for
unequal fork movement.
COn faster fork (one that bottoms first), screw
flow restrictor in (CW) 1/2-turn.
DRepeat Steps B and C until fork movement
is equal. Tighten jam nuts.
11
Front View
FP0194.ill
Flow Restrictor
Adjustment Screw
AUXILIARY VALVE FUNCTIONS
Check for compliance with ITA (ISO)
standards:
A
Fork
Positioning
Cylinder
Jam Nut
'T' fitting
C
FP0204.ill FP0204.ill
FP0204.ill

7
P
ERIODIC MAINTENANCE
100-Hour Maintenance
Every time the lift truck is serviced or every 100 hours of
truck operation, whichever comes first, complete the
following maintenance procedures on the Fork Positioner:
•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 lower hook capscrews to:
Class II, III Mounting –120 ft.-lbs. (165 Nm)
Class IV Mounting – 190 ft.-lbs. (255 Nm)
•Apply chassis grease to fork bearing grease fittings.
•Apply chassis grease to fork cylinder rod anchors.
•Apply chassis grease to sideshifter (if equipped) upper
bearing grease fittings and lower flat bearings.
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 bearings for wear and replace if necessary.
•Inspect fork cylinder rod anchors for wear and replace
if necessary.
•Inspect sideshifter (if equipped) upper and lower
bearings for wear and replace if necessary.
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.
Back (Driver's) View
Fork Bearing
Grease Fittings (4)
Lower Mounting Hook
Capscrews (4)
Cylinder Rod
Anchors (2)
Fork
Bearings (4)
Sideshifter Upper Bearing
Grease Fittings (2).
(sideshift to expose fittings.)
Sideshifter
Lower Bearings (2)
FP0201.ill
FP0215.ill
Front View

QCascade Corporation 1998 2-98 Part Number 219990
c
Do you have questions you need
answered right now? Call your
nearest Cascade Service Department.
Cascade N.V.
European Headquarters
P.O. Box 3009
1300 El Almere
Damsluisweg 56
1332 ED Almere
The Netherlands
Tel: [phone]
FAX: [phone]
Cascade Norway
Østerliveien 37A
1153 Oslo
Norway
Tel: [phone]
FAX: [phone]
Cascade Corporation
U.S. Headquarters
2201 NE 201st
Fairview, OR 97024-9718
Tel: 800-CASCADE (227-2233)
FAX: [phone]
Cascade Korea
Room 508, Pum Yang Bldg.
750-14, Bang Bac-Dong
Se-Cho Ku, Seoul
Korea
Tel: [phone] ext. 512
FAX: [phone]
Cascade-Xiamen
Wanshan No. 1 Workshop
Huli Road
Xiamen 361006
Fujian, PRC
Tel: [phone]
FAX: [phone]
Cascade (UK) Ltd.
15, Orgreave Crescent
Dore House Industrial Estate
Handsworth
Sheffield S13 9NQ
England
Tel: [phone]
FAX: [phone]
Cascade Scandinavia
Hydraulik A.B.
Muskötgatan 19, E8-9
S25466 Helsingborg
Sweden
Tel: [phone]
FAX: [phone]
Cascade France S.A.R.L.
11, Rue Jean Charcot
Zone Industrielle Sud or
B.P. 22
91421 Morangis Cedex
France
Tel: [phone]
FAX: [phone]
Cascade Hispania S.A.
Avenida De La Fabregada, 7
Hospitalet De Llobregat
Barcelona
Spain
Tel: [phone]
FAX: [phone]
Cascade Canada Inc.
5570 Timberlea Blvd.
Mississauga, Ontario
Canada L4W-4M6
Tel: [phone]
FAX: [phone]
Cascade GmbH
D-41199 Monchengladbach
Klosterhofweg 52
Germany
Tel: [phone]
FAX: [phone]
Cascade N.V.
Benelux Sales and Service
P.O. Box 3009
1300 El Almere
Damsluisweg 56
1332 ED Almere
The Netherlands
Tel: [phone]
FAX: [phone]
Cascade Finland
01370 Vantas
Finland
Tel: [phone]
FAX: [phone]
Cascade Japan Ltd.
5-5-41,
Torikai Kami
Settsu, Osaka
Japan, 566
Tel: [phone]
FAX: [phone]
HYCO-Cascade Pty. Ltd.
87 Antimony Street
Carole Park,
Brisbane 4300
Australia
Tel: [phone]
FAX: [phone]
HYCO-Cascade (NZ) Ltd.
15 Ra Ora Drive, East Tamaki
P.O. Box 38-440
Howick, Auckland
New Zealand
Tel: [phone]
FAX: [phone]
Cascade (Africa) Pty. Ltd.
P.O. Box 625, Isando 1600
60A Steel Road
Sparton, Kempton Park
South Africa
Tel: [phone]
FAX: [phone]
Cascade (Singapore)
Trading Co.
Four Seasons Park
Autumn Block - Apt. 1802
12 Cascaden Walk
Singapore
Tel: [phone]
FAX: [phone]