Cascade E Series User manual

E-Series
ForkPositioner
Manual Number 200396
Cascade IS a Registered Trademark of Cascade Corporation

ONTENTS
INTRODUCTION. Section 1
Page
1
Special Definitions 1
INSTALLATION INSTRUCTIONS, Section 2 2
Truck Reauirements 2
Recommended Hydraulic Supply
Attachment Installation
PERIODIC MAINTENANCE, Section 3
TROUBLESHOOTING. Section 4
General Procedures 8
Plumbing 9
Hosina Diaarams 9-11
Circuit Schematics 9-11
Fork Position Crrcuit 12
Srdeshift Circuit 13
Electrical Circuit 14
SERVICE, Section 5 15
Attachment Removal 15
Threaded Assemblv 16
Threaded Assembly Lubrication 16
Threaded Assemblv Removal 16
Threaded Assembly Service 17
Drive Motor 18
Drive Motor Removal 18
Drive Motor Disassembly 19
Drive Motor Inspection 19
Drive Motor Reassembly 20
Valve 71
-.
Valve Removal 21
Standard Valve Service 21
Sequence Valve Service 22
Solenoid Valve Service 23
Bearings 24
Bearina Lubrication 24
Bearing Service 24
Cylinders 25
Winder Speed Adiustment 25
Cvlinder Removal and Installation 25
Cvlinder Disassemblv 26
Cylinder Inspection 26
Cylinder Reassembly 27
SPECIFICATIONS, Section 6 28
Hvdraulics 78
d --
Auxiliary Valve Functions 28
Truck Carriage 29
Torque Values 29
200396 Rev. 0

NTRODUCTION
l
This manual provides the installation instructions, periodic
maintenance requirements, troubleshooting procedures
and service guides for E-Series Fork Positioners. Note that
all specifications are shown in US and (Metric) units where
applicable.
IMPORTANT: All hardware on E-Series attachments is
metric. All hosing and fittings are JIC.
1.1 Special Definitions
1 A WARNING 1
A statement preceded by A WARNING is information
that should be acted upon to prevent bodily injury. A
WARNING is always inside a ruled box.
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.
200396 Rev. 0 1

.’
NSTALLATION
2.1 Truck Requirements
Truck Relief Setting
2000 psi (140) bar - Recommended
2300 psi (160) bar - Maximum
Truck Flow Volume
3 GPM (11 L/min.) - Minimum
8 GPM (30 L/min.) - Recommended
10 GPM (37 L/min.) - Maximum
Mounting Dimension A-ITA (ISO)
Minimum Maximum
A Class II 14.94 in. (380.0mm) 15.00 in. (381.0mm)
Class Ill 18.68 in. (474.5mm) 18.74 in. (476.Omm) Clean carriage bars
L 1 Inspect for damaged notches
2.2 Recommended
Hydraulic Supply
The attachment will require one of the following hydraulic
supply arrangements. All hoses and fittings should be at
least No. 6 with 9/32 in. (7 mm) minimum from I.D. Refer to
Hose and Cable Reel Selection Guide Form 4099 to select
the correct hose reels for the mast and truck.
RECOMMENDED HYDRAULIC SUPPLY OPTIONS
Fork Positioner with Standard Valve
Non-Sideshifting
A LH THINLINETM 2-Port Hose Reel Supply Group
or
B Mast Internal Reeving
Sideshifting
A and B LH THINLINET” 2-Port Hose Reel Group and C
Mast Internal Reeving
or
A and C RH and LH THINLINET” 2-Port Hose Reel Groups
or
A LH THINLINET” 4-Port Hose Reel Supply Group
Fork Positioner with Sequence Valve
A LH THINLINETM 2-Port Hose Reel Group
or
B Mast Internal Reeving
Fork Positioner with Solenoid Valve
A LH 6-N-i Cable/Hose Reel Supply Group
or
A and B LH Cable Reel Supply Group and Mast Internal Reeving
2 200396 Rev. 0

NSTALLATION
l
2.3 Attachment Installation
1
Remove from box
Sideshifter
OR
/ False Carriage
I
2Remove lower hooks
3Mount on Iift truck Truck carriage
center notch
55D - .60-66 in. (16-17 mm)
60D, 100D - .72-.78 in. (18-20 mm)
55D - .32-.36 in. (7-9 mm)
60D, 100D - .40-.44 in. (9-11 mm)
install lower hooks
.06 in. (1.5 mm)
.13 in. (3.0 mm) Tighten to
115-l25 ft.-tbs.
(155-170 Nm)
200396 Rev.0

NSTALLATION
l
2.3 Attachment Installation (Cont.)
5 Install forks
Remove fork
Lock pins .
7Install solenoid control knob -
Solenoid equipped units.
-8 Install wiring - Solenoid
equipped units.
7.5 Amp
. 1 Diode
18 gauge wire -
l/4 in. Solenoid
Terminals coils
install carrier
that matches
fork width
45 - 52 ft.-lbs.
(60 - 70 Nm)
25 - 30 ft.-lbs.
Install Fork
Positioner
115 - 125 ft-lbs.
(155 - 175 Nm)
Button toward
driver
Cable assembly
Truck control
valve handle
_ -e-----
User supplied
wire
4 200396 Rev. 0

9 Flush hydraulic supply hoses
A Install hoses
Internal reeving
hydraulic supply
I
/ I
B Operate auxiliary valves
(both directions)
C Remove hoses
/
Hose reel
hydraulic supply
10
Install hoses
Cut hoses to length and install reuseable fittings.
FORK POSITIONER WITH
STANDARD VALVE
Using Installation Kit 689175 (Non-SS)
Using Installation Kit 689174 (SS)
FORK POSiTlONER WITH
SEQUENCE VALVE
Using Installation Kit 689176
FORK POSITIONER WITH
SOLENOID VALVE
Using Installation Kit 689177
Forks In* -
Forks Out* .SSR (if equipped)
,SSL (if equipped)
*Allow length for 4 in. sideshift in each direction
Forks
Forks
Forks In/SSR*
Forks Out&S
1 Kit
*Allow length for4 in. sideshift in each direction
*Allow length for 4 in. sideshift in each
1 Kit
200396 Rev. 0 5

NSTALLATION
2.3 Attachment Installation (Cont.)
Liftdown
Tilt forward
11
Auxiliary valve functions
If functions are backward,
switch hoses at hose terminal,
hose reel or auxiliary valve. \ \
-I
FORK POSITIONER
WITH STANDARD VALVE
A Sideshift Left
B Sideshift Right
C Forks Out
D Forks In
B C
D
FORK POSITIONER WITH
SEQUENCE VALVE
A Sideshift Left - Forks Out
B Sideshift Right - Forks in
B
Lift uP Tilt back
FORK POSITIONER WITH SOLENOID
A Sideshift Left
A Forks Out (press knob button)
B Sideshift Right
B Forks In (press knob button)
B A
Acme threads
12
Sideshift speed adjust
orifice - Enlarge orifice - .l00 in. max.
(2.5 mm)
Decrease speed
Reduce orifice by brazing and
redrilling.
Fork
Bars
7
13
Lubrication points - 500 hours
Use chassis grease.
200396 Rev. 0

Periodic Maintenance
3.1 100 Hour IMPORTANT: After completing any service proce-
Maintenance dure, test each function through 5 complete cycles.
Every time the lift truck is serviced or every 100 hours of
truck operation, whichever comes first, complete the
following maintenance procedures.
First test the attachment empty, then test each function
with a load to make sure the attachment operates
correctly before returning it to the job.
0 Inspect the clearance between the truck lower carriage
bar and the sideshifter or false carriage lower hooks.
Retighten the lower hook capscrews. See Section 5.1
step 8.
Q Inspect the hoses for wear and kinking
3.2 500 Hour
Maintenance
After each 500 hours of lift truck operation, in addition to
the 100 hour maintenance, perform the following proce-
dures.
LI Apply chassis grease to the sideshifter upper bearing
zerk fittings, acme threaded shafts and fork bars. See
Section 2.3 step 13.
3.3 1000 Hour
a Maintenance
After each 1000 hours of lift truck operation, in addition to
the 100 and 500 hour maintenance procedures, perform
the following procedures.
D Inspect the thickness of the sideshifter upper bearings.
If either of the bearings are worn to less than l/16 in.
(1.5 mm) thick on the back surface, see Section 5.5-2
for replacement.
D Inspect the exposed thickness of the sideshifter lower
bearings. If the exposed thickness is worn to less than
l/l 6 in. (1.5 mm) on the back surface, see Section 5.5-2
for replacement.
Q Inspect the threaded assembly outer end plate bush-
ings. If the looseness is excessive, see Section 5.5-2 for
replacement.
3.4 2000 Hour
Maintenance
After each 2000 hours of lift truck operation, in addition to
the 100, 500 and 1000 hour maintenance, perform the
following procedure.
Q Replace the sideshifter upper and lower bearings sets.
See Section 5.2-2.
200396 Rev. 0 7

Troubleshooting
4.1 General Procedures
A WARNING: Before servicing any hydraulic
component, relieve pressure in the system.
Fully extend the faceplate, turn the truck off
and open the truck auxiliary valves several
times in both directions.
After completing any service procedure, always test
the function through several cycles. First test the at-
tachment empty to bleed air trapped in the system to
the truck tank. Then test the attachment with a load to
be sure it operates correctly before returning to the
job.
Stay clear of the load while testing. Do not raise the
load more than 3 in. (75 cm) off the floor while testing.
4.1-1Truck System
Requirements
l The lift truck must supply sufficient hydraulic pressure to
handle the heaviest load, PRESSURE MUST NOT
EXCEED 2300 psi (160 bar).
l Hydraulic flow should be within volume range shown.
. The truck hydraulic system must supply hydraulic oil to
the attachment that meets the specifications shown.
4.1-2 Tools Required (Metric)
In addition to a normal selection oimetric hand tools you
will need:
l A pressure gauge capable of measuring pressure to
2500 psi (175 bar), Cascade part no. 671212.
l An inline flow meter capable of measuring hydraulic flow
to 20 GPM (80 L/min), Cascade part no. 671477.
4.1-3Get All The Facts
It is important that you gather all the facts regarding the
problem before you begin service procedures. The best
way is to talk to the operator. Ask for a complete descrip-
tion of the malfunction. The following guidelines will help
you decide where to begin your troubleshooting proce-
dures.
l Forks will not move.
l Forks move slowly. Normal speed is 4 in. (100mm) per
second.
For help with one of these problems, see Section 4.3.
l Attachment will not sideshift
l Attachment sideshifts slowly.
For help with one of these problems, see Section 4.4
Truck Relief Setting
2000 psi (140) bar - Recommended
2300 psi (160) bar - Maximum
Truck Flow Volume
3 GPM (1lL/mrn.) - Minimum
8 GPM (30 L/min.) - Recommended
IO GPM (37 L/min.) - Maximum
Hydraulic Oil
Cascade attachments are compatible with SAE
IOW petroleum base oil per Mil. Spec. MIL-0-5606
or MIL-O-2104B.
Use of synthetic or aqueous base hydraulic oil is
not recommended. Conact Cascade if fire
resistant hydraulic oil must be used.
Flow Meter Kit 671477
(2) No. 8-12
JICIO-Ring Flow Meter
IB” E!jTfibm I3
(2) No. 6-8 JIC Reducer
Pressure Gauge Kit 671212
Pressure No. 6 and No. 8
Gauge No. 6-6 Hose JIC Swivel Tee
No. 4-6 Pipe\/JIC No. 6-8 JIC
Reducer *No. 6 JIG/O-Ring
*Not included in Pressure Gauge Kit part no. 671212
200396 Rev.0

Troubleshooting
4.2 Plumbing
4.2-l Hosing Diagram-
Standard Valve
4.2-2 Circuit Schematic-
Standard Valve
Motor rt3-l
Standard
Valve
Sideshift
Cylinder
Truck
Auxiliar
Valves
Hose Terminals
1
Truck Truck
Relief Hydraulic
Valve Pump
200396 Rev.0 9

TROUBLESHOOTING
Hosing Diagram-
Sequence Valve Hose
POSITION FORKS INWARD and
SIDESHIFT RIGHT
PRESSURE
RETURN
Reel
equence
alve
NOTE: For Position Forks OUTWARD
and Sideshift LEFT,reverse the shades
shown
Motor rol
----.
Sequence I I( >(
Valve
r-;,
4.2-4 Circuit Schematic-
Sequence Valve
SIdeshift
Cylinder I
I I’
I ,
Relief Hydraulic
Valve Pump
10 200396 Rev. 0

.
c
TROUBLESHOOTING
*
4.2-5 Hosing Diagram-
Solenoid Valve Hose
Solenoid
Valve
POSITION FORKS INWARD and
SIDESHIFT RIGHT
PRESSURE
.....i...:.:.:.:.:.:.:.:.:.)~:.:.:,:.~::::::::
RETURN m
NOTE: For Position Forks OUTWARD
and Sideshift LEFT, reverse the shades
shown.
4.2-6 Circuit Schematic-
Solenoid Valve
Sideshift
Cylinder
1
Hose Reel
d!
J
r--
l
0 4
T34 TLu,ck
Relief Hydraulic
Valve Puma,
200396 Rev.0 11

TROUBLESHOOTING
:
4.3 Fork Position Circuit
There are eight potential problems that could affect fork
position operation.
l Incorrect hydraulic pressure/volume from truck.
l Kinked supply hoses.
l External leaks.
l Physically jammed mechanism or cocked forks,
l Faulty electrical connection (solenoid equipped attach-
ments).
0 Defective solenoid valves (solenoid equipped attach-
ments).
l Valve assembly malfunction.
l Worn or defective motor.
WARNING: Before removing any hoses,
relieve pressure in the hydraulic system.
control valve(s) several times in both
1 Check the pressure delivered by the truck. Refer to the
truck service manual. The recommended truck pressure
is 2000 psi (140 bar). TRUCK PRESSURE MUST NOT
EXCEED 2300 PSI (160 BAR), measured at the
carriage hose terminal.
2 Check the flow volume at the carriage hose terminal.
The recommended flow volume is:
3 GPM (11 L/min.) - Minimum
8 GPM (30 Urnin.) - Recommended
10 GPM (37 Urnin.) - Maximum
3 Solenoid Valve equipped attachments - Press the
control knob position forks button.
l If the solenoid valve “clicks”, it is working correctly.
Continue troubleshooting.
l If the solenoid valve does not “click”, troubleshoot the
electrical circuit as described in Section 4.5.
4 Sequence Valve equipped attachments - Start the
truck. Sideshift a capacity load completely to one side to
activate the fork position function.
0 If the forks do not position, raise the truck relief
pressure. increase the pressure a small amount at a
time until the forks position. TRUCK PRESSURE
MUST NOT EXCEED 2300 PSI (160 BAR).
0 If the forks still do not position, continue trouble-
shooting.
5 Install pressure gauges between the valve and motor
12 200396 Rev.0

TROUBLESHOOTING
6 Start the truck. Position the forks and note the gauge
readings.
l If the difference between the gauge readings is
approximately 1500 psi (105 bar), there may be
physically jammed components or the motor output
shaft may need repair. Continue troubleshooting.
l If the difference between the gauge readings is
substantially less than 1500 psi (105 bar), the motor
or valve may require service. Continue trouble-
shooting.
7 Disconnect the hoses from the tee fittings. Install
metal caps to the tee fittings. Start the truck. Position
the forks and note the gauge readings.
l If the higher gauge reading is close to 1500 psi (105
bar), the motor may need repair. Refer to Section
5.3-2 for motor service.
l If the higher gauge reading is substantially less than
1500 psi (105 bar), the valve may need repair. Refer
to Sections 5.4-2, 3 or 4 for valve service.
4.4 Sideshift Circuit
There are five potential problems that could affect side-
shifting operation.
l Insufficient hydraulic pressure/volume from the truck
l External leaks.
l Lower mounting hooks installed incorrectly. See
Section 5.1 step 8.
l Worn bearings. See Section 5.5-2.
l Worn or defective cylinder seals.
A WARNING: Before removing any hoses
or tubes, relieve pressure in the
hydraulic system. With the truck off,
open the truck auxiliary control valve(s)
several times in both directions.
1 Check the pressure delivered by the truck. Refer to
the truck service manual. The pressure must be
within 100 psi (7 bar) of specified truck pressure.
TRUCK PRESSURE MUST NOT EXCEED 2300 PSI
(160 BAR), measured at the carriage hose terminal.
2 Check the flow volume at the carriage hose terminal.
The recommended flow volume is 8 GPM (30 L/min).
3 Sideshift completely to the right and hold the control
handle in this position for 5 seconds. Check for
external leaks at the cylinder, fittings and hoses.
4 Sideshift completely to the left and hold the control
handle in this position for 5 seconds. Check for
external leaks at the cylinder, fittings and hoses.
200396 Rev.0 13

_ TROUBLESHOOTING
4.4 Sideshift Circuit
(Continued)
5 Disconnect the cylinder base end hose from the hose
terminal or internal reeving fitting. Place the hose end in
a bucket. Start the truck. Actuate the sideshift left
control handle for 5 seconds.
l If there is oil flow out of the base end of the cylinder,
the cylinder seals are defective and require service.
Refer to Section 5.6-2.
l If there is no oil flow out of the base end of the cylin-
der, the problem is not hydraulic.
4.5 Electrical Circuit
(Solenoid equipped attachments)
See the wire diagram and schematic shown
1 Check for truck voltage at the solenoid coil terminals
when the knob button is pushed.
2 Check the solenoid coil to make sure it matches the
truck voltage. The coil voltage is marked at the termi-
nals. Verify by checking the resistance across the
terminals with wires disconnected.
Coil Voltage Ohms Resistance
12v 9
24V 35
36V 82
48V 133
l If there is no ohmmeter reading shown, the solenoid
coil is defective and requires replacing.
3 Check the control knob circuit fuse. Replace if neces-
sary.
4 Check for loose electrical connections at the truck
ignition switch, control knob button(s), solenoid valve
terminals and diodes.
5 Remove the diode(s) from the solenoid valve terminals
Test with an ohmmeter for high resistance in one
direction and no resistance in the other direction. If
there is no resistance in both directions, replace the
diode.
5 Place the cylinder base
end hose in a bucket.
Two-Function (One button control knob)
Knob
7.5 Amp button
,,sILWh(le d yck ,
Diode
18 gauge wire _ ,+$$
l/4 in.
Terminals
User supplied
14 200396 Rev.0

SERVICE
5.1 Attachment Removal
1 Attach an overhead hoist to the fork postioner frame.
Take up slack in the chain.
hoses, relieve pressure in the hydraulic
system. Turn the truck off, then actuate
the truck control valve several times in
Disconnect hoses from the valve and sideshift
cylinder (if equipped). Tag the hoses for reassembly.
Remove the capscrews fastening the fork positioner
frame to the sideshifter or false carriage. For reas-
sembly, tighten the capscrews to a torque of
115-125 ft.-lbs. (155-175 Nm).
Lift away the fork positioner.
Remove the forks.
Remove the lower hooks.
Attach an overhead hoist to the sideshifter lifting
bracket. Lift away the sideshifter.
For installation, reverse the above procedures except
as follows:
l Install the lower mounting hooks up tight against
the carriage bar then back off one rib position, The
clearance between the hooks and lower carriage
bar must be l/16 in. (1.5 mm) minimum to l/8 in.
(3.0 mm) maximum. Tighten the capscrews to a
torque of 115-125 ft.-lbs. (155-175 Nm).
1116 in.115 mm
116 in.13.0 mm
Install Hooks
I I
200396 Rev.0 15

-sSERVICE *
Acme threads
5.2 Threaded Assembly
5.24 Threaded Assembly
Lubrication -
The threaded assembly acme threads will require lubricatIon
with chassis grease every 500 hours of operation.
5.2-2 Threaded Assembly Removal
1 Remove the capscrews fastening the cover plates to the
frame. For reassembly, tighten the capscrews to a
torque of 13-15 ft.-lbs. (17-21 Nm).
2 Disconnect the chain master Irnk.
Remove the chain.
3 Remove the capscrews fastening
the threaded assembly end plates
to the frame. For reassembly,
tighten the capscrews to a torque
of 13-15 ft.-lbs. (17-21 Nm).
4 Remove the capscrews and nuts
fasteninq the center support to
the frame. Remove the threaded
assembly. For reassembly,
tighten the capscrews to a torque
of 13-15 ft.-lbs. (17-21 Nm).
\
End
Plate
5 For reassembly, reverse the /’
above procedures except as
follows:
l The nut blocks on the acme
thread shafts must be an equal
distance apart f l/l 6 in.
(2 mm) when engaged with the
fork carriers.
Nut
Block
Position nut blocks at
an equal distance.
A=!3
2 l/16 in. (2mm) I
2
16 200396 Rev. 0

SERVICE
/ 5.2-3 Threaded Assembly Service
1 Remove the capscrews fastening the bearing plates
to the center support. For reassembly, tighten the
capscrews to a torque of 5-7 ft.-lbs. (7-9 Nm).
2 Drive out the roll pins connecting the coupler and
sprocket to the threaded shafts. Inspect the sprocket
and coupler for wear or damage. Replace as
required.
3 Remove the nut blocks from the threaded shafts.
Drive out the nut block roll pin to remove the acme
nut.
4 Inspect the acme nuts and bearing plates for wear.
Replace as required
5 For reassembly, reverse the above procedures
except as follows:
l Thread the threaded shafts into the coupler until
they stop, then unthread until the roll pin holes line
up. Install the roll pins.
l Inspect the end plate bearings for wear or dam-
age. Replace as required.
Threaded
Support
End Plate
and Bearing
200396 Rev.0

-S SERVICE
5.3 Drive Motor
6.3-1 Drive Motor Removal
1 Remove the capscrews fastening the cover plate to the
frame. For reassembly, tighten the capscrews to a
torque of 13-15 ft.-lbs. (17-21 Nm).
WARNING: Before removing any hoses,
relieve pressure in the hydraulic system.
Wrth the truck off, open the truck auxilary
control valve(s) several times in both
2 Remove the hoses from the motor fittings. Tag the
hoses for reassembly.
3 Disconnect the chain master link. Remove the chain.
4 Loosen the sprocket set screw. Pull the sprocket off the
motor shaft.
5 Remove the capscrews fastening the motor to the
bracket.
6 For reassembly. tighten the capscrews to a torque of
5-7 ft.-lbs. (7-9 Nm). Reverse the above procedures
except as follows:
l Install shims, part no. 686011. under the motor bracket
to adjust chain slack.
18 200396 Rev.'0