Cascade E Series User manual

Cascade is a Registered Trademark of Cascade Corporation
cascadeT
Manual Number 213372 R-1
NSTALLATION INSTRUCTIONS
E-Series
Single-Double
Pallet Handler
I

i
ONTENTS
C
ECOMMENDED HYDRAULIC SUPPLY OPTIONS
R
This Manual provides instructions for installing the Cascade
Single-Double Pallet Handler. Follow the suggested
installation procedures for best results. If you have any
questions or need more information, contact your nearest
Cascade Service Department (see back cover).
Read the WARNING Statements placed throughout this
Manual to emphasize safety during Attachment installation.
IMPORTANT: Field alterations may impair performance or
capability and could result in loss of warranty. Consult
Cascade for any required modifications.
Recommended Hydraulic Supply i
Truck Requirements 1
Installation Procedure 2
Periodic Maintenance 9
The E-Series Single-Double Pallet Handler will operate with any
of the hydraulic supply arrangements listed below.
• All hoses and fittings for FORK POSITION and SIDESHIFT
functions should be at least No. 6 with a minimum internal
diameter of 9/32 in. (7 mm).
Refer to Cascade
Hose & Cable Reel Selection Guide , Part No.
212199, to select the correct hose reel for the mast and truck.
GA0033.ill
Sideshifting
A and B
RH and LH THINLINE™ 2-port hose reel groups.
OR
CMast double internal hose reeving group.
Solenoid Adaption
A6-N-1 cable/hose reel group.
OR
A and C
Cable reel and single internal hose reeving group.
AB
C

213372 Rev. 1 1
RUCK REQUIREMENTS
T
GA0080.ill
GA0082.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 14.96 in. (380.0 mm) 15.00 in. (381.0 mm)
Class III 18.68 in. (474.5 mm) 18.74 in. (476.0 mm)
Truck Relief Setting
2300 psi (160 bar) Recommended
2600 psi (180 bar) Maximum
Truck Flow Volume ➀
Min. ➁Recommended Max. ➂
4 GPM 7 GPM 10 GPM
55E (15 L/min.) (26 L/min.) (38 L/min.)
➀Cascade E-Series Single-Double Pallet Handlers 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 will result in reduced or unequal
arm speed.
➂Flow greater than maximum can result in excessive heating,
reduced system performance and reduced hydraulic system life.
A

2 213372 Rev. 1
NSTALLATION
Follow the steps shown to install the Single-Double Pallet
Handler on the truck. Read all WARNINGS and CAUTIONS
carefully. If you don't understand a procedure, ask your
supervisor, or call the nearest Cascade Service Department
for assistance.
I
1Attach overhead hoist
ARemove banding.
BSet Attachment upright on pallet.
CRemove bolt-on lower hooks (if equipped).
WARNING: Make sure overhead
hoist has rated capacity of at least
2000 lbs. (900 kg).
2Unlock Quick-Change lower
mounting hooks
ARemove pin and drop hooks into
unlocked position.
BReinstall pin in lower hole (unlocked).
Tighten Capscrews:
Class II / III – 120 ft.-lbs. (165 Nm)
cascade
®
C-675514-1
CL0097.ill
Pin
LH Lower
Hook
NOTE: Guides can be reversed to
reduce hook-to-carriage clearance
(See Step 4).
5/8-in. offset
on top
provides
maximum
clearance.
SD0068.ill
SD0069.ill
Lower hooks
Guide A
B
B
C
B

213372 Rev. 1 3
SD0070.ill
cascade
®
C-675514-1
SD0065.ill
NSTALLATION
3Mount Attachment on
truck carriage
ACenter truck behind attachment.
BTilt forward and raise carriage into position.
CEngage top mounting hooks with carriage.
Make sure center locator tab engages
center notch on top carriage bar.
DLift Attachment 2 in. (5 cm) off pallet.
I
BOLT-ON TYPE
(if fitted)
QUICK-CHANGE TYPE
Tighten Capscrews:
Class II / III – 120 ft.-lbs. (165 Nm)
4Install and engage lower hooks
Inspect hooks for
excessive clearance.
(Reverse guides to reduce
clearance – see Step 2.)
B
Slide hook up
to engage
bar, install
pin in upper
hole (locked).
Upper
Bearings SD0023.ill
GA0035.ill
ADJUST
SD0066.ill
Lower
Carriage
Bar
Lower
Carriage
Bar
SD0071.ill
A
3/16 in.
(5 mm)
max.
Tap into position, then
add clearance for
sideshifting:
3/32 in. (2.5 mm) min.
3/16 in. (5 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)
Center
Notch
Truck
Carriage
CCC

4 213372 Rev. 1
NSTALLATION
I
5Prepare hoses
ADetermine hose lengths required for hydrau-
lic supply configuration of truck.
BCut hoses to length, install end fittings or
quick-disconnect kits.
RH & LH 2-PORT THINLINE™HOSE REELS DOUBLE INTERNAL HOSE REEVING
SD0073.ill
SD0072.ill
Class III Back
SD0074.ill
CLASS II VALVE
CLOSE
Port
OPEN
Port
SD0075.ill
CLOSE
Port OPEN
Port
SD0088.ill SD0089.ill
Class II Back
Sideshift Right Sideshift Left
Spread
Forks Close
Forks
Close
Forks Spread
Forks
Sideshift Right Sideshift Left
CLASS III VALVE
NOTE: Attachment serial numbers
less than 55E-FD-500 use both
types of valves, newer serial
numbers use only the CL III valve.
CAUTION: Allow 4 in. (10 cm) extra hose length
in each direction for sideshifting movement
between Attachment valve and truck carriage.

213372 Rev. 1 5
NSTALLATION
I
SINGLE INTERNAL HOSE REEVING
with CABLE REEL
6-N-1 CABLE / HOSE REEL
SD0172.ill SD0171.ill
SOLENOID VALVE – CLASS II OR III
Sideshift Right / Close Forks
(PRESSURE Port)
Sideshift Left / Spread Forks
(TANK Port)
Class II Back
SD0173.ill
Sideshift Right/
Close Forks Sideshift Left/ Spread Forks
Solenoid
Cable
CAUTION: Allow 4 in. (10 cm) extra hose length
in each direction for sideshifting movement
between solenoid valve and truck carriage.
Back (Driver's) View

6 213372 Rev. 1
SD0095.ill
I
NSTALLATION
Connect hoses prepared
in Step 5 to Attachment fittings
Flush hydraulic supply hoses
AInstall hoses using union fittings.
BOperate auxiliary valves for 30 sec.
CRemove union fittings.
89
6
SIDESHIFT
PRESS BUTTON
TO POSITION
FORKS
CL0240.ill
7Install wiring –
(Solenoid-equipped units)
GA0092.ill
White Black
7.5-Amp
Fuse
Solenoid
Coil
User-supplied wire
SD0094.ill
7.5-Amp
Fuse Knob Button
Solenoid
Coil
Diode
18-gauge wire,
1/4-in. (6 mm) terminals
BlackWhite
SD0076.ill
Control Lever Knob
with Pushbutton
Install solenoid control knob –
(Solenoid-equipped units)
Adapter
Truck control
valve handle
Button
toward
driver

213372 Rev. 1 7
I
NSTALLATION
WARNING: Make sure all personnel are
clear of the Attachment during testing.
10
AUXILIARY VALVE
FUNCTIONS
Check Attachment functions
•With no load, cycle all Attachment
functions several times.
•Check for operation in accordance with
ITA (ISO) standards.
•Lift a maximum load and sideshift left and
right. Check for smoothness and
adequate speed.
•Check for leaks at fittings, valve, manifold
and cylinders.
SIDESHIFTING WITH SOLENOID VALVE
ASideshift Left
ASpread Forks (press knob button)
BSideshift Right
BClose Forks (press knob button)
ASideshift Left
BSideshift Right
CSpread Forks
DClose Forks
SIDESHIFTING
SD0064.ill
B
SD0064.ill
AA
A
B
DC
C
A
B
BD
C
A
GA0005.ill
Hoist down Tilt forward
Hoist up Tilt back

8 213372 Rev. 1
I
11 Adjust relief cartridge
For over-pressure protection, the relief valve
cartridge for the FORK POSITION function
should be adjusted to match the truck
hydraulic flow rate. MAXIMUM RELIEF
VALVE SETTING = 2600 psi (180 bar).
Fork positioning relief adjustment:
AConfirm that the truck pressure is between
2300–2600 psi (160–180 bar).
BInstall a 3000-psi (200 bar) pressure gauge
on the TEST port of the main hydraulic
valve (No. 4 O-ring fitting required).
CCycle forks to full open, then slowly close
forks fully. Hold lever in the CLOSE
position and accelerate engine to develop
full system pressure.
DAdjust the relief cartridge for an indicated
2300 psi (160 bar). Turn clockwise (CW)
to increase pressure, counterclockwise
(CCW) to decrease pressure. Tighten jam
nut and replace cap.
WARNING: Before removing hydraulic
lines or components, relieve pressure in
the hydraulic system. Turn the truck off
and open the truck auxiliary control valves
several times in both directions.
SD0198.ill
B
SD0199.ill
CC
CLASS III VALVE
Back (Driver's) View
CL0623.ill
Relief Valve
Cartridge
Decrease
Pressure (CCW)
5/16-in. (8 mm)
Allen Wrench
Adjustment
Screw
Cap
3/4 in. (19 mm)
Jam Nut
D
Increase
Pressure
(CW)
Front View
Valve
NSTALLATION

213372 Rev. 1 9
P
ERIODIC MAINTENANCE
WARNING: After completing maintenance
procedures, always test the Attachment
through five complete cycles. First test the
Attachment empty, then test with a load to
make sure the Attachment operates
correctly before returning it to the job.
IMPORTANT: The Single-Double Pallet Handler is
prelubed at the Factory. Lubrication is not necessary
for installation.
100-Hour Maintenance
Every time the lift truck is serviced or every 100 hours of
truck operation, whichever comes first, complete the
following maintenance on the Attachment:
• Check for loose or missing bolts, worn or damaged
hoses and hydraulic leaks.
• Inspect the cylinder rod anchors for damage. Anchors
operate with a loose clearance and require no
lubrication.
• Check for equal movement of the inner and outer forks.
500-Hour Maintenance
After each 500 hours of truck operation, in addition to the
100-hour maintenance, perform the following procedures:
• Inspect the inner and outer fork bearing surfaces for
wear or damage. Lubricate with silicone spray or light
grease as required.
• Apply chassis grease to the sideshifter upper bearing
grease fittings and lower bearing surfaces.
• Check the clearance between the lower mounting hooks
and the truck carriage bar:
Quick-Change Hooks – 3/16 in. (5 mm) max.
Bolt-on Hooks – 3/32 in. (2.5 mm) min., 3/16 in.
(5 mm) max. for sideshifting.
If adjustment is necessary, refer to Installation Step 4.
Tighten the lower hook capscrews to 120 ft.-lbs.
(165 Nm).
• Inspect the inner fork gas springs for damage or
looseness. Replace if necessary (see Service Manual).
1000-Hour Maintenance
After each 1000 hours of truck operation, in addition to the
100 and 500-hour maintenance, perform the following
procedures:
• Tighten the inner and outer fork capscrews to 220 ft.-lbs.
(300 Nm).
• Tighten the frame capscrews to 75 ft.-lbs. (100 Nm).
SD0078.ill
Upper
Mounting
Hooks Upper Bearing
Grease Fittings
Quick Disconnect Lower
Mounting Hooks
Fork
Capscrews
Cylinder Rod
Anchors (2)
SD0077.ill
Inner Fork
Bearings
Outer Fork
Bearings
Sideshift Lower
Bearings
Back view
Front view
Frame Capscrews
Inner Fork
Gas springs (2)

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Do you have questions you need
answered right now? Call your
nearest Cascade Service Department.
AMERICAS
Cascade Corporation
U.S. Headquarters
2201 NE 201st
Fairview, OR 97024-9718
Tel: 800-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
37030 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]