Cascade H Series User manual

Cascade is a Registered Trademark of Cascade Corporation
cascadeT
Manual Number 217521
NSTALLATION INSTRUCTIONS
H-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 217521 Rev. 0
C
B
H-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 No. 6
with 9/32 in. (7 mm) minimum I.D.
This Manual provides instructions for installing Cascade
H-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
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

217521 Rev. 0 1
T
RUCK 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 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 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)
A
Truck Relief Setting
2300 psi (160 bar) Recommended
2600 psi (180 bar) Maximum
Truck Flow Volume ➀
150H Min. ➁Recommended Max. ➂
Fork 3 GPM 4 GPM 5 GPM
Position (11 L/min.) (15 L/min.) (19 L/min.)
Sideshift 1 GPM 6 GPM 12 GPM
(4 L/min.) (23 L/min.) (45 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

2 217521 Rev. 0
NSTALLATION
I
Attach overhead hoist
ARemove banding.
BAttach hoist to top of backrest as shown and
lift Attachment 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.
WARNING: Make sure overhead hoist
has a rated capacity of at least
2000 lbs. (910 kg.)
FP0211.ill
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
B
C

217521 Rev. 0 3
FP0209.ill
cascade
®
C-675514-1
SS0141.ill
NSTALLATION
3Mount Fork Positioner on truck
ALower Attachment onto truck carriage.
BEngage upper mounting hooks. 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)
Class IV Mounting – 190 ft.-lbs. (255 Nm)
4Install or engage lower hooks
Inspect hooks for
excessive clear-
ance. (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.
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.
B
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
A
Sideshifter
Upper Bearings
SD0023.ill

4 217521 Rev. 0
5
FP0210.ill
Install Forks
AAttach overhead hoist to backrest as shown.
BRemove capscrews fastening Fork Positioner
frame to sideshifter or false carriage. Raise
frame to install forks.
CInstall forks, using bottom fork slot to engage
forks with carriage.
DLine up forks with fork carriers on frame.
EReinstall frame, engaging fork carriers with
forks and top carriage bar. Tighten mounting
capscrews to 115–125 ft.-lbs. (155–170 Nm).
Mounting Capscrews (4).
Fork Carriers
B
C
D
A
WARNING: Remove locking pins
from forks. Assure that forks slide
freely on carriage bars.
NSTALLATION
I
Fork Positioner Frame
Forks
Sideshifter or
False Carriage

217521 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
Sideshifting / Non-sideshifting HOSE REELS
Sideshifting / Non-Sideshifting
FP0207.ill
Sideshift Right Sideshift Left
Close Forks Spread Forks Spread Forks Close Forks
FP0208.ill
Sideshift Right Sideshift Left
7Flush 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
Back (Driver's) View

6 217521 Rev. 0
10 Install wiring –
(Solenoid equipped units)
PRESS
BUTTON
TO POSITION SIDESHIFT
CL0240.ill
Button
toward
driver
Truck control
valve handle
Adapter
9Install solenoid control knob –
(Solenoid equipped units)
CL0258.ill
CL0257.ill
Solenoid CoilUser-supplied wire
7.5-Amp
Fuse
White Black
7.5-Amp Fuse
White Black
Solenoid Coil
Diode
Diode
Knob
Button
Control Lever Knob
8Connect hoses prepared in
Step 6 to Attachment fittings
FP0219.ill
I
NSTALLATION

217521 Rev. 0 7
I
NSTALLATION
BD
C
A
GA0005.ill
Tilt backHoist 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 movement.
• 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
12
Front View
FP0176.ill
Flow
Restrictor
Fittings
Valve
AUXILIARY VALVE FUNCTIONS
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 flow restrictor fittings below valve.
Loosen jam nuts and screw both flow
restrictors in until they bottom. Screw
each restrictor out (CCW) three turns.
BOpen 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 move-
ment is equal. Tighten jam nuts.
A

8 217521 Rev. 0
P
ERIODIC 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 fork positioner frame mounting capscrews to
115-125 ft.-lbs. (155-170 Nm).
• Tighten lower hook capscrews to:
Class II, III – 125 ft.-lbs. (165 Nm).
Class IV – 190 ft.-lbs. (255 Nm).
• Apply chassis grease to fork carrier 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 carrier bearings for wear and replace if
necessary.
• Inspect fork cylinder rod anchors for wear and replace
if necessary.
• Inspect thickness of of sideshifter (if equipped) upper
bearing sets. If either bearing segment is worn to less
than 1/16-in. (1.5 mm) thick, replace the bearing set.
• Inspect exposed thickness of sideshifter (if equipped)
lower bearings. If either has less than 1/16-in. (1.5
mm) showing, replace both bearings (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.
FP0206.ill
FP0205.ill
Front View
Back (Driver's) View
Fork Carrier
Grease Fittings (2)
Frame Mounting Capscrews (4)
Cylinder Rod Anchors (2)
Fork Carrier
Bearings (2)
Sideshifter Upper Bearing
Grease Fittings (2)
(sideshift to expose fittings)
Sideshifter
Lower Bearings (2) Lower Mounting Hook
Capscrews (4)

QCascade Corporation 1998 2-98 Part Number 217521
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]
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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]
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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]
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15 Ra Ora Drive, East Tamaki
P.O. Box 38-440
Howick, Auckland
New Zealand
Tel: [phone]
FAX: [phone]
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P.O. Box 625, Isando 1600
60A Steel Road
Sparton, Kempton Park
South Africa
Tel: [phone]
FAX: [phone]
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Trading Co.
Four Seasons Park
Autumn Block - Apt. 1802
12 Cascaden Walk
Singapore
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FAX: [phone]