Cascade C Series Bedienungsanleitung

Cascade is a Registered Trademark of Cascade Corporation

cascadeT

Manual Number 219990

NSTALLATION INSTRUCTIONS

C-Series

Fork Positioners

Non-Sideshifting

A Mast Single Internal Reeving

C LH THINLINEE2-Port Hose Reel Group

Sideshifting

A Mast Double Internal Reeving

A and C Mast Single Internal Reeving and

RH THINLINEE2-Port Hose Reel

Group

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

B RH 6-N-1 Cable/Hose Reel Group

ONTENTS

ECOMMENDED HYDRAULIC SUPPLY OPTIONS

Recommended Hydraulic Supply

Truck Requirements 1

Installation 2

Periodic Maintenance 7

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

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.

NSTALLATION

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).

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)

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.

FP0202.ill

Bolt-on

Lower Hooks

Wood Blocking

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.

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.

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

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

Prepare hoses

ADetermine hose lengths required for

hydraulic supply configuration of truck.

BCut hoses to length and install end fittings

or quick-disconnect kits.

INTERNAL HOSE REEVING

Sideshifting / Non-sideshifting SOLENOID – 6-N-1 CABLE/HOSE REEL

Sideshifting

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

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

NSTALLATION

GA0005.ill Tilt backHoist up

Hoist down Tilt forward

Cycle Fork Positioner functions

SIDESHIFTING WITH

SOLENOID VALVE

ASideshift Left

ASpread Forks

(press knob button)

BSideshift Right

BClose Forks

(press knob button)

NON-SIDESHIFTING

ASpread Forks

BClose Forks

(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.

BBA

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.

Front View

FP0194.ill

Flow Restrictor

Adjustment Screw

AUXILIARY VALVE FUNCTIONS

Check for compliance with ITA (ISO)

standards:

Fork

Positioning

Cylinder

Jam Nut

'T' fitting

FP0204.ill FP0204.ill

FP0204.ill

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

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: 31-36-5492911

FAX: 31-36-5492964

Cascade Norway

Østerliveien 37A

1153 Oslo

Norway

Tel: 47-22-743160

FAX: 47-22-743157

Cascade Corporation

U.S. Headquarters

2201 NE 201st

Fairview, OR 97024-9718

Tel: 800-CASCADE (227-2233)

FAX: 888-329-8207

Cascade Korea

Room 508, Pum Yang Bldg.

750-14, Bang Bac-Dong

Se-Cho Ku, Seoul

Korea

Tel: 2599-7131 ext. 512

FAX: 2533-8089

Cascade-Xiamen

Wanshan No. 1 Workshop

Huli Road

Xiamen 361006

Fujian, PRC

Tel: 592-562-4600

FAX: 592-562-4671

Cascade (UK) Ltd.

15, Orgreave Crescent

Dore House Industrial Estate

Handsworth

Sheffield S13 9NQ

England

Tel: 742-697524

FAX: 742-695121

Cascade Scandinavia

Hydraulik A.B.

Muskötgatan 19, E8-9

S25466 Helsingborg

Sweden

Tel: 42-151135

FAX: 42-152997

Cascade France S.A.R.L.

11, Rue Jean Charcot

Zone Industrielle Sud or

B.P. 22

91421 Morangis Cedex

France

Tel: 1- 64547501

FAX: 1-9790584

Cascade Hispania S.A.

Avenida De La Fabregada, 7

Hospitalet De Llobregat

Barcelona

Spain

Tel: 3-335-5158

FAX: 3-335-4756

Cascade Canada Inc.

5570 Timberlea Blvd.

Mississauga, Ontario

Canada L4W-4M6

Tel: 905-629-7777

FAX: 905-629-7785

Cascade GmbH

D-41199 Monchengladbach

Klosterhofweg 52

Germany

Tel: 21-66-602091

FAX: 21-66-680947

Cascade N.V.

Benelux Sales and Service

P.O. Box 3009

1300 El Almere

Damsluisweg 56

1332 ED Almere

The Netherlands

Tel: 31-36-5492950

FAX: 31-36-5492974

Cascade Finland

01370 Vantas

Finland

Tel: 358-0-836-1925

FAX: 358-0-836-1935

Cascade Japan Ltd.

5-5-41,

Torikai Kami

Settsu, Osaka

Japan, 566

Tel: 81-726-53-3490

FAX: 81-726-53-3497

HYCO-Cascade Pty. Ltd.

87 Antimony Street

Carole Park,

Brisbane 4300

Australia

Tel: 7-271-1966

FAX: 7-271-3830

HYCO-Cascade (NZ) Ltd.

15 Ra Ora Drive, East Tamaki

P.O. Box 38-440

Howick, Auckland

New Zealand

Tel: 9-273-9136

FAX: 9-273-9137

Cascade (Africa) Pty. Ltd.

P.O. Box 625, Isando 1600

60A Steel Road

Sparton, Kempton Park

South Africa

Tel: 975-9240

FAX: 394-1147

Cascade (Singapore)

Trading Co.

Four Seasons Park

Autumn Block - Apt. 1802

12 Cascaden Walk

Singapore

Tel: 65-834-1935

FAX: 65-834-1936

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