G-Series Multiple Load Handlers
Contents
1. eh IM ooo m9 9 Bas amp ope OH T FNo o LH Sideshift RH Fork Control LH Fork Control RH Sideshift RH amp LH 2 PORT THINLINE HOSE REELS 6088640 R2 NSTALLATION Flush hydraulic supply hoses Install hoses using union fittings B Operate auxiliary valves for 30 sec C Remove union fittings GAO0092 eps Check attachment functions e With no load cycle all attachment functions several times e Check for operation in accordance with ANSI ISO standards e ift a maximum load Sideshift left and right Check for smoothness and adequate speed e Check for leaks at fittings valve manifold and cylinders Tilt Forward Hoist iu f 914 ul 1 Hoist Up Tilt Back GAO005 eps WARNING Truck control handle and attachment function activation shown here conforms to ASME ANSI B56 1 recommended practices Failure to follow these practices may lead to serious bodily injury or property damage End user dealer and OEMs should review any deviation from the practices for safe operation Connect hoses to attachment fittings CAUTION When removing attachment from truck fully close the forks prior to disconnecting the supply hoses 500747 WARNING Make sure all personnel are clear of the attachment during testing FORK POSITION amp SIDESHIFT oideshift Left oideshift Right Open Forks Close2. Truck Carriage Upper Bearings GA0035 eps SD0489 eps 6088640 R2 NSTALLATION Install and engage lower hooks Lower Carriage Bar Rotate hook up and release pin Pull pin Clearance for sideshifting 10 in 2 5 mm min 20 in 5 mm max fefe SD0740 eps i 500776 Tighten capscrews to a double torque of 165 ft lbs 225 Nm If required convert to left hand fork control Disconnect hoses and label B Flip valve over Tighten capscrews to 9 ft los 12 Nm C Reconnect hoses as shown TET o Ji CEBE ne loma 1 9 Hose 2 wis i O id Bh 7 NN QEeMoAL LB Hg oo O fe e brae ua e sp SDO741 eps E EE SD0742 eps Lo EE Hose 4 Valve nne Hose 3 Valve RH Hose Layout LH Hose Layout 6 6088640 R2 u NSTALLATION Prepare hoses Determine hose lengths required for CAUTION Allow extra hose length for hydraulic supply configuration of truck sideshift movement of 4 in 10 cm in each B Cut hoses to length install end fittings or direction between attachment valve and quick disconnect kits truck Carriage RH amp LH INTERNAL HOSE REEVING Sideshift Sideshift Close Open Close Open Sideshift Sideshift Right Left Forks Forks Forks Forks Right Left t BERA A ercan 5 n pee macm T
3. 500793 SSL P ON oideshift Cylinder SD0794 eps 6088640 R2 u S ERVICE si Attachment Removal 2 1 Position the outer forks approximately at the width of the frame WARNING Before removing any hoses relieve pressure in the hydraulic system Turn the truck off then actuate the truck control valve several times in both directions 2 Disconnect the supply hoses from the bulkhead fittings and sideshift cylinder fittings Tag hoses for reassembly SD0795 eps 3 Disconnect remove the lower hooks Bolt On Hooks Remove the lower mounting hooks For reassembly tighten capscrews to a double torque of 165 ft Ibs 225 Nm Check clearance for sideshifting leaving a minimum of 10 in 2 5 mm space Quick Change Hooks Pull out pin and rotate hook down Release pin For reassembly pull pin and rotate hook up Release pin 4 Position the attachment over a pallet Lower the attachment onto the pallet Tilt the truck carriage forward Lower carriage and back truck away 5 For installation reverse the above procedures except for the following special instructions e Clean the upper and lower bearings and bearing contact surfaces e Refer to Section 2 for complete installation instructions 500129 3 Bolt On Hooks Lower Carriage Bar Quick Change Hooks Wy Pull pin Clearance for sideshifting 10 in 2 5 mm mi
4. ES SD0560 eps xS 6088640 R2 Anti Rotation Pin u S ERVICE 5 4 4 Cylinder Reassembly 1 Using 400 grit emery cloth polish the piston and retainer chamfer angles to ease seal installation Clean all parts thoroughly 2 Lubricate all new seals and O rings with petroleum jelly 3 Install a new seal on the piston Install the seal from the rod end side of the piston by hooking one side into the groove and carefully working the seal over the piston as shown 4 Install the composite wear rings on the piston 5 Install a new rod seal and wiper seal in the retainer I D and a new O ring and back up ring on the retainer O D as shown NOTE Use internal seal installation tool Cascade Part No 599512 to ease installation If installing by hand form seal into kidney shape and position into internal groove Use finger pressure to smooth into groove 6 IMPORTANT Prior to loading the piston into the shell assure that no sharp edges exist on the internal threads within the shell 7 Apply petroleum jelly to the piston and shell threads Carefully insert the piston into the cylinder shell and using a rubber mallet to drive the piston rod assembly into the shell 8 Apply petroleum jelly to the retainer D and slide onto the rod Screw the retainer into the shell Use a claw type spanner wrench tighten the retainer to 125 ft Ibs 170 Nm 9 Make sure anti rotation pin fits tightly in place at cyl
5. qood GA0082 eps Hoist Up Close Forks Tilt Back Sideshift Right 6088640 R2 Open Forks GAO0397 eps 31 u S PECIFICATIONS 6 1 3 Truck Carriage Carriage Mount Dimension A ITA ISO Minimum Maximum Class 1 14 94 in 380 0 mm 15 00 in 381 0 mm Class Ill 18 68 in 474 5 mm 18 74 in 476 0 mm Class 2344 in 595 5 mm 23 50 in 597 0 mm 32 6088640 R2 u S PECIFICATIONS 6 1 4 To rq ue Val ues NOTE All fasteners have a torque value range of 10 of stated value Fastener torque values for the G Series Multiple Load Handler are shown in the table below in both U S and Metric units Torque values are also found in each specific service procedure section throughout the manual m Faso Se ts wm A omens fa e 2 racine me 3 smomews wie ar Ca ronson we s 5 wi 6 mesmo we 1 8 uring Hk we 68 25 a we s 5 ecas 9 oa 25 Double torque SD0591 eps j HI II EJ o ON __ ____ e Lu EE _ EJ pue ol SD0592 eps SD0801 eps 6088640 R2 Do you have questions you need answered right now Call your nearest Cascade Service Departmen
6. NSTALLATION 2 3 Installation Procedures Follow the steps shown to install the Multiple Load 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 Attach overhead hoist WARNING Check the attachment A Remove banding weight located on nameplate to make B Set attach t upriaht let sure the overhead hoistis at least the rated capacity of the attachment C equipped remove bolt on lower hooks SD0624 eps SD0623 eps If equipped unlock quick disconnect lower mounting hooks Pull pin from guide Rotate hook downward NOTE If the hook is jammed place a screwdriver in the pocket recess hole located in the bottom surface of the hook 500739 6088640 R2 NSTALLATION Mount attachment on truck carriage Center truck behind the attachment B Tilt forward and raise carriage into position C Engage top mounting hooks with carriage Make sure center locator tab engages center notch on top carriage bar D Lift attachment off pallet ITA Class Il 0 60 0 66 in 15 17 mm ITA Class Ill 0 72 0 78 in 18 20 mm ITA Class IV 0 72 0 78 in 18 20 mm Center Notch ITA Class Il 0 32 0 36 in 8 9 mm ITA Class IIl 0 39 0 43 in 10 11 mm ITA Class IV 0 47 0 51 in 12 13 mm Ss
7. ERVICE MANUAL G Series Multiple Pallet Handler Manual Number 6088640 R2 Cascade Cascade is a Registered Trademark of Cascade Corporation C ONTENTS Page INTRODUCTION Section 1 Introduction 1 opecial Definitions 1 INSTALLATION Section 2 Truck System Requirements e Hecommended Hydraulic Supply Options 9 Installation Procedures 4 PERIODIC MAINTENANCE Section 3 100 Hour Maintenance 9 500 Hour Maintenance 9 1000 Hour Maintenance 10 2000 Hour Maintenance 10 TROUBLESHOOTING Section 4 General Procedures 11 Truck System Requirements 11 Tools Required 11 Troubleshooting Chart 11 Plumbing 12 Hosing Diagram 12 Circuit Schematic 12 Fork Position Function 13 Fork Position Circuit Test 13 Sideshift Function 14 Sideshift Circuit Test 14 SERVICE Section 5 Attachment Removal 15 Forks and Arms 16 Fork Removal 16 Inner Fork Spring Cylinder Service 16 Outer Fork and Arm Removal 1f Outer Arm Bearing Service 18 Inner Fork Carrier Service 19 Fork Tip Alignment 20 Inner Fork Control Service 21 oideshift Cylinder 22 Cylinder Removal 22 Cylinder Disassembly 23 Cylinder Inspection 23 Cylinder Reassembly 24 Fork Cylinder 25 Cylinder Removal 25 Cylinder Disassembly 26 Cylinder Inspection 26 Cylinder Reassembly ef Valve 28 Valve Removal 28 Valve Service 29 Base Unit 30 oideshift Bearing Service 30 SPECIFICATIONS Section 6 opecifications 31 Hydraulics 31 Auxiliary Valve Functions 31 Truck Carriage 31 Torque Value
8. Fully retract the sideshift cylinder rod Disconnect the hoses from the cylinder ports Tag the hoses for reassembly Hemove the clevis pins from the cylinder ends Remove the cylinder For reassembly reverse the above procedures except for the following special instructions e Operate the sideshifter through several full cycles to force air in the system to the truck hydraulic tank Check for leaks at all fittings SD0796 eps EHM NN a 4 ANN 6088640 R2 u S ERVICE 5 3 2 Cylinder Disassembly Hose 1 Clamp the cylinder in a soft jawed vise Clamp lightly at the extreme base end only 2 Connect a hose to the rod end port The hose should lead to a catch bucket Fully extend the cylinder rod Hemove the spiral snap ring from the retainer as shown 4 Tap the retainer into the shell approximately 2 in 50 mm Remove the retaining ring by prying it out of its groove on the opposite side from the split ends The retaining ring will compress and turn sideways for removal Remove the retainer CAUTION Do not scratch the cylinder bore To prevent damage to the components and ease of retaining ring removal use Service Tool Kit 674424 Cylinder SS0857 eps 5 Remove the rod assembly from the cylinder as shown 6 To remove the piston clamp the rod assembly is a vise on the clevis end as shown CAUTION Do not clamp on the cylinder rod sealing surface 7 Remove the pi
9. 6153293 For reassembly tighten the socket screws to a torque of 24 ft Ibs 32 Nm NOTE remove the upper outer fork carrier fork stop place a 11 in long 2 in x 6 in board between the forks Close the forks Remove the stop capscrews 2 2 Extend the outer forks outside the width of the frame Position the forks 5 in 12 mm above the floor 3 Remove nut from the cylinder rod end Use Cascade flat wrench part number 6153275 on the flat of the rod to ease removal of the nut Support the cylinder with a cable tie For reassembly tighten the nut to a torque of 52 ft Ibs 70 Nm 4 Attach a suitable overhead hoist around the fork Pull the fork assembly out of the frame Cylinder rod extension tool part number 6151448 can be installed on the cylinder rod to help push the arm out of the frame 5 Inspect the arm bearings for wear If the bearings are worn in any area to less than 08 in 2 0 mm they should be replaced For bearing removal refer to 500972 Section 5 2 4 NOTE Check wear on the outer inside area of the Outer Left Carrier bearings Upper Fork Stop SD0555 eps D Z 2 6 For reassembly reverse the above procedures e Apply arm bar rust inhibitor Part No 6145867 to outer arm bars e nspect outer lower arm bar for wear If wear is detected refer to kit 6148830 to install an addit
10. 5 4 3 Anti Roll Pin 26 Clamp the cylinder in a soft jawed vise at the extreme head end only Do not clamp on the shell Unscrew and remove the retainer using a claw type spanner wrench as shown Cascade Part No 678598 Remove the piston rod assembly from the cylinder Clamp the piston rod or retainer in a soft jawed vise and remove the seals Piston is a shrink fit on the rod and not removable Pry the seals or O rings up with a brass seal removal tool Cascade Part No 674424 and cut the seals to remove them CAUTION Do not scratch the seal grooves Cylinder Inspection Inspect the rod piston and retainer for nicks or burrs Minor nicks or burrs may be removed with 400 grit emery cloth If they cannot be removed replace the parts Inspect the cylinder bore and remove any minor nicks or burrs with a butterfly hone If they cannot be removed replace the part Inspect the outside of the shell for any damage that could impair performance or cause leaks under pressure If necessary replace the part Inspect the rod end anchor nut for wear and replace as necessary Inspect anti roll pin for wear or looseness and replace as necessary MSN KILO LL Piston Rod Assembly Shell 1 2 Qe QE Es fC wis Retainer WA 500556 IMPORTANT Clamp ooft Jawed Vice Only Cx lt gt Y ES G i Retainer Hd EN
11. External leaks caused by worn or defective cylinder seals Check the truck pressure at the carriage hose terminal Pressure must be within 100 psi 17 bar of that specified in the truck service manual TRUCK PRESSURE MUST NOT EXCEED 2900 psi 200 Bar oee Section 6 1 for recommended operating pressure Check the flow volume at the carriage hose terminal oee Section 6 1 for recommended flow volume Fully retract the sideshift cylinder rod Hold the lever in the SIDESHIFT LEFT position for a few seconds Helease the lever and check for external leaks at fittings hoses valve and manifold Turn the truck off and relieve system pressure Disconnect the SIDESHIFT RIGHT supply hose from the sideshift cylinder Plug the hose end Install a drain hose from the cylinder fitting to a catch bucket Start the truck Actuate the SIDESHIFT LEFT lever for 10 seconds e fthere is substantial hydraulic flow out of the drain hose the sideshift cylinder is faulty and requires service Hefer to Section 5 3 e fthere is no hydraulic flow out of the hose the problem is not hydraulic Refer to Section 4 1 3 SSR saN Plug oZ Drain Hose Back Driver s View 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 7072 mJ oum
12. Forks SD0526 eps 6088640 R2 u P ERIODIC MAINTENANCE IMPORTANT Attachment is prelubed at the factory and lubrication is not required for installation If required teflon spray or light grease is recommended CAUTION When removing attachment from the truck fully close the forks prior to disconnecting the supply hoses 31 100 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 Cylinder anchors operate with a loose clearance and require no lubrication Check for equal movement of the inner and outer forks 32 500 Hour Maintenance After each 500 hours of truck operation in addition to the 100 hour maintenance perform the following procedures Inspect the inner fork bearings and inner fork rod surface for wear and damage Inspect the outer fork arm bars and bearings for wear or damage If bearing thickness is less than 06 in 1 5 mm replace both bearings Apply chassis grease to the upper sideshift bearing grease fittings Sideshift the attachment several cycles to distribute the grease Apply chassis grease to the lower bearings Lower the attachment to the ground for access to the bearings Apply chassis grease to the inner fork
13. Hose Heel OR LP Internal Reeving SIDESHIFT LEFT OPEN FORKS PRESSURE IEEE RETURN c NOTE For SIDESHIFT RIGHT CLOSE FORKS reverse the colors shown 500779 42 2 Circuit Schematic Cylinders Attachment Valve with Crossover Relief Cartridge SIDESHIFT Truck OPEN CLOSE FORKS Auxiliary Valve AMI _ XW _ XW Truck Auxiliary Valve Truck Truck Relief Pump SD0781 eps 12 6088640 R2 _ T BQUBLESHOOTING 43 Fork Position Function There are six potential problems that could affect the fork WARNING Before removing hydraulic positioning function lines or components relieve pressure in the e Incorrect hydraulic pressure or flow from lift truck hydraulic system With the truck off open the truck auxiliary control valves several e Bent arm bars times in both directions e Defective spring cylinders e External leaks caused by defective cartridge valve or FowNieier cylinder seals 2 e Defective inner fork control cylinders Refer to Section 5 2 7 4 3 1 Fork Position Circuit Test Check the truck pressure at the carriage hose terminal Pressure must be within 100 psi 7 bar of that specified in the truck service manual TRUCK PRESSURE MUST NOT EXCEED 2900 psi 200 BAR See Section 6 1 for recommended operating pressure 2 Check the flow volume at the carriage hose terminal oee Section 6 1 1 for recommended flow volume Open the forks and check that the inner forks rem
14. Retainer 6 8 6088640 R2 24 u S ERVICE s4 Fork Cylinders 5 4 1 Cylinder Removal and Installation NOTE The following procedures can be performed with the attachment mounted on the truck 1 Fully close the forks WARNING Before disconnecting hydraulic lines relieve pressure in the attachment hydraulic system Turn the truck off and move the auxiliary control levers several times in both directions erf 88 1 BCECIe TB 2 Disconnect the hoses from the cylinder ports Plug 4 the hoses and cap the cylinder ports Tag hoses for reassembly 3 Remove the cylinder rod end nut 4 Remove the cylinder base head end nut Disengage Jen e the cylinder from it s mounting boss and lift away from the frame SD0797 eps 5 For reassembly reverse the above procedures with the following exceptions e Tighten cylinder nuts to 52 ft Ibs 70 Nm e Make sure anti roll pin is installed in cylinder base head end e Cycle forks through five complete cycles to remove air in the cylinders WARNING After completing this service procedure test the forks through five complete cycles First test empty then test with a load to make sure the forks operates correctly before returning it to the job AY SD0562 eps Anti Roll Pin 6088640 R2 25 S ERVICE 5 4 2 Cylinder Disassembly 1 2 Go
15. instructions e The cartridge O rings and back up rings must be installed as shown for proper hydraulic operation e Lubricate the cartridges and seals with petroleum jelly prior to reassembly Flow Divider Cartridge O Rings CLO341 eps Back up Rings Crossover Relief Cartridge O Rings CL2850 eps Back up Rings 6088640 R2 Single Cartridge Valve Flow Divider Cartridge Valve 500799 Two Cartridge Valve Flow Divider 1 Cartridge 1 Cartridge 2 Fitting S va Ze SD0800 eps 29 u S ERVICE se Base Unit 5 6 1 Sideshift Bearing Service 1 Remove attachment from the truck as described in Section 5 1 2 Remove clevis pin from head base end of the oideshift cylinder 3 Inspect the upper bearing thickness If either one is worn less then 06 in 1 5 mm thick on the back surface replace both bearings 4 Inspect the lower bearing exposed thickness If the exposed thickness is less than 06 in 1 5 mm replace both bearings 5 For reassembly reverse the above procedures except for the following instructions e Clean the upper and lower bearings and bearing surfaces e Locate the upper bearings in the anchor bracket cutouts Be careful not to install the bearings backwards e Check the upper
16. mounting hook capscrew torque Double torque to 166 ft lbs 225 Nm Bearing in 1 5 mm minimum Upper Bearing 30 6088640 R2 u S PECIFICATIONS Specifications 6 1 1 Hydraulics Truck Relief Setting 2600 psi 160 bar Recommended 2900 psi 200 bar Maximum Truck Flow Volume Min 9 Recommended 9 126 FQS 20G 32G FDS 256G 30G FTS 4 GPM 7 GPM 7 GPM 15 L min 26 L min 26 L min 25G FZS 25G 46G FOS 4 10 GPM 10 GPM 36G 50G FDS 15L min 37L min 37 L min 36G 45G FTS m uu m ou d ou wo Rie Cascade G Series Multiple Load Handlers are compatible with SAE 10W petroleum base hydraulic fluid meeting Mil Spec MIL 0 5606 or MIL 0O 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 Flow less than recommended will result in reduced or unequal arm speed Flow greater than maximum can result in excessive heating reduced system performance and short hydraulic system life Hoses and Fittings All supply hoses must be at least No 6 minimum All fittings must have an orifice size of 9 32 in 7 mm minimum 6 1 2 Auxiliary Valve Functions Check for compliance with ANSI ISO standards Sideshift Forward Left Hoist Down WA dd d
17. open or close To correct these problems see Section 4 3 Sideshift Circuit e Attachment will not sideshift e Attachment sideshifts slowly To correct these problems see Section 4 4 6088640 R2 WARNING Before servicing any hydraulic component relieve pressure in the system Turn the truck off and move the truck auxiliary control valves several times in both directions After completing any service procedure always test the attachment through several cycles First test the attachment empty to bleed any 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 otay clear of the load while testing Do not raise the load more than 10 cm off the floor while testing Flow Meter Kit 671477 2 No 8 12 JIC O Ring Flow Meter GAO0013 eps 2 No 6 8 JIC Reducer Pressure Gauge Kit 671212 No 6 and No 8 JIC Swivel Tee Pressure Gauge No 6 6 Hose cen GAQO014 eps 7 2 No 4 6 Pipe JIC No 6 8 JIC No 4 No Heducer 6 and No 8 JIC O Ring Quick Coupler No 4 and No 6 Male m d Straight or JIC Thread Mit O ring Coupler No 6 Female otraight Thread O ring Coupler ACO127 eps 11 _ J BQUBLESHOOTING 2 Port Hose 4 2 Plumbing 4 2 1 Hosing Diagram deut Cylinders Reeving oideshift Cylinder Valve SSH Truck Auxiliary Valves 2 Port
18. 2633 Screw in tight 4 Du r pog m eee SS Ss 2220 yO Wa E RUIZ SD0579 eps 6088640 R2 S ERVICE 5 2 5 Inner Fork Carrier Service 1 2 3 SD0970 eps 6088640 R2 Type 2 Wear Pad Position forks about 5 in 12 mm off the floor Fully close forks Open outer forks about 12 in 300 mm to access the inner fork carrier The inner forks should not move WARNING Do not remove the spring cylinder rod end nut when the forks are completely open Hemove the spring cylinder rod end nut from the inner fork carrier Support the fork spring cylinder with a cable tie For reassembly tighten the nut to 37 ft Ibs 50 Nm Completely lower mast carriage Remove outer fork arms as described in section 5 2 3 Hemove the capscrew from the pin retainer on the right hand side of the bar Use a slide hammer M16 to move the round bar to the left to remove the inner forks CAUTION On the left end of the round bar is a keeper pin Failure to remove the round bar out the left side can damage the grease seals on the inner fork carrier Inspect the wear pads for wear Replace wear pads if the pads are worn flush with the plastic carrier To remove wear pad pry out from left or right side Use a C clamp and flat plate against the pad to press the new wear pad in place For reassembly reverse the above procedures except as follows
19. 51 2500 Fax 86 592 651 2571 Sunstream Industries Pte Ltd 18 Tuas South Street 5 oingapore 637796 Tel 65 6795 7555 Fax 65 6863 1368 10 2011 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 91 020 2432 5490 Fax 91 020 2433 0881 Part Number 6088640 R2
20. E p a nie lele H Ld 500783 25 in 7 mm 0 in mm 2 2 Ae Wear Pad Wear Pad SD0970 eps SD1144 eps Type 1 Wear Pad SD0785 eps Outer Fork Bend Tabs Lower Inner Fork Carrier 20 SD0784 eps in 0 mm Inner Fork 25 Ms minimum mm maximum Inner Fork Outer Fork 6088640 R2 u S ERVICE 5 2 7 Inner Fork Control Service 1 Follow steps 1 through 3 in Section 5 2 4 2 Loosen or remove capscrew in the split collar For reassembly tighten to a torque of 10 ft lbs 13 Nm 3 Slide inner fork control group from round bar 4 Remove the two capscrews from the bracket and cylinder For reassembly tighten capscrews to a torque of 10 ft Ibs 13 Nm 5 Remove gas cylinder from the bracket V 6 For reassembly reverse the above procedures except as follows e Replace gas cylinder if needed 1 e Replace inner fork carrier Teflon bearings Bracket gt lt CH Collar 2 6088640 R2 21 u S ERVICE s sideshift Cylinder 5 3 1 Cylinder Removal 22 N A WARNING Before removing any hoses relieve pressure in the truck hydraulic system Turn the truck off then actuate the truck control valve several times in both directions
21. ain in contact with the outer forks until reaching their stops If they do not a spring cylinder is faulty Heplace the faulty spring cylinder Refer to Section 5 2 2 eps 4 Fully open and close the forks If the arms move at different speeds the flow divider cartridge may be faulty Replace the cartridge 5 Fully open and close the forks 6 Turn the truck off and relieve system pressure Disconnect the fork positioning bottom cylinder supply hose base head end at the valve Plug the valve Place supply hose end into a catch bucket 7 Start the truck Actuate the OPEN FORKS lever for 10 seconds Upper cylinder e lf there is substantial hydraulic flow out of the hose the bottom cylinder is faulty and requires service Refer to Section 5 4 e lf there is no hydraulic flow out of the hose the upper cylinder may be faulty see Section 5 4 or the problem is not hydraulic due to bent arms or frame 500792 Plug Supply hose 6088640 R2 13 Zo Sideshift Function There are four potential problems that could affect the sideshifting function 4 4 4 4 1 14 Sideshift Circuit Test 1 ROUBLESHOOTING Incorrect hydraulic pressure or flow from lift truck Lower mounting hooks installed incorrectly Refer to oection 5 1 Step 5 Inadequate sideshift upper bearing lubrication or worn bearings Refer to Section 5 6 1
22. bearing grease fittings Apply Teflon spray or light grease to the inner fork rod surfaces Apply Teflon spray or light grease to the outer fork arm bar bearing surfaces Check the clearance between the lower mounting hooks and the truck carriage bar QD Hooks 3 16 in 4 8 mm maximum Bolt on Hooks 10 in 2 5 mm minimum 20 in 5 mm maximum If adjustment is necessary refer to Installation Step 4 Tighten lower hook capscrews to a double torque of 166 ft Ibs 225 Nm Inspect the inner fork springs for damage 6088640 R2 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 Upper Mounting Hooks Upper Sideshift Bearing Grease Fittings Cylinder Rod Anchors Hd Bolt on Lower Lower Bearings QD Lower Mounting Hook Mounting Hook Inner Fork Bearings Outer Fork Inner Fork Hod Bearings pi 1 Lx oL 1 1 j Ll of lo 0 Z SD1143 eps Outer Fork Inner Fork Arm Bars oprings P 3 3 3 4 10 ERIODIC MAINTENANCE 1000 Hour Maintenance After each 1000 hours of truck operation in addition to the 100 and 500 hour maintenance perform the following
23. e Replace inner fork carrier Teflon bearings using a Blind Hole Bearing Puller e Forfork tip alignment refer to section 5 2 6 A Ge KID N Q 2 NV P KO amp o Wear Pad Shims SD1144 eps Keeper Pin Hound Bar SD0581 eps Slide Hammer Teflon Bearings Inner Fork Carrier ERVICE S 5 2 6 Fork Tip Alignment 1 2 Fully close forks Measure the vertical offset of the forks 5 in 125 mm from the tip of the forks Outer forks can have a maximum vertical offset of 25 in 7 mm above the inner fork The inner fork must be lower then the outer fork Fully open forks Measure the vertical offset of the forks Outer fork can have a maximum vertical offset of 25 in 7 mm above or O in mm below the inner fork To align forks open outer forks so that the inner fork carrier can be accessed Lift fork carrier enough to access wear pad Loosen wear pad and slide shim between wear pad and fork carrier IMPORTANT Do not exceed 12 in 3 mm of shims in stack Check vertical offset of outer fork carrier by repeating steps 1 through 4 When fork height offset is set within the values above bend shim tabs to keep in place amp j BOOS p Bo ee E o LHH EHH o
24. eed Flow greater than maximum can result in excessive heating reduced system performance and short hydraulic system life Carriage Mount Dimension A ITA ISO Minimum Maximum Clean carriage bars inspect for damaged notches Make sure carriage upper bar is level Class 1 14 94 in 380 0 mm 15 00 in 381 0 mm Class Ill 18 68 in 474 5 mm 18 74 in 476 0 mm Class 2344 in 595 5 mm 23 50 in 597 0 mm Auxiliary Valve Functions Check for compliance with ANSI ISO standards Sideshitt Tilt Forward Left Hoist Down Open Forks GA0082 eps Hoist Up Close Forks Tilt Back Sideshift 2 6088640 2 u NSTALLATION 22 Recommended Hydraulic Supply Options G Series Multiple Load Handlers will operate with any of the hydraulic supply arrangements listed below e All hoses and fittings for FORK POSITION and SIDESHIFT functions should be at least No 6 with a minimum internal diameter of 7 mm Refer to Cascade Hose amp Cable Heel Selection Guide Part No 21299 to select the correct hose reel for the mast and truck Non Sideshifting RH THINLINE 2 Port Hose Reels OR A B Bs LH THINLINE 2 Port Hose Reels OR C Mast single internal hose reeving 4 C mu Sideshifting j A and B IU HH RH and LH THINLINE 2 Port Hose Reels GAO0033 eps OR C Mast double internal hose reeving 6088640 R2
25. inder head end Replace if necessary pin size M5 x 12 Piston Rod Assembly 9 Piston NE ee ON N N Wy PN ES LN N77 57 77 YA EES Wear Ring Wear Ring Two Piece Seal 6088640 R2 QS oS ew st RES A N TY S CO Ae Z Chamfer angle 2 Ring Hetainer threads in shell SD0558 eps Piston Rod Assembly G 8 GR SD0559 eps Wiper Seal Rod Seal 500561 Cylinder Retainer 27 O Ring Backup Ring u S ERVICE 5 5 Valve 55 1 Valve Removal 28 1 Remove attachment as described in Section 5 1 WARNING Before removing any hoses relieve pressure in the hydraulic system Turn the truck off then actuate the truck control valve several times in both directions 2 Disconnect the hoses from the valve ports Plug the hoses and tag them for reassembly 3 Remove the capscrews fastening the valve to the frame For reassembly tighten the capscrews to a torque of 10 ft Ibs 13 Nm 4 For reassembly reverse the above procedures RH HOSE LAYOUT LH HOSE LAYOUT SD0848 eps 6088640 R2 u S ERVICE 55 2 Valve Service 1 Remove the cartridge from the valve 2 Remove the remaining fittings 3 Remove the O rings and back up rings from the cartridge 4 Clean all parts with cleaning solvent 5 For reassembly reverse the above procedures except for the following special
26. ional bearing to inner fork carrier hook flange o GO SD0597 eps 6088640 R2 17 S ERVICE 5 2 4 Outer Arm Bearing Service NOTE Outer fork arms must be removed to install new bearings Bearings can be serviced with the attachment on the truck 1 Remove the bearing retainer plugs using Cascade Tool 6042633 see illustration For reassembly reverse the above procedures with the following exceptions Install new retainer plugs by using the tool s capscrew to drive the plug in Bearing retainer plugs are an interference tight fit in the frames Use a small amount of grease to ease installation NOTE An M8 x1 25 x 80L capscrew and 40 mm OD fender washer can also be used to remove the retainer plug 2 Replace the old bearing by tapping a new one into the frame pushing out the old bearing The following bearing service kits are available IMPORTANT Remove the left arm bearings out the left side Remove the right arm bearings out the right side 18 New Left Arm Bearing N Arm Frame Width Bearing Service Kit 47 25 in 1200 mm 6073031 45 27 in 1150 mm 6073032 Frame E 1 Bearings 3 Remove Remove Retainer Plug 4 e Left Arm Bearing 0 SD0583 eps New Right Arm Bearing 2 Install Right Arm Bearing Bearing Retainer 3 0 Turn nut CW to extract plug Tool 604
27. k amp carriage wear gauge 209560 Class 1 209561 Class 1 and 6104118 Class IV SD1141 eps Lower Bearings Fork Capscrews SD1142 eps Inner Fork Wear Pads Lower Arm Bar front surface Do not grease 6088640 R2 ROUBLESHOOTING 41 General Procedures 4131 Truck System Requirements Truck hydraulic pressure should be within the pressure range as shown in Section 6 1 PRESSURE MUST NOT EXCEED 2900 psi 200 bar Truck hydraulic flow should be within the volume range as shown in Section 6 1 1 Truck hydraulic fluid supplied to the attachment must meet the specifications as shown in Section 6 1 1 41 2 Tools Required In addition to a normal selection of hand tools the following are required Inline flow meter 10 GPM 38 L Min OR 20 GPM 75 L min Pressure Gauge Kit 3000 psi 207 bar Cascade Part No 671476 Cascade Part No 671477 Cascade Part No 671212 e Assorted fittings lines drain hoses and quick couplers as required 41 3 Troubleshooting Chart Determine All The Facts It is important to gather all the facts about the problem before beginning any service procedures The first step is to talk to the equipment operator Ask for a complete description of the malfunction Guidelines below can then be used as a starting point to begin troubleshooting Fork Position Circuit e Forks open and close unevenly e Forks will not
28. l the e nspect the outside of the shell for deformities that could circular retaining ring groove weaken the shells performance when under pressure 11 Pull the rod out to fully extended position Install the Replace if necessary spiral snap ring on the retainer 5 3 4 Cylinder Reassembly 1 Piston 1 Polish the piston and retainer chamfer angle with 400 grit emery cloth This allows the seals to slide over the chamfer easier 2 Wash all components with cleaning solvent Lubricate all new seals and rings with petroleum jelly 3 Note the direction of the U cup seals If the seals are installed backward they will not work properly For proper seal placement see the illustration below 4 Install new pressure seal wiper seal O ring and back up ring on the retainer as shown SS0063 eps 5 Clamp piston rod at the clevis end in a soft jawed vise CAUTION Do not clamp on the cylinder rod sealing surface Install new seals 6 Apply a thick film of petroleum jelly to the retainer ID 4 and install the retainer on the rod Use a seal loader as required to prevent damage to seals Back up Ring A IM 7 m Note seal direction direction ci Ww Y 7 4 SNA NN NS NS ON WS s S NS NN SN NS NNN TO LL gt MIMS LN a T T _ ye SOSA SA AS OSS NS NS SS SN NGS 550739 Piston
29. n 20 in 5 mm max Rotate hook up and release pin Jj ps SD0776 eps Tighten capscrews to a double torque of 165 ft Ibs 225 Nm SD0740 eps 6088640 R2 15 u S ERVICE s2 Forks and Arms 52 1 Fork Removal NOTE Remove forks one at a time 1 Position outer forks approximately at the width of the frame 2 Position attachment over a pallet Lower the attachment onto the pallet 3 Remove capscrews from fork For reassembly tighten the capscrews to a double torque of 200 ft Ibs 270 Nm NOTE For fork tip alignment refer to Section 5 2 6 pil PEE pH Po 5 2 2 Inner Fork Spring Cylinder Service IMPORTANT Attachment must remain on truck to service spring cylinders 1 Position forks about 5 in 12 mm above the floor 2 Open forks about 12 in 300 mm to access the inner fork carrier Remove the spring cylinder rod end nut from gt the carrier For reassembly tighten the nut to 39 ft Ibs 50 Nm 3 Fully open forks 4 Remove the cylinder head base nut from the frame For reassembly tighten the nut gt to 39 ft Ibs 50 Nm 5 Slide spring cylinders out Inner Fork Carrier 16 nd 6088640 R2 u S ERVICE 52 3 Outer Fork and Arm Removal 1 Remove the bolt on stops from the outer fork arms using a modified 6 mm allen wrench Cascade Part No
30. n that should be acted upon to prevent bodily injury A WARNING is always inside a ruled box CAUTION 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 6088640 R2 1 NSTALLATION 21 Tru C k Syste WARNING Rated capacity of the truck attachment combination is a responsibility f the original truck fact d Hequirements be less than that shown on the attachment nameplate Consult the truck nameplate GAO400 eps Truck Relief Setting 2600 psi 160 bar Recommended 2900 psi 200 bar Maximum Truck Flow Volume Min 9 Recommended 126 FQS 20G 32G FDS 256G 30G FTS 4 GPM 7 GPM 7 GPM 15 L min 26 L min 26 L min 25G FZS 25G 46G FOS 4GPM 10 GPM 10 GPM 36G 50G FDS 15L min 37 L min 37 L min 36G 45G FTS D Cascade G Series Multiple Load Handlers are compatible with SAE 10W petroleum base hydraulic fluid meeting Mil Spec MIL 0 5606 or MIL 0O 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 Flow less than recommended will result in reduced or unequal arm sp
31. procedures e Tighten fork capscrews to a double torque of 200 ft Ibs 270 Nm e Inspect the inner fork wear pads for wear Wear pads worn to flush with the plastic carrier should be replaced CAUTION Do not lubricate or paint the lower arm bar front surface that the inner fork wear pads contact Apply arm bar rust inhibitor part no 6145867 to the front surface e nspect upper and lower bearings for wear If any bearing is worn to less than 3 32 in 2 5 mm thickness replace the entire bearing set See Service Manual for replacement procedure 2000 Hour Maintenance After 2000 hours of truck operation in addition to the 100 500 and 1000 hour maintenance forks in use shall be inspected at intervals of not more than 12 months for single shift operations or whenever any defect or permanent deformation is detected Severe applications will require more frequent inspection Fork inspection shall be carried out by trained personnel to detect any damage that might impair safe use Any fork that is defective shall be removed from service Reference ANSI B56 1 2005 Inspect for the following defects e Surface cracks e Straightness of blade and shank e Fork angle e Difference in height of fork tips Positioning lock e Wear on fork blade and shank e Wear on fork hooks e Legibility of marking NOTE Fork Safety Kit 3014162 contains wear calipers inspection sheets and safety poster Also available is fork hoo
32. s 32 i 6088640 R2 __ NTRODUCTION 11 Introduction This manual provides the Installation Periodic Maintenance Troubleshooting Service and Specifications for Cascade G Series Multiple Load Handlers These attachments are designed for continuous duty operations with minimal maintenance They offer exception visibility for the lift truck driver and provide optimized load handling In any communication about the attachment refer to the product catalog and serial numbers stamped on the nameplate If the nameplate is missing the numbers can be found stamped on the top left side driver s view of the frame IMPORTANT All hoses tubes and fittings on these attachments are SAE NOTE Specifications are shown in both inch and Metric units All fasteners have a torque value range of 10 of stated value Nameplate 22 25 32 FDS B221 wa 23125 2 05 5 00001 ETE ie i C CascaQ Corporation www cascorp com e Icons amp Patents www cascorp com support 6095754 SD1126 eps 12 Special Definitions The statements shown appear throughout this Manual where special emphasis is required Read all WARNINGS and CAUTIONS before proceeding with any work Statements labeled IMPORTANT and NOTE are provided as additional information of special significance or to make your job easier WARNING A statement preceded by WARNING is informatio
33. ston nut and the piston from the cylinder rod 8 To remove seals clamp the piston or retainer in a soft jawed vice Pry the seals out with a brass seal removal tool Part No 674424 Cut the seals SS0336 eps CAUTION Do not scratch the seal grooves Piston Retainer j SS0061 eps Restrictor Washer Snap Ring Retaining Ring T JA 4 C ul Piston Rod shell QE A pides SANNA NN NY AN ENN NEN ss ost AL 24 Q SS0858 eps UNE MEN SENSN 3 UW gt gt SIN SENSN D 6088640 R2 23 Piston Nut KAS KS j Hetainer u S ERVICE 5 3 3 Cyl nder Inspection 7 Install a new pressure seal and back up ring on the piston aS shown e Inspect all components for nicks burrs Minor nicks 8 or burrs can be removed with 400 grit emery cloth Install the piston on the rod Tighten the nut to 63 ft Ibs 85 Nm NOTE Minor nicks are those that will not bypass oil a under pressure If nicks cannot be removed with emery 9 Apply a thick film of petroleum jelly to the cylinder cloth replace the part shell and piston OD install the rod assembly into the cylinder shell Use a piston seal loader as required to y v revent damage to the seals or burrs with a butterfly If they can not be remove P 9 replace the parts 10 Tap the retainer into the shell far enough to instal
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