E and F Series Single-Double Pallet Handlers
Contents
1. Early 55E FD Class Valve 5 6 2 Valve Service 3 Class Il Serial No s less than 55E FD 442 Class Ill Serial No s less than 55E FD 018 1 Remove the cartridges from the valve 2 Remove the remaining fittings 3 Remove the O rings and back up rings from the cartridges 4 Clean all parts with kerosene or cleaning solvent 5 For reassembly reverse the above procedures except for the following special instructions e The cartridge O rings and back up rings must be installed as shown for proper hydraulic operation Early 55E FD e Lubricate the cartridges and seals with petroleum Class III Valve jelly prior to reassembly Flow Divider Cartridge Crossover Relief Cartridge Check Valve Cartridge O Rings CL0340 eps CL0341 eps CL0342 eps Back up Rings Back up Rings Back up Rings 36 215793 R2 __ S ERVICE 5 6 3 Valve Service Class Il Serial No s greater than 55E FD 509 Class Ill Serial No s greater than 55E FD 104 and 70E Models 1 Remove the cartridges from the valve 2 Remove the remaining fittings 3 Remove the O rings and back up rings from the cartridges 4 Clean all parts with kerosene or cleaning solvent 5 For reassembly reverse the above procedures except for the following special instructions e The cartridge O R2. 18 EJ EN E 500669 T Inner Fork Control Bracket Capscrews 50 Upper Fork Stop Capscrews Use Loctite 242 Blue SD0664 eps 46 215793 R2 __ S PECIFICATIONS 6 1 6 48F 55F 60F Torque Values Ref Fastener Location Size Nm Ft Ibs 1 Bague 20 2 6 Cylinder Capscrews Anchor Bar 5 Center Spring Retainer Capscrews Inner Lower Bearing Retainer Capscrews Inner Fork Control Bracket Capscrews Fork Stop Capscrews M10 Quick Disconnect Guide Capscrews 1 Sideshift Plate Capscrews 11 712 Upper Mounting Hook 170 1 13 sip Beng Caps 1 M ate 4 8 venoosse a Anchor Bracket Capscrew 1 Inner Outer Fork Capscrews 2 Center Spring End Capscrews 3 Lower Hook Capscrews 12 Center Spring Bracket Capscrews 3 Lower Bearing Bracket Capscrews 3 SD0666 eps 8 5 65 17 0 5 0 0 Use Loctite 242 Blue A Use Loctite 277 Red SD0670 eps 215793 R2 Do you have questions you need answered right now Call your nearest Cascade Service Department Visit uS online at
3. 5 ERVICE MANUAL E amp F Series Single Double Pallet Handler Manual Number 215793 R2 Cascade Cascade is a Registered Trademark of Cascade Corporation u C ONTENTS INTRODUCTION Section 1 1 Introduction 1 opecial Definitions 1 INSTALLATION Section 2 2 Truck System Requirements 2 Hecommended Hydraulic Supply Options 3 Installation Procedures 4 PERIODIC MAINTENANCE Section 3 11 TROUBLESHOOTING Section 4 12 General Procedures 12 Plumbing 13 Hosing Diagram 13 Circuit Schematic 13 Fork Position Function 14 Sideshift Function 15 Electrical Circuit 16 SERVICE Section 5 17 Attachment Removal 17 Forks 18 Outer Fork Removal 18 Inner Fork Removal 19 Outer Fork Bearing Service 22 Inner Fork Bearing Service 22 Fork Tip Alignment 23 Inner Fork Shimming 24 sideshift Cylinder Center Mount 25 Cylinder Removal eo Cylinder Disassembly 26 Cylinder Inspection 26 Cylinder Reassembly 27 Sideshift Cylinder Top Mount 28 Cylinder Removal 28 Cylinder Disassembly 29 Cylinder Inspection 29 Cylinder Reassembly 30 Fork Position Cylinders 31 Cylinder Removal 31 Cylinder Disassembly 32 Cylinder Inspection 33 Cylinder Reassembly 34 Valve and Manifold 36 Valve Removal 36 Valve Service 36 Manifold Service 38 Valve Relief Adjustment 39 Base Unit 40 oideshift Bearing Service 40 Lower Mounted Gas Cylinder Service 41 Upper Mounter Gas Sylinder Service 42 Inner Fork Control IFC 42 opring Cylinder Servic
4. D Lift Attachment 2 in 5 cm off pallet 500071 ITA Class Il 0 60 0 66 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 ITA Class II 0 32 0 36 in 8 9 ITA Class III 0 39 0 43 in 10 11 mm ITA Class III 0 47 0 51 in 12 13 mm SD0493 eps Truck Carriage Bearings 9 GA0035 eps 9 SD0489 eps Install and engage lower hooks QUICK CHANGE TYPE BOLT ON TYPE if fitted Inspect hooks for excessive clearance Reverse guides to reduce Lower clearance see Step 2 Carriage Bar Lower Carriage Tap into position Bar Allow clearance for sideshifting 3 32 in 2 5 mm min 3 16 in 5 mm max L Slide hook up to engage bar install pin in upper hole locked 2 O 1 1 500065 500066 Tighten Capscrews to 120 ft lbs 165 Nm 215793 R2 NSTALLATION Prepare hoses oideshift Right Close Forks SOLENOID VALVE Determine hose lengths required for hydraulic supply configuration of truck B Cut hoses to length install end fittings or quick disconnect kits CAUTION Allow 4 in 10 cm extra hose length in each direction for sideshifting movement between Attachment valve and truck carriage Close Open 45 55E CLASS 60E 80E F SERIES VALVE 500173 less than 55E FD 500 use both types of va
5. 2 500122 5 Attach a suitable overhead hoist around the fork Pull the fork assembly out of the frame 6 Inspect the arm bearings for wear If the bearing are worn any area to less than 06 in 1 5 mm they should be replaced 7 For reassembly reverse the above procedures POY Rod end bolt May be installed from above E OE DE LY 500135 18 215793 R2 ERVICE 5 2 2 Inner Fork Removal Serial numbers less than 55E FD 500 1 2 N Extend the outer forks outside the width of the frame Position the forks 5 in 12 mm above the floor Remove the bolt on stops from the outer fork lower arms For reassembly tighten the capscrews to a torque of 30 ft Ibs 40 Nm Open the outer forks to full width Remove the capscrews fastening the cylinder rod anchor bars to the outer forks For reassembly apply Loctite 242 to the capscrew threads then tighten them to a torque of 30 ft Ibs 40 Nm WARNING The outer forks must be fully extended prior to disconnecting the gas cylinder rod end Disconnect the gas spring rod end from the outer fork anchor by removing the wire clip or rod end bolt Remove the gas spring by pulling with a quick jerk to disengage the base end from the anchor Move the inner fork to center then lift up to remove Inspect the arm bearings for wear If t
6. 30 Nm Remove retainer and pin Remove cylinder from brackets Pin F Series Spring Can Assembly 1 2 3 215793 R2 Open outer forks enough to not engage fork stops with inner forks Remove attachment as described Section 5 1 Remove anchor bracket from attachment by removing the clevis pin and cotter hair pin from the sideshifter Remove spring cylinder capcrews from the back of the attachment For reassembly tighten capscrews to a torque of 30 ft Ibs 40 Nm Remove capscrews from the spring cylinder retainers For reassembly apply Loctite 242 blue to capscrews and tighten to a torque of 15 ft lbs 20 Remove spring cylinder assembly from the attachment Pull the rod out from spring cylinder and place a pin or screwdriver into the second hole as shown Move the retainer towards the spring cylinder assembly and pull the rod pin out from the rod Remove the retainer from the rod SD0657 eps NN 4 c 00161 5 500658 43 __ 5 PECIFICATIONS Specifications 6 1 1 Hydraulics Truck Relief Setting 2300 psi 160 bar Recommended 2600 psi 180 bar Maximum Truck Flow Volume gt Min 2 Recommended Max 4 GPM 7 GPM 7 GPM F Series 15 L min 26 L min 26 L min 0 Single Double Pallet Handlers are compati
7. Clean and dry capscews and threaded holes Apply Loctite 242 blue to the capscrew threads and tighten to a torque of 48E 55E 60E 80E 30 ft lbs 40 Nm 48F 55F 60F 70E 48 ft bs 65 Nm Remove the hose from the valve OPEN port fitting Remove the hose and fitting from the valve TEST port Install the supply hose and TEST port plug 10 Cycle the attachment through 10 complete cycles to remove air from the hydraulic circuit Check for leaks and proper operation 10 215793 R2 500122 SD0159 eps 35 __ 5 ERVICE ss Valve and Manifold 5 6 1 Valve Removal WARNING Before removing any hoses pressure in the hydraulic system Turn the truck off then actuate the truck control valve several times in both directions 1 Disconnect the hoses from the valve ports Plug the hoses and tag them for reassembly 2 Attachments with Valve Guard Remove the capscrews fastening the valve guard to the frame For reassembly tighten the capscrews to a torque of E Series 30 1 105 40 Nm F Series 40 ft lbs 55 Nm 3 Remove the capscrews fastening the valve to the manifold For reassembly tighten the capscrews to a torque of 15 ft Ibs 20 Nm SD0649 eps 4 For reassembly reverse the above procedures except for the following special instructions e Apply asmall amount of thick grease to hold the O rings in position while installing the valve
8. Cylinder Service 1 Remove the bolt on stops from the outer fork lower arms For reassembly clean and dry capscews and threaded holes Apply Loctite 242 blue to the capscrew threads and tighten to a torque of 48E 55E 60E 80E 30 ft lbs 40 Nm 48F 55F 60F 70E 48 ft bs 65 Nm 2 Remove the gas spring rod end guard For reassembly tighten the capscrews to a torque of 22 1 105 30 Nm 500141 WARNING The outer forks must be fully extended prior to disconnecting the gas cylinder rod end Fully extend the outer forks Disconnect the gas spring rod end from the anchor by removing the wire clip or rod end bolt Remove the gas spring by pulling with a quick jerk to A disengage the base end from the anchor Wire Clip For reassembly reverse the above procedures Rod end bolt May be installed from above o gt CC 500142 215793 R2 41 S 5 7 3 5 7 4 42 ERVICE Upper Mounted Gas Cylinder Service 1 Fully close the inner forks WARNING The outer forks must be fully extended prior to disconnecting the gas cylinder rod end 2 Remove the capscrew fastening the gas cylinder anchor plate to the frame For reassembly tighten the capscrew to a torque of 22 ft lbs 30 3 Remove the gas spring by pulling with a quick jerk to disengage the base end from the anchor plate or unscrew the threaded ball joint end 4 For
9. double internal hose reeving group Solenoid Adaption 6 N 1 cable hose reel group A A and C Cable reel and single internal hose reeving group 215793 R2 NSTALLATION 2 Installation Procedures 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 Attach overhead hoist A WARNING Make sure overhead Remove banding hoist has rated capacity of at least B Set Attachment upright on pallet 2000 Ibs 900 kg C Remove bolt on lower hooks if equipped 99 oj Sg EA VID Lower hooks SD0068 eps SD0069 eps Unlock Quick Change lower mounting hooks Remove and drop hooks into unlocked position B Re install pin in lower hole NOTE Guides can be reversed to reduce hook to carriage clearance See Step 4 CL0097 eps 5 8 in offset on top provides maximum clearance Tighten Capscrews to 125 ft lbs 170 Nm 4 215793 R2 __ NSTALLATION Mount Attachment on truck carriage A Center truck behind 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
10. e ighten the inner and outer fork capscrews to 225 ft Ibs 300 Nm e ighten the frame capscrews to the following torque 48 55 65 E amp F 75 ft lbs 100 Nm 70E 80E Class Ill 130 ft lbs 175 Nm 80E Class IV 195 ft Ibs 265 Nm 215793 R2 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 Upper Fork Cylinder Rod Mounting Capscrews Ends and Hooks Upper Bearing Anchor Bars Grease Fittings 500078 Lower Bearings Frame Capscrews Lower Mounting Hooks Back view Outer Fork Bearings Inner Fork Bearings SD0638 eps Inner Fork Springs Gas Springs Front view Alternate locations 11 _ T BQUBLESHOOTING 41 General Procedures 41 1 Truck System Requirements e Truck hydraulic pressure should be within the pressure range as shown in Section 6 1 PRESSURE MUST NOT EXCEED 2600 psi 180 bar e Truck hydraulic flow should be within the volume range as shown in Section 6 1 1 e Truck hydraulic fluid supplied to the Attachment must meet the specifications as shown in Section 6 1 1 4 1 2 Tools Required Metric In addition to a normal selection of hand tools the following are required 20 GPM 80 L min inline flow meter Cascade Flow
11. ere counterclockwise CCW to decrease pressure Tighten 122 E the jam nut and the replace m poe See 0 ee LA _ p E n Ho E 500198 500490 Relief Valve Cartridge Increase Pressure CL0623 eps Decrease Pressure CCW Adjustment Screw 5 16 in 8 mm Allen Wrench Cap 215793 R2 39 __ 5 ERVICE 5 7 40 Base Unit 5 7 1 Sideshift Bearing Service 1 2 Remove the attachment from the truck as described In Section 5 1 Center Mount Sideshifters Loosen the support bracket capscrews Lift away the cylinder For reassembly tighten the capscrews to a torque of 48E 55E 22 ft lbs 30 Nm A 70E 80E 15 ft lbs 20 Nm A Apply Loctite 242 Blue to threads Inspect the upper bearing thickness either bearing is worn to less than 1 16 in 1 5 mm thick on the back surface replace both bearings Upper Inspect the lower bearing exposed thickness If the thickness 15 less than 1 16 in 1 5 mm replace both bearings For reassembly reverse the above procedures except for the following special instructions e Clean the upper and lower bearings and bearing contact surfaces e Locate the upper bearings in the anchor bracket cutouts Be careful not to install the bearings backwards Upper Bearing 215793 R2 __ S ERVICE 5 7 2 Lower Mounted Gas
12. for shorts e f there is current to the solenoid test for coil continuity D Test for coil continuity by placing an ohmmeter test lead on each solenoid coil terminal ohmmeter on Rx1 scale fthere is an ohmmeter reading the coil is good fthe coil is good but the solenoid does not click when the control button is depressed the solenoid cartridge may be jammed e fthere is no ohmmeter reading the coil is defective and should be replaced 7 5 Amp Knob Fuse Button White Black Fuse Diode Solenoid SD0094 eps Coil User supplied wire SD0095 eps Solenoid Coil 215793 R2 __ S ERVICE 5 Attachment Removal 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 valve and sideshift cylinder fittings Tag hoses for reassembly 3 Remove the lower mounting hooks Quick Disconnect Hooks Remove the pins to lower the hooks Bolt On Hooks Remove the capscrews fastening the hooks to the baseplate For reassembly install the lower hooks to the truck lower carriage bar leaving 09 in 2 5 mm clearance for sideshifting Tighten the hook capscrews to a torque of 125 ft lbs 170 4 Position the attachment over a pallet Lower the attach
13. of the forks 5 in 125 mm from the tip of the forks Outer forks can have a i maximum vertical offset of 2 in 5 mm from the inner nace 4 Measure the vertical offset of the forks Outer fork can have a maximum vertical offset of 08 in 2 mm above fork The inner fork must be lower then the outer fork or 12 in 3 mm below the inner fork 4 5 align arm bars remove forks from arm bars For reassembly tighten capscrews to 220 ft lbs 300 Nm IMPORTANT For 7OE 80E and F Series apply Loctite 242 blue to capscrew threads for reassembly 6 Place shims where needed To lower fork tips add shim s to the upper arm bar To raise fork tips add shim shims to lower arm bar IMPORTANT Do not exceed 3 mm of shimming Shim Part Numbers 48E 55E 60E 797610 797611 70E 80E 6108554 6108555 48F 55F 60F 797610 797611 500646 SD0647 eps Outer Fork a in 12 in Inner Fork 2 mm Inner Fork Outer Fork 8 mm max max 215793 R2 23 __ 5 ERVICE 5 2 8 Inner Fork Shimming 1 Rock the inner forks to check for looseness 2 Install shims as required to remove looseness Use shim kit 219316 for E Series attachments and shim Bearing 228395 for F Series attachments For E Series shim packs should not exceed 25 in 6 mm of shims Position the arm bars by
14. reassembly reverse the above procedures except as follows e Assure rod end of gas cylinder is secure in pocket of inner fork bracket or ball joint is properly connected e Alarge C Clamp may be helpful to compress the gas cylinder during reassembly e Use of a longer M8 x 25L capscrew will aid in pulling the bearing retainer plates flush with the frame during installation Inner Fork Control IFC E Series 1 Remove attachment as described in Section 5 1 2 Remove capscrews from bracket For reassembly tighten capscrews to a torque value of 30 ft Ibs 40 Nm 3 IFC Spring Cylinder arrangement Replace the assembly 4 IFC Gas Cylinder arrangement Remove capscrew from gas cylinder retainer Remove gas cylinder For reassembly tighten capscrews to a torque value of 6 ft Ibs 8 Nm F Series 1 Remove capscrews from spring can assembly For reassembly apply Loctite 242 blue to capscrews and tighten to a torque value of 30 ft lbs 40 2 Replace the assembly 500656 Longer Caspscrew Gas Spring Ball Joint Washer Bearing Retainer Plate Mounting Capscrews SD0428 eps SD0654 eps E Series IFC Gas Cylinder 215793 R2 __ S ERVICE 5 7 5 Spring Cylinder Service E Series Spring Cylinder 1 2 3 4 Fully close the inner forks Remove capscrews from retainers For reassembly tighten capscrews to a torque of 22 ft Ibs
15. 5 ERVICE 5 2 5 Outer Fork Bearing Service 5 2 6 22 1 2 3 4 Fully close the outer forks Remove the capscrews from the bearing retainers For reassembly clean and dry capscrews and threaded holes Apply Loctite 242 blue to capscrews and tighten to a torque of 48E 55E 60E 30 ft Ibs 40 Nm 70E 80E 48F 55F 60F 15 1 05 20 Nm Remove and replace one bearing at a time Grab the end of the bearing with vise grips to remove For reassembly reverse the above procedures Inner Fork Bearing Service 1 2 Position outer forks just outside the width of the frame Hemove the inner fork bearing retainers For reassembly clean and dry capscrews and threaded holes Apply Loctite 242 blue to capscrews and tighten to a torque of 48E 55E 60E 30 ft lbs 40 Nm 70E 80E Upper Retainers 30 ft bs 40 Nm 70E 80E Lower Retainers 15 1 05 20 Nm 48F 55F 60F 15 ft bs 20 Nm Hemove and replace one bearing at a time Grab the end of the bearing with vise grips to remove For reassembly reverse the above procedures except as follows e Refer to Section 5 2 8 for properly shimming inner lower hooks a NS WW S C NN ANSE SD0134 eps 500137 215793 R2 __ S ERVICE 5 2 7 Fork Tip Alignment 1 3 Fully open forks 1 Fully close forks 2 Measure the vertical offset
16. 51 25 71 Sunstream Industries Pte Ltd 18 Tuas South Street 5 singapore 637796 Tel 65 6795 7555 Fax 65 6863 1368 5 2007 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 215793 R2
17. 6 8 JIC Reducer Pressure Gauge Kit 671212 Pressure No 6 and No 8 Gauge No 6 6 Hose JIC Swivel Tee 4 OD Sp m cho GA0014 eps 7 No 4 6 Pipe JIC No 6 8 JIC No 4 No Reducer 6 and No 8 JIC O Ring Quick Coupler No 4 and No 6 Male Straight or JIC Thread Ux Oring C 98 No 6 Female Straight Thread O ring Coupler 215793 R2 _ TROUBLESHOOTING 4 2 Plumbing u 421 Hosing Diagram 2 Port Hose Reel OR Internal Reeving Cylinders a oideshift Cylinder SS Manifold IA SSR 2 Port Hose Reel OR Internal Reeving lt gt SSL Truck Auxiliary Valve Sideshift SD0158 eps SD0162 eps Truck Auxiliary Valve Spread Forks Close Forks SIDESHIFT RIGHT SIDESHIFT LEFT CLOSE FORKS OPEN FORKS Pressure Pressure Return Return Manifold Open 42 2 Circuit Schematic Close Cylinders A TIT Attachment Valve Check 9 Crossover cdm Relief Sideshift Cylinder Lo e Flow Divider OP CL Combiner 2 Port Hose Reels OR Internal Reeving Truck Auxiliary Valve Sideshift Close Forks Open Forks kai X AMET Truck Auxiliary Valve Truck Relief Truck Pum d E Truck Tank 21 5793 R2 SD0157 eps 13 T BQUBLESHOOTING 43 Fork Position Function There are
18. Meter Kit part no 671477 e 3500 psi 240 bar pressure gauge Cascade Pressure Gauge Kit 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 e Forks spread and close unevenly e Forks will not or close To correct these problems see Section 4 3 e Attachment will not sideshift Attachment sideshifts slowly To correct these problems see Section 4 4 12 WARNING Before servicing any hydraulic component relieve pressure 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 operates correctly before returning to the job stay clear of the load while testing Do not raise the load more than 4 in 10 cm off the floor while testing Flow Meter Kit 671477 2 No 8 12 JIC O Ring Flow Meter A at E GAO0013 eps 2 No
19. 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 information 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 15 information that is handy to know and may make your job easier 215793 R2 _ NSTALLATION 2 1 Truck System WARNING Rated capacity of the truck ttach t bination ibilit equirements A In n be less than that shown on the attachment nameplate Consult the truck nameplate The Single Double Pallet Handler will provide maximum operating efficiency and capability when the following requirements are met Truck Relief Setting 2300 psi 160 bar Recommended 2600 psi 180 bar Maximum Truck Flow Volume Min 2 Recommended Max E Series 4 GPM 7 GPM 7 GPM F Series 15 L min 26 L min 26 L min 0 Cascade E Series Single Double Pallet Handlers are compatible with SAE 10W petroleum base hydraulic fluid meeting Mil Spec MIL 0 5606 or 0 2104 Use of synthetic or aqueous b
20. anually extend the cylinder rod to remove oil from the shell and leave it extended Repeat the procedure for the top cylinder SD0160 eps 215793 R2 __ S ERVICE Place a towel or drip pan under the cylinder retainer 10 Scribe a mark on the cylinder retainer and shell for alignment during reassembly 11 Use a6 mm hex extension to remove the capscrews 6 fastening the cylinder retainer to the shell Be prepared to collect a small amount of oil from the cylinder cavity Q when the retainer is loosened from the shell Remove CLO312 eps the retainer 12 Remove the rod assembly and spacer if included from the cylinder Place a towel in the cylinder bore to absorb oll 13 Remove the end cap 14 Remove all seals from the piston spacer if included retainer and end cap by prying them out with a brass tool and cutting with diagonal cutters CAUTION Do not scratch the seal grooves CLO313 eps 5 5 3 Cylinder Inspection e Inspect the rod piston and retainer for nicks or burrs Minor nicks and burrs may be removed with 320 grit emery cloth If they cannot be removed replace the part e Inspect the cylinder shell bore and remove any minor e nicks or burrs with a butterfly hone If they cannot be CLO315 eps NY 0 removed replace the part e Inspect the outside of the shell for any deformities or cuts that could impair performance or cause leaks under pressure If necessary replace the pa
21. ase 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 9 Flow greater than maximum can result in excessive heating reduced system performance and reduced hydraulic system life GAO080 eps Carriage Mount Dimension A ITA ISO Minimum Maximum Class 14 96 in 380 0 mm 15 00 in 381 0 mm Carriage Class Ill 18 68 in 474 5 mm 18 74 in 476 0 mm Clean carriage bars and inspect for Class IV 23 44 in 595 5 mm 23 50 in 597 0 mm damaged notches GAO028 eps Tilt opread forward Forks Auxiliary Valve Functions Check for compliance with ANSI standards y Sideshift Hoist down L eft on 4844 GA0082 eps Hoist up Sideshift Right Tilt Retract back Forks 215793 R2 __ NSTALLATION 22 Recommended Hydraulic Supply Options The E and F Series Single Double Pallet Handler 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 9 32 in 7 mm Refer to Cascade Hose amp Cable Heel Selection Guide Part No 212199 to select the correct hose reel for the mast and truck Sideshifting A and B RH and LH THINLINE 2 port hose reel groups OR C Mast
22. ble with SAE 10W petroleum base hydraulic fluid meeting Mil Spec MIL 0 5606 or 0 2104 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 m iu i W Hu 9 Flow greater than maximum can result in excessive heating reduced system performance and reduced 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 e 1 2 Auxiliary Valve Functions ITA ANSI Standards Tilt opread Forward Forks Sideshift Hoist Down L eft eir GAO0082 eps Hoist Up Sideshift Hight Tilt Retract Back Forks 6 1 3 Truck Carriage Carriage Mount Dimension A 150 Minimum Maximum Class 14 96 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 IV 23 44 in 595 5 mm 23 50 in 597 0 mm gt GA0028 eps E o a di mi GAO090 eps nu tt Hi d 44 215793 R2 6 1 4 PECIFICATIONS 48E 55E 60E Torque Values Fastener torque values for the E Series Multi Load Handler are shown the table below both U S and Metric units Torque values are also found in each specific service procedure section throug
23. blems that could affect the in the hydraulic system Turn the truck sideshifting function off and open the truck auxiliary control nadequate sideshifter upper bearing lubrication or valves several times in both directions worn bearings see Section 5 7 1 e ncorrect hydraulic pressure or flow from lift truck e External leaks e Lower mounting hooks installed incorrectly see Section 5 1 Step 6 e Worn or defective cylinder seals 441 Sideshift Circuit Test Mele 1 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 2600 psi 180 bar See Section 6 1 for recommended operating pressure 2 Check the flow volume at the carriage hose terminal oee Section 6 1 for recommended flow volume SD0148 eps 3 Sideshift left or right fully holding the lever in the lt SIDESHIFT position for a few seconds Release the lever and check for external leaks at fittings hoses valve and manifold Center Mount 4 Press the solenoid button if equipped and listen for a Sideshift Cylinder click at the solenoid valve If no sound is heard check the fuse wiring and coil See Section 4 5 IMPORTANT Solenoid operated valves must be plumbed so that the solenoid is energized during the fork positioning not sideshifting function 5 Turn the truck off and relieve system pressure Disconne
24. ct 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 6 Start the truck Actuate the SIDESHIFT LEFT lever for 5 seconds e lf there is substantial hydraulic flow out of the drain hose the sideshift cylinder is faulty and requires service see Section 5 3 e f there is no hydraulic flow out of the hose the problem is not hydraulic see Section 4 1 3 w Upper Mount Drain Hose Sideshift Cylinder Back Driver s View 215793 R2 15 T BQUBLESHOOTING 4 5 16 Electrical Circuit Solenoid equipped attachments Use the schematic shown and follow the steps below 1 Check the control knob circuit fuse Replace if necessary 2 Check for loose electrical connections at the truck ignition switch control knob button solenoid coil terminals and diode 3 Remove the diode from the solenoid coil terminal 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 NOTE When replacing the diode the banded end must be connected to the coil and wiring as shown 4 Disconnect the electrical leads from the solenoid coil terminals Use a voltmeter to take a current reading at the electrical lead terminals when the button is depressed e f there is no current to the solenoid troubleshoot the electrical circuit
25. e 43 SPECIFICATIONS Section 6 44 Hydraulics O MA Auxiliary Valve Functions 44 Truck Carriage 44 48E 55E 60E Torque Values 45 OE 80E Torque Values 46 58F 55F 60F Torque Values 47 215793 R2 __ NTRODUCTION Introduction This Manual provides the Installation Periodic Maintenance Troubleshooting Service and Specifications for Cascade E and F Series Single Double Pallet Handlers These attachments are designed for three shift a day continuous duty operations with minimal maintenance They offer exceptional visibility for the lift truck driver and provide optimized load handling In any communication about the attachment refer to the product I D number stamped on the nameplate as shown If the nameplate is missing the numbers can be found stamped on the right front web of the baseplate IMPORTANT All hoses tubes and fittings on these attachments are JIC NOTE Specifications are shown in both inch and Metric units CAPACITY OF TRUCK AND ATTACHMENT COMBINATION MAY BE LESS cascade THAN ATTACHMENT CAPACITY SHOWN ABOVE oo 8 CONSULT TRUCK NAMEPLATE MAXIMUM STRUCTURAL CAPACITY OF ATTACHMENT ONLY IS 25 E AT CENTER EQUIPMENT 5 SYSTEM PRESSURE ADDITIONAL PSI SD0634 eps P lt S 25 O D gt 12 Special Definitions The statements shown appear throughout this Manual where special emphasis 15 required Read all
26. e fittings into the cylinder port to maximum depth This allows the restrictor washer to operate correctly 2 3 T lt Optional Spacers SS0122 eps SS0039 eps 222 22 SSS LLL ZZ Z Z 2 ZZ AV AP A87 LAL LULL RLL LLL Z 22 2 JA Restrictor Washer or C fa _ de I2 2522 SS0120 eps 215793 R2 ERVICE 5 3 4 Cylinder Reassembly 1 Polish the piston and retainer chamfer angle with 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 or STP 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 the new seals on the piston and retainer Hook one side of the seal in the groove and push it over the piston or retainer 5 Apply a thick film of petroleum jelly or STP to the inside of the cylinder shell piston seals and retainers 6 Insert the rod assembly into the cylinder shell If resistance is encountered tap the rod end with a rubber mallet 7 the retainers into the shell far enough to install the 550046 retaining rings their grooves 8 Pull the rod out to one side to the fully extended position This will position the retainer so the spiral snap ring can be install
27. ed Repeat for the retainer on the other end 3 1 lt E OL er KITU NDA TITI gt fs Va A SS ee mmm AS NN j IN E I Optional SS0740 eps Retainer Restrictor Washer 215793 R2 27 __ 5 ERVICE s4 Sideshift Cylinder Top Mount 5 444 Cylinder Removal 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 1 Disconnect the hoses from the cylinder ports Tag the hoses for reassembly 2 Remove the clevis pins from the cylinder ends Remove the cylinder 3 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 500143 28 215793 R2 __ S ERVICE 5 4 2 Cylinder Disassembly 1 Clamp the cylinder in a soft jawed vise Clamp lightly at the extreme base end only 2 Position the cylinder rod in the fully extended position Remove the spiral snap ring from the retainer See the illustration below 3 Tap the retainer into the shell approximately 2 in 50 mm Remove the retaining ring by placing a screwdriver on one side of the ring near the split and 3 SS0059 eps tapping with ahammer The retaining ring w
28. ers 5 5 1 Cylinder Removal The cylinder internal components can be serviced with the cylinder in place on the attachment The following procedures need to be followed only if the cylinder assembly is being replaced 1 Extend the outer forks outside the width of the frame 2 Remove the outer fork that rides on the cylinder to be removed Refer to Section 5 2 1 3 Remove the attachment from the truck as described in Section 5 1 4 Remove the sideshifting anchor bracket Center Mount Loosen the support bracket capscrews For reassembly tighten the capscrews to a torque of 48E 55E 22 ft lbs 30 Nm A 70E 80E 15 ft lbs 20 Nm A Apply Loctite 242 Blue to threads Top Mount Remove the sideshift cylinder base end pivot pin from the anchor bracket 5 Remove the upper mounting hooks For reassembly tighten the capscrews to a torque of 125 ft lbs 170 Nm 6 Remove the capscrews fastening the valve and manifold to the cylinder being removed For reassembly tighten the capscrews to a torque of 15 ft Ibs 20 Nm 7 Remove the capscrews fastening the cylinder to the frame For reassembly tighten the capscrews to a torque of 75 ft Ibs 100 Nm 48 55 60 E amp F 75 ft Ibs 100 Nm 70E 80E 130 ft lbs 175 Nm 8 Lift the cylinder away from the frame Collect the O rings between the cylinder and manifold 9 For reassembly reverse the above procedures except for the following s
29. hand If the arm bars will not move with minimum force check the following e Check the adjusting screws if equipped If the adjusting screws are loose and the arm bars are tight the lower hooks may need to be inspected e Check the inner fork timing If the arm bars move without the forks stops engaged the bearing may need to be loosened Locking Screw e Arm bars that can not be positioned with minimal Capscrew force should be inspected for further interferences 4 equipped install locking screws into adjusting screws Tighten locking screw approximately one quarter turn Sb0648 eps Adjusting Screw after locking screw engages the adjusting screw 24 215793 R2 __ S ERVICE s sideshift Cylinder Center Mount 5 3 1 Cylinder Removal 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 1 Remove the attachment from the truck as described in Section 5 1 2 Loosen the support bracket capscrews Lift away the cylinder For reassembly tighten the capscews to a torque of 48E 55E 22 it los 30 70E 80E 15 ft lbs 20 Nm A Apply Loctite 242 Blue to threads 3 For reassembly reverse the above procedures except for the following special instructions e Clean the upper and lower bearings and bearing contact surfaces e Locate the
30. he bearing are worn in any area to less than 06 in 1 5 mm they should be replaced For reassembly reverse the above procedures except as follows e Refer to Section 5 2 8 for properly shimming inner lower hooks 500138 215793 R2 1 SD0121 eps Rod end bolt May be installed from above 19 __ 5 ERVICE 5 2 3 Inner Fork Removal 20 Serial Numbers greater than 55E FD 499 and 70E 80E 1 2 Extend the outer forks outside the width of the frame Position the forks 5 in 12 mm above the floor Remove the bolt on stops from the outer fork arms For reassembly clean and dry capscrews and threaded holes Apply Loctite 242 blue to the capscrews threads and tighten to a torque of 55E 80E 30 ft lbs 40 Nm TOE 48 ft bs 65 Nm Open the outer forks to full width Remove the capscrews fastening the cylinder rod anchor bars to the outer forks Tighten capscrews to a torque of 55E 30 ft Ibs 40 Nm TOE 80E 50 ft lbs 70 Nm Move the inner fork to center then lift up to remove The upper gas cylinders will disengage with inner fork bracket Inspect the arm bearings for wear If the bearing are worn in any area to less than 06 in 1 5 mm they should be replaced For reassembly reverse the above procedures except as follows e Place the rod end of the upper gas oylinders in the pockets of the inner fork bracke
31. hout the Manual Ref Fastener Location ioe ACET ACC 4 anor arcas _____ m 6 8 cone song Rater Canes Wb 20 55 6 over as Spin yine mio m 5 8 ok Domen Guide mi6 10 125m L8 ner For conta apse m 9 10 CeriorSideshiter ve 20 Sm Ci esses eng casos 12 mi6 10 18 13 5 x 15 wo a 16 merou Fokoa ute 39 20m 18 cnr song 19 rner towa Bear Reaer Cuero wo 20 15 Use Loctite 242 Blue SD0662 eps 215793 R2 ex SD0660 eps SD0661 eps __ 5 PECIFICATIONS 6 1 5 70 80 Torque Values Ret Fastener Location Size 1 opberg Reamer 40 am 2 we 25 10 3 mr Ena Cap Capsaens ve 5 Bening einer 7 5 Gas Cynder teas En case __ Timor Lower barro einer im Cg ouis Disconnect we 70 10 m 5 Ci essere Bearing casos oe 70 12 mounting Hook Canserons 70 71257 14 _____ 0 15 osuva casos ____ we 20 15 16 Gas Cynder 3
32. iced or every 100 hours of truck operation whichever comes first complete the following maintenance on the attachment e Check for loose or missing bolts worn or damaged supply hoses and hydraulic leaks e Inspect the cylinder rod ends and anchor bars for damage Anchors operate with a loose clearance and require no lubrication e 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 e Rock the inner forks to check for looseness Install shims as required See Section 5 2 8 e Apply chassis grease to the upper bearing grease fittings and lower bearings e Check the clearance between the lower mounting hooks and the truck carriage bar Quick Change Hooks 3 16 in 4 8 mm max Bolt on Hooks 3 32 in 2 4 mm min and 3 16 in 4 8 mm max for sideshifting If adjustment is necessary refer to Installation Step 4 Tighten the lower hook capscrews to 125 ft Ibs 170 Nm e Inspect the gas springs and inner fork springs for damage or loose fasteners Replace or tighten fasteners as necessary 1000 Hour Maintenance After each 1000 hours of truck operation in addition to the 100 and 500 hour maintenance perform the following procedures
33. ill compress and turn sideways for removal Remove the retainer CAUTION Do not scratch the cylinder bore 4 Remove the rod assembly from the cylinder See the b ae illustration below Retainer 5 Clamp the rod assembly in a soft jawed vise to remove the seals Never clamp directly on the rod sealing surface Remove the nut fastening the piston to the rod Pry the seals up with a blunt screwdriver or dental tool Cut the seals to remove CAUTION Do not scratch the seal grooves 550060 5 4 3 Cylinder Inspection e Inspect all components for nicks burrs Minor nicks or burrs can be removed with 400 grit emery cloth NOTE Minor nicks are those that will not bypass oil 0061 eps under pressure If nicks cannot be removed with emery cloth replace the part Inspect the outside of the shell for deformities that could weaken the shell s performance when under pressure Heplace if necessary 2 Hestrictor Washer 4 e L I gt 77 2 7222 JA L T N LS 2 Z SSS A _ 550738 215793 R2 29 __ 5 ERVICE 544 Cylinder Reassembly 1 Polish the piston and retainer chamfer angle with emery cloth This allows the seals to slide over the chamfer easier 2 Wash all components with cleaning so
34. ings 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 500211 Flow Divider Cartridge Crossover Relief Cartridge Back up Rings O Rings Back up GA0097 eps SD0652 eps CL0681 eps 215793 R2 37 __ 5 ERVICE 5 6 4 Valve Service 45E 55E 65E FDS Models 80E and F Series Models 1 Remove the cartridges from the valve 2 Remove the remaining fittings 3 Remove the O rings and back up rings from the cartridges 4 Clean all parts with kerosene or cleaning solvent 5 For reassembly reverse the above procedures except for the following special 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 Crossover Relief Cartridge Back up Rings Back up Rings SD0652 eps 500651 5 6 5 Manifold Service 1 Remove the attachment from the truck as described in Section 5 1 2 Remove the valve from the manifold as described in Section 5 6 1 3 Remove the capscrews fastening the manifold to the cylinders Collect the O rings For reassembly tighten the capscrews to a t
35. lly If the arms move at different speeds the flow divider combiner cartridge may be faulty Replace the cartridge Turn the truck off and connect a 3500 psi 240 bar pressure gauge to the TEST port on the main valve otart the truck and close the forks fully Hold the lever in the CLOSE position for a few seconds Release the lever and watch the pressure gauge e fthe pressure drop is less than 150 psi 10 bar initially and additional drop does not exceed 25 psi 2 bar per minute the problem is not hydraulic see section 4 1 3 fthe pressure drop is more than above the check valve cartridge may be faulty Replace the cartridge Close the forks fully and hold the lever in the CLOSE position for a few seconds If the pressure still drops as before the cylinders are at fault and must be serviced 55E CLASS 70E VALVE Cartridge WARNING Before removing hydraulic lines or components relieve pressure in the hydraulic system With the truck off open the truck auxiliary control valves several times in both directions 2 Flow Meter A 500150 Gauge on TEST Port Check Valve Cartridge 9 NE 500165 Flow Divider 45E 55E CLASS Ill 60E 80E F SERIES VALVE 215793 R2 T BQUBLESHOOTING 44 S des h Fu WARNING Before removing hydraulic lines or components relieve pressure There are five potential pro
36. lvent 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 the new seals on the piston and retainer Hook S side of the seal in the groove and push it over the piston or retainer 5 Install the retainer and piston on the rod and tighten the piston retaining nut to 75 ft Ibs 102 Nm 6 Apply a thick film of petroleum jelly to the inside of the SS0063 eps cylinder shell piston seals and retainer 7 Insert the rod assembly into the cylinder shell If resistance is encountered tap the rod end with a Install new seals rubber mallet 8 Tap the retainer into the shell far enough to install the retaining ring in the groove 9 Pull the rod out to the fully extended position This will position the retainer so the spiral snap ring can be installed Back up Ring Back up Ring a JI Ya 7a 3 Le Note seal A 2 direction 550742 special O Ring oval Do not use a standard O Ring L say JAV gt lt 1 SS a Gs 0 Teoh e 4 NETS N Z 1 T NN oS 2 gt NS OX f SS0741 eps SADa Piston Rod Retainer 6 8 30 215793 R2 __ S ERVICE 55 Fork Position Cylind
37. lves 500075 NOTE Attachment serial numbers Se Sideshift Left Open Forks p 55E CLASS II 70E VALVE Open Close SD0074 eps MAST DOUBLE INTERNAL REEVING RH amp LH 2 PORT THINLINE HOSE REELS 55E CLASS Il 1o Open Forks a Forks Ta 7 5 ol o Close Me SD0073 eps 55E CLASS III Class Back Sideshift Right 48F 55F 65F Close Forks 500072 Sideshift Left ff 20 ILLE E 5 b Sideshift Right Sideshift Left oO oO SD0089 eps Class Back 500088 215793 R2 NSTALLATION CAUTION Allow 4 in 10 cm extra hose length in each direction for sideshifting movement between solenoid valve and truck carriage 6 N 1 CABLE HOSE REEL E SERIES Sideshift Right Close Forks Sideshift Left Open Forks F SERIES Sideshift Left Open Forks Sideshift Right Close Forks Solenoid SD0492 eps 215793 R2 SINGLE INTERNAL HOSE REEVING with CABLE REEL 9400 6 o Oloof 9 500171 LI o of olo of SD0491 eps 1 NSTALLATION Install solenoid control knob Solenoid equipped units A PRESS BUTTO TO POS FOR N ITION SIDESHIFT ORKS Button SE toward up driver G D Adapter Truck con
38. ment onto the pallet Tilt the truck carriage forward and back 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 Locate the upper bearings in the anchor bracket cutouts Be careful not to install the bearings backwards 3 500129 500130 Upper Bearing SENA 4 09 in 2 2 mm C clearance Q Lower Hook SD0131 eps SD0132 eps 215793 R2 17 __ 5 ERVICE 52 Forks 52 1 Outer Fork Removal 1 Extend the outer forks outside the width of the frame Position the forks 5 in 12 mm above the floor 2 Remove the bolt on stops from the outer fork arms For reassembly clean and dry capscews and threaded holes Apply Loctite 242 blue to the capscrew threads and tighten to a torque of 48E 55E 60E 80E 30 ft lbs 40 Nm 48F 55F 60F 70E 48 ft bs 65 Nm 3 Open the outer forks to full width Remove the capscrews fastening the cylinder rod anchor bars to the outer forks For reassembly tighten capscrews of 48 55 60 E amp F 30 ft lbs 40 Nm 70E 80E 50 ft lbs 70 Nm WARNING The outer forks must be fully extended prior to disconnecting the gas cylinder rod end 4 Units with Serial No s less than 55E FD 500 Disconnect the gas spring rod end from the anchor by removing the wire clip or rod end bolt S
39. orque of 15 ft Ibs 20 Nm 4 Clean all parts with cleaning solvent 5 Check for imperfections and scratches where O rings SIL 6 For reassembly reverse the above procedures except for the following special instructions e Apply asmall amount of petroleum jelly to hold the O rings position while installing the manifold 38 500650 Check Valve Cartridge SD0217 eps SD0653 eps Back up 215793 R2 __ S ERVICE 5 6 6 Valve Relief Adjustment WARNING Before installing Class Serial numbers greater than 55E FD 509 AA A E 2 9 Class Ill Serial numbers greater than 55E FD 104 11 system All FDS Models and open the truck auxiliary control valves several times both directions 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 1 Confirm that the truck pressure is between 2300 2600 psi 160 180 bar 2 Install a 3000 psi 200 bar pressure gauge to the valve 2 Valve TEST port No 4 O ring fitting required O 3 Cycle the forks to full open then slowly close the forks fully Hold the lever in the CLOSE position and accelerate engine to develop full system pressure 4 Adjust the relief cartridge for an indicated 2300 psi dex 2271 160 bar Turn clockwise CW to increase pressure _
40. pecial instructions e Apply a small amount of petroleum jelly to hold the O rings in position while installing the cylinder e Apply an anti seize compound such as Chesterton 25 Anti Seize Compound to the cylinder and baseplate mating surfaces SD0156 eps 215793 R2 31 __ 5 ERVICE 5 5 2 Cylinder Disassembly 32 These cylinders can be serviced in place on the attachment The following procedures can be performed with the forks in place and the attachment mounted on the truck It is recommended that both cylinders be serviced at the same time 1 Fully close the forks 2 Remove the capscrews fastening the cylinder rod anchor bars to the arm 3 Power the cylinders out 3 in 75 mm to expose the cylinder rod end 4 Slide the rod ends inward to to remove the split rings Remove rod ends from the cylinder rods 500161 5 Completely retract the cylinders Split Rings WARNING Before disconnecting hoses Rod End relieve pressure the hydraulic system Turn the truck off and open the truck auxiliary control valves several times in both CY directions Jp Vo y 6 Disconnect the supply hose from the valve OPEN port and plug the hose end Install No 6 drain hose to the fitting and place the hose end in a bucket 7 Install a No 4 fitting and drain hose to the valve TEST port Place the hose end in the bucket 8 Starting with the bottom cylinder in the retracted position m
41. r components relieve pressure in should be adjusted to match the truck the hydraulic system Turn the truck off hydraulic flow rate MAXIMUM RELIEF VALVE and open the truck auxiliary control valves SETTING 2600 psi 180 bar several times in both directions Fork positioning relief adjustment A Confirm that the truck pressure is between B Valve 2300 2600 psi 160 180 bar B Install a 3000 psi 200 bar pressure gauge on the TEST port of the main hydraulic valve No 4 O ring fitting required C Cycle forks to full open then slowly close 2 f forks fully Hold lever in the CLOSE position and accelerate engine to develop lull Co system pressure D Adjust the relief cartridge for an indicated 2300 psi 160 bar Turn clockwise CW to increase pressure counterclockwise a CCW to decrease pressure Tighten jam nut and replace cap E 1 E 1 SD0501 eps 5 m CLASS III VALVE SD0490 eps D Relief Valve Back Driver s View Cartridge Increase Jam Nut Pressure CCW Adjustment Screw 5 16 in 8 mm Allen Wrench cap 10 215793 R2 3 1 3 2 3 3 IMPORTANT Attachement is prelubed at the factory Lubrication is not required for installation If required silicone spray or light grease is recommended 100 Hour Maintenance Every time the lift truck is serv
42. rt 1 2 Spacer Shell Shell Bore Rod if Included Piston End Cap Een N Equum 5 SNe if Wa an 22 ANN SS 2 Aust SD0641 eps 215793 R2 33 ERVICE 5 5 4 Cylinder Reassembly 1 Lubricate all new seals and O rings with petroleum jelly 2 Note the direction of the U cup seals Pressure seals must always be installed with the lip toward the high pressure side to the cylinder Pressure Seal Pressure Seal Bearing NAS eee m 777777 ARH SQW RS wD QS Wiper SD0642 eps 3 Install new seals on the piston spacer if included retainer and end cap Install the piston seal on the rod side of the piston Hook one side of the seal in the 7 groove and carefully work It over the piston 7 V S CX 2 7 CLO318 eps 4 Apply a thick film of petroleum jelly to the inside of the cylinder shell and piston seals 5 Using a rubber mallet tap the rod assembly into the cylinder shell 6 Apply thick film of petroleum jelly to the retainer N V 7 Slide the retainer onto the rod and align with the scribe mark and shell holes Install the end cap Install and tighten the retainer and end cap capscrews to a torque of 18 ft Ibs 25 Nm gt 4 5 CLO319 eps 6 34 215793 R2 __ S ERVICE 8 Reassemble the rod end split rings and anchor bar to the fork
43. six potential problems that could affect the fork positioning function e Bent arm bars e Incorrect hydraulic pressure or flow from lift truck e Defective gas cylinders e External leaks e Defective solenoid coil or valve if equipped Worn defective cartridge valves or cylinder seals 4 3 1 Fork Position Circuit Test 1 10 14 Check the truck pressure at the carriage hose terminal Pressure must be within 100 psi 7 bar of the specifications in the truck service manual TRUCK PRESSURE MUST NOT EXCEED 2600 psi 180 bar see Section 6 1 for recommended operating pressure Check the flow volume at the carriage hose terminal see Section 6 1 for recommended flow volume Spread the forks and check that the inner forks remain in contact with the outer forks until reaching their stops If they do not the gas cylinders or spring cylinders are faulty Replace the gas cylinders see Section 5 7 2 or 3 or spring cylinders see Section 5 7 5 spread the forks fully and hold the lever in the OPEN position for 2 seconds Release the lever and check for external leaks at fittings hoses valve and manifold Press the solenoid button if equipped and listen for a click at the solenoid valve If no sound 15 heard check the fuse wiring and coil See Section 4 5 IMPORTANT Solenoid operated valves must be plumbed so that the solenoid is energized during the fork positioning function Open and close the forks fu
44. trol valve handle SD0093 eps Install wiring Solenoid equipped units 7 5 Knob Fuse Button White Black 7 5 Ly Fuse 18 gauge wire 1 4 in terminals User supplied wire SD0094 eps SD0095 eps X oolenoid Coil Flush hydraulic supply hoses Connect hoses as shown in Step 5 to attachment fittings Install hoses as shown B Operate auxiliary valves for 30 sec C Remove hoses GAO0092 eps SD0076 eps 215793 R2 __ NSTALLATION 1 0 Check Attachment functions WARNING Make sure all personnel are clear of the attachment during functions several times testing Check for operation in accordance with ITA ISO standards Lift maximum load and sideshift left and right Check for smoothness and adequate speed Check for leaks at fittings valve manifold and cylinders SIDESHIFTING sideshift Left SIDESHIFTING WITH SOLENOID VALVE oideshift Right opread Forks oideshift Left Retract Forks Spread Forks press knob button oideshift Right Retract Forks press knob button Auxiliary Valve Functions Tilt forward Hoist down GAO005 eps Hoist up Tilt back 215793 R2 9 NSTALLATION Adjust Relief Cartridge For over pressure protection the relief valve WARNING Before removing hydraulic cartridge for the FORK POSITION function lines o
45. ts Refer to Section 5 2 8 for properly shimming inner lower hooks SD0213 eps 500122 500215 500214 215793 R2 __ S ERVICE 5 2 4 Inner Fork Removal 48E 60E 55E FDS and all F Series 1 Extend the outer forks outside the width of the frame Position the forks 5 in 12 mm above the floor 2 Remove the bolt on stops from the outer fork arms For reassembly clean and dry capscrews and threaded holes Apply Loctite 242 blue to the capscrews threads and tighten to a torque of 48E 55E 60E 30 ft Ibs 40 Nm 48F 55F 60F 48 ft bs 65 Nm 3 Open the outer forks to full width Remove the capscrews fastening the cylinder rod anchor bars to the outer forks Tighten capscrews to a torque of 30 ft Ibs 40 Nm 4 Remove spring cylinder bracket from inner forks For reassembly apply Loctite 242 blue to capscrews and tighten to 30 ft Ibs 40 Nm SD0644 eps 5 Move the inner fork to center then lift up to remove 6 Inspect the arm bearings for wear If the bearing are worn in any area to less than 06 in 1 5 mm they should be replaced 7 For reassembly reverse the above procedures except QU as follows Refer to Section 5 2 8 for properly shimming Spee inner lower hooks and setting adjusting screw if equipped 6 7 SD0213 eps 215793 R2 21 __
46. upper bearings in the anchor bracket cutouts Be careful not to install the bearings backwards SD0152 eps SD0139 eps 215793 R2 ERVICE 5 3 2 Cylinder Disassembly 5 3 3 26 1 2 Clamp the cylinder in soft jawed vise Do not clamp on the cylinder shell Center the cylinder rod in the cylinder Remove the Spiral snap rings from the retainers See the illustration below Tap the retainers into the shell approximately 2 in 50 mm Remove the retaining rings by prying one end up and working the ring out of the groove service Tool Kit 674424 includes two double ended brass tools that make seal and retaining ring removal easy and won t damage the cylinder components with dents or scratches CAUTION Do not scratch the cylinder bore Remove the rod assembly from the cylinder See the illustration below Clamp the rod assembly in a soft jawed vise or between two blocks of wood to remove the seals Pry the seals up with a brass tool Cut the seals to remove CAUTION Do not scratch the seal grooves Cylinder Inspection Inspect all components for nicks or burrs Minor nicks or burrs can be removed with 400 grit emery cloth NOTE Minor nicks are those that will not bypass oil under pressure If nicks cannot be removed with emery cloth replace the part Inspect the outside of the shell for deformities that could weaken the shell s performance when under pressure Heplace if necessary Thread th
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