c ontents - Cascade Corporation
Contents
1. Fork Locking Cascade Backrest Tighten to 145 ft lbs 195 Nm For other backrests see OEM SS0389 eps recommendations SS0388 eps Check Sideshifter bearing lubrication Upper bearing grease fittings Bearings are prelubed at the factory with break in grease No additional lubrication is required during installation NOTE After 600 hours of operation sideshitter bearings should be lubricated with general purpose chassis grease SS0382 eps Lower bearing grease areas Front View 6014809 R7 7 ERIODIC MAINTENANCE P Dai ly WARNING After completing any service Check items shown each day Report problems to your procedure always test the Integral supervisor See Service Manual for troubleshooting Sideshifter through five complete cycles maintenance and repair procedures First test with no load then test with a load to make sure the sideshifter operates NOTE Carriage should be maintained per OEM service correctly before returning it to the job specifications IMPORTANT Visually check wear on lower hook and Capscrew conditions WARNING If the fork locking pin is not fully engaged the fork could become disengaged from the carriage Fork Grease Fittin Lockin e Check for loose or missing bolts worn or damaged Backrest Pin hoses hydraulic leaks and damaged or missing fork stops a e Check decals and nameplate for legibilit2. Inspect for the following defects e Surface cracks e Straightness of blade and shank e Fork angle e Difference in height of fork tips e 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 hook amp carriage wear gauge 209560 Class II and 8 209561 Class III 6014809 R7 ARTS Recommended Spare Parts Product Identification This section shows replacement parts for integral sideshifters The product model number WARNING For the safety of yourself and and serial number are stamped on the inside surface of the others DO NOT install the parts shown in RH vertical sideplate driver s view and must be provided this manual unless you have thoroughly when ordering replacement parts The cylinder assembly reviewed the appropriate service manual part number is stamped on the LH frontside driver s view Stamped model number serial Sticker showing patent numbers number and specifications and phone numbers for service Stamped cylinder assembly part A OAT td Stamped frame part number aN LH frontside SS0361 eps iar Back Driver s View 35C 55C 70C Integral Sideshifter DESCRIPTION BASE UNIT 667225 WashenHO MI6 0 4 8 po OYUNDER S O CYLINDER 6020048 Cylinder Assembly o
3. cance or to make the 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 is information that is handy to know and may make the job easier PERATION This section contains operating instructions for the Backrest Cascade Integral Sideshitters It will help you avoid common errors which often cause damage to the equipment or product being handled This information is intended to simplify operator understanding about effective and safe sideshifter use and operation Read this information thoroughly before operating the attachment Be sure you know and understand all operating procedures and safety precautions If you have any questions or don t Cylinder understand a procedure ask your supervisor Carriage Emphasize Safety Most accidents are caused by operator carelessness or misjudgment You must watch for poorly maintained equipment and Sideshifter hazardous situations and correct them Frame e SS0380 eps Forks 6014809 R7 1 PERATION Safet
4. e elimination of any parts Additional counter weighting of fork trucks shall not be done unless approved by the truck manufacturer Industrial trucks shall be examined before being placed in service and shall not be placed in service if the examination shows any condition adversely affecting the safety of the vehicle Such examinations shall be made at least daily When industrial trucks are used on a round the clock basis they shall be examined after each shift Defects when found shall be immediately reported and corrected 6014809 R7 _ NSTALLATION Truck Requirements Truck Relief Setting 2000 psi 140 bar Recommended 3500 psi 240 bar Maximum Truck Flow Volume o Min Recommended Max 1 GPM 2 GPM 3 GPM 4 L min 7 5 L min 12 L min 35C 55C 70C Cascade Integral Sideshifters are compatible with SAE 10W petroleum base hydraulic fluid meeting Mil Spec MIL O 5606 or MIL 0 2104B Use of synthetic or aqueous base hydraulic fluid is not recommended If fire resistant hydraulic fluid is required special seals must be used Contact Cascade Flow less than recommended will result in slow sideshift soeed Flow greater than maximum can result in excessive heating reduced system performance and short hydraulic system life GA0158 eps Auxiliary Valve Functions Check for compliance with ITA ISO standards Tilt Forward Hoist Down Sideshift Recommended Hydraulic Supply The Integral Sidesh
5. ifter requires the hydraulic supply arrangement shown below All hoses and fittings should GA0094 eps Hoist Up Sideshift be No 6 with 7 32 in 7 mm minimum ID Tilt Right Back A Mast single Internal Reeving Poth Silt sapi GA0157 eps 6014809 R7 _ NSTALLATION Installation Procedure IMPORTANT Integral attachment installation is an OEM or dealer responsibility Some of the following steps may or may not be required but are shown for reference Refer to the appropriate service manual for service and repair procedures Integral Sideshifter carriage should be installed in mast per OEM specifications and procedures a SS0387 eps Lower Hook Check lower hook clearance ae Tighten bolts to 120 ft lbs 165 Nm i H D Clearance 1 32 in 0 8 mm Min 1 16 in 1 6 mm Max Carriage Sideshifting P Frame FRONT Front View SS0365 eps Flush supply hoses Connect hoses Sideshift LEFT Sideshift RIGHT Union Fitting GA0171 eps i SS0362 eps Front View 6 6014809 R7 _ NSTALLATION Install forks Install backrest Use pallet or blocks as necessary to raise forks to installation height Keep feet clear of forks when installing WARNING If the fork locking pin is not fully engaged the fork could become disengaged from the carriage
6. l ANSI B56 1 except for vehicles intended primarily for earth moving or over the road hauling I Operator Training Only trained and authorized operators shall be permitted to operate a powered industrial truck Methods shall be devised to train operators in the safe operation of powered industrial trucks m Truck Operations 1 2 3 4 Si 5ii 5iii Trucks shall not be driven up to anyone standing in front of a bench or other fixed object No person shall be allowed to stand or pass under the elevated portion of any truck whether loaded or empty Unauthorized personnel shall not be permitted to ride on powered industrial trucks A safe place to ride shall be provided where riding of trucks is authorized The employer shall prohibit arms or legs from being placed between the uprights of the mast or outside the running lines of the truck When a powered industrial truck is left unattended load engaging means shall be fully lowered controls shall be neutralized power shall be shut off and brakes set Wheels shall be blocked if the truck is parked on an incline A powered industrial truck is unattended when the operator is 25 feet or more away from the vehicle which remains in his view or whenever the operator leaves the vehicle and it is not in his view When the operator of an industrial truck is dismounted and within 25 feet of the truck still in his view the load engaging means shall be ful
7. ly lowered controls neutralized and the brakes set to prevent movement A safe distance shall be maintained from the edge of ramps or platforms while on any elevated dock or platform or freight car Trucks shall not be used for opening or closing freight doors 10 AFE OPERATION AND MAINTENANCE OSHA Regulations Trucks and Attachments Specific Regulations from OSHA 1910 178 A load backrest extension shall be used whenever necessary to minimize the possibility of the load or part of it from falling rearward n Traveling 4 The driver shall be required to slow down and sound the horn at cross isles and other locations where vision is obstructed If the load being carried obstructs forward view the driver shall be required to travel with the load trailing 7i When ascending or descending grades in excess of 10 percent loaded trucks shall be driven with the load upgrade 7ili On all grades the load and load engaging means shall be tilted back if applicable and raised only as far as necessary to clear the road surface o Loading 1 Only stable or safely arranged loads shall be handled Caution shall be exercised when handling off center loads which cannot be centered Only loads within the rated capacity of the truck shall be handled The long or high including multiple tiered loads which may affect capacity shall be adjusted Trucks equipped with attachments shall be operated as partiall
8. mdong Ind Complex 691 8 Gojan Dong Namdong Ku Inchon Korea Tel 82 32 821 2051 Fax 82 32 821 2055 Cascade New Zealand 15 Ra Ora Drive East Tamaki Auckland New Zealand Tel 64 9 273 9136 Fax 64 9 273 9137 Cascade do Brasil Rua Joao Guerra 134 Macuco Santos SP Brasil 11015 130 Tel 55 13 2105 8800 Fax 55 13 2105 8899 Cascade Xiamen No 668 Yangguang Rd Xinyang Industrial Zone Haicang Xiamen City Fujian Province P R China 361026 Tel 86 592 651 2500 Fax 86 592 651 2571 Sunstream Industries Pte Ltd 18 Tuas South Street 5 singapore 637796 Tel 65 6795 7555 Fax 65 6863 1368 09 2012 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 6014809 R7
9. o 1 M See specific parts page for part number UBLICATIONS PART NO DESCRIPTION 6014809 6020275 cascade Service Literature Index and Order Form All dealerships with an open account please indicate quantity desired and purchase order number All others 679929 Tool Catalog 673964 Literature Order Form GAO098 eps 6014809 R7 Do you have questions you need answered right now Call your nearest Cascade Service Department Visit us online at www cascorp com AMERICAS Cascade Corporation U S Headquarters 2201 NE 201st Fairview OR 97024 9718 Tel 800 CASCADE 227 2233 Fax 888 329 8207 EUROPE AFRICA Cascade ltalia S R L European Headquarters Via Dell Artigianato 1 37030 Vago di Lavagno VR ltaly Tel 39 045 89891 11 Fax 39 045 8989160 ASIA PACIFIC Cascade Japan Ltd 2 23 2 Chome Kukuchi Nishimachi Amagasaki Hyogo Japan 661 0978 Tel 81 6 6420 977 1 Fax 81 6 6420 9777 Cascade Australia Pty Ltd 1445 Ipswich Road Rocklea QLD 4107 Australia Tel 1 800 227 223 Fax 61 7 3373 7333 cascade om Cm TM Cascade Corporation 2012 Cascade Canada Inc 5570 Timberlea Blvd Mississauga Ontario Canada L4W 4M6 Tel 905 629 7777 Fax 905 629 7785 Cascade Africa Pty Ltd PO Box 625 Isando 1600 60A Steel Road Sparton Kempton Park South Africa Tel 27 11 975 9240 Fax 27 11 394 1147 Cascade Korea 121B 9L Na
10. pJ SER MANUAL C Series Integral Sideshifter Manual Number 6014809 R7 Cascade Cascade is a Registered Trademark of Cascade Corporation A ONTENTS U pe Q D INTRODUCTION Special Definitions OPERATION Safety Rules Industrial Lift Trucks Handling Loads Integral Sideshifter Operation Safe Operation and Maintenance OSHA Regulations INSTALLATION Truck Requirements Recommended Hydraulic Supply Installation Procedure PERIODIC MAINTENANCE Daily 1000 Hour 2000 Hour PARTS Recommended Spare Parts PUBLICATIONS Ol O O CO DBD O S O HINH SWIHRIHRIW WsPMl hMy i 6014809 R7 NTRODUCTION This User Manual is for Cascade Integral Sideshitters Contents include an Operator s Guide Installation WARNING Rated capacity of the truck Instructions Periodic Maintenance and Parts eyed aa a feelin NOTE Specifications are shown in both US and Metric ee i Serger ea units nameplate Consult the truck nameplate IMPORTANT C series Sideshifter ports are SAE 9 16 in x 18 UNF for No 6 O ring fittings with 9 32 in 7 mm WARNING Do not operate this attachment minimum ID unless you are a trained and authorized lift truck driver 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 signifi
11. rd for Powered Industrial Trucks ANSI B56 1 When operating and maintaining industrial trucks equipped with attachments you should pay particular attention to the following sections of these regulations You should be familiar with all sections of these regulations Ask your employer for the complete regulations a General Requirement 4 6 Modifications and additions which affect capacity and safe operation shall not be performed by the customer or user without manufacturers prior written approval Capacity operation and maintenance instruction plates tags or decals shall be changed accordingly If the truck is equipped with front end attachments other than factory installed attachments the user shall request that the truck be marked to identify the attachments and show the appropriate weight of the truck and attachment combination at maximum elevation with load laterally centered The user shall see that all nameplates and markings are in place and maintained in a legible condition e Safety Guards 2 If the type of load presents a hazard the user shall equip fork trucks with a vertical load backrest extension in accordance with a 2 following a 2 All new powered industrial trucks acquired and used by an employer after February 15 1972 shall meet the design and construction requirements for powered industrial trucks established in the American National Standard for Powered Industrial Trucks Part I
12. y 1 000 Hour Cylinder and Every time the lift truck is serviced or every 1000 hours pose of truck operation whichever comes first complete the following maintenance procedures Fork Stops e Tighten backrest capscrews Cascade to 145 ft lbs 195 Nm For truck manufacturer s backrest refer to truck service manual zE NN Gua Ca LS C aA wan e Inspect lower hooks for wear and proper clearance i lo o Adjust if necessary refer to Installation step 4 Tighten Forks L lower hook capscrews to 120 ft lbs 165 Nm E e Lubricate Sideshifter upper and lower bearings with general purpose chassis grease noo Fasteners e Inspect upper and lower bearings for wear If any SS0386 eps Baas bearing is worn to less than 3 32 in 2 5 mm thickness replace the entire bearing set Refer to service manual for replacement procedure 2000 Hour After 2000 hours of truck operation in addition to the 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
13. y Rules Industrial Lift Trucks No riders Motor off park lower load EP ee No parking on ramp TRAFFIC G Observe k Workers Stops tis a O n Wet floors Bumps Dips No reaching through mast a cm Traveling No turning on ramp No standing under load No load vale Veg Sg sl La Watch clearances GAO0048 eps se Jou To B Sound horn slow at corner TET Slow for Sound horn slow two way traffic at intersection 6014809 R7 _ 0 PERATION Safety Rules Handling Loads Limit sideshifting Top of load with raised load Should not extend above backrest CAUTION Do not put side loads on forks Center load prior to traveling Limit truck movement FP0174 eps with raised load Load weight must not exceed combined truck attachment capacity see truck nameplate Total fork capacity LH RH fork must be greater Raise load prior than load weight Check capacity stamp on forks to sideshifting Sideshifter Operation AUXILIARY VALVE SIDESHIFTING FUNCTIONS A Sideshift Left B Sideshift Right GAO0010 eps SS0367 eps Hoist up Tilt Back 6014809 R7 3 WARNING The safe operation and maintenance of industrial trucks is regulated by Occupational Safety and Health OSHA regulations 1910 178 and American National Standards Institute ANSI Safety Standa
14. y loaded trucks when not handling a load A load engaging means shall be placed under the load as far as possible the mast shall be carefully tilted backward to stabilize the load Extreme care shall be used when tilting the load forward or backward particularly when high tiering Tilting forward with load engaging means elevated shall be prohibited except to pick up a load An elevated load shall not be tilted forward except when the load is in a deposit position over a rack or stack When stacking or tiering only enough backward tilt to stabilize the load shall be used 0 Operation of the Truck 1 If at any time a powered industrial truck is found to be in need of repair defective or in any way unsafe the truck shall be taken out of service until it has been restored to safe operating condition q Maintenance of Industrial Trucks 1 5 Any power operated industrial truck not in safe operating condition shall be removed from service All repairs shall be made by authorized personnel All parts of any such industrial truck requiring replacement shall be replaced only by parts equivalent as to safety with those used in the original design Industrial trucks shall not be altered so that the relative positions of the various parts are different from what they were when originally received from the manufacturer nor shall they be altered either by the addition of extra parts not provided by the manufacturer or by th
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