6054520R7 K-Int FP User Manual
Contents
1. L Li FP1120 eps Stamped Fork Positioner Part Number Back Driver s View i 6054520 R7 NTRODUCTION 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 the job easier WARNING Rated capacity of the truck attachment combination is a responsibility of the original truck manufacturer and may be less than shown on the attachment nameplate Consult the truck nameplate WARNING Do not operate this attachment 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 A unless you are a trained and authorized lift truck driver WARNING For forks longer than 60 in 1500 mm or load centers exceeding 30 in 760 mm consult Cascade 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 contains2. B Mast Single Internal Reeving with RF Hydraulic Control OR C Mast Single Internal Reeving with electrical cable and attachment mounted solenoid valve FP0869 eps 6054520 R7 NSTALLATION Attachment Installation 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 overhead hoist and chains or straps are at WARNING Check the attachment weight located on the nameplate to make sure the least the rated capacity of the attachment be installed in mast per OEM 1 Integral Sideshifter carriage should specifications and procedures FPO866 eps 2 Check lower hook clearance Mast a ee 6054520 R7 Carriage Lower Hook Tighten capscrews to 120 ft lbs 165 Nm Clearance 1 32 in 0 8 mm Min 1 16 in 1 6 mm Max Sideshifting ba Frame FRONT FP0860 eps NSTALLATION NOTE Some configurations of this product are shipped with the fork positioner unmounted Follow this step to install the mounting shims and capscrews Install Shims and Capscrews A Shim as necessary with a maximum of 4 shims per side B install capscrews and tighten to 50 ft Ibs 65 Nm
3. Sideshifter Fork Positioner NOTE Maximum 4 shims per side Maximum difference in number of shims per side is 2 CAUTION Total allowable gap before tightening capscrews is 0 020 in 0 5 mm maximum Capscrews Use lockwashers and tighten to 50 ft lbs 65 Nm a z jy Shims Maximum 4 per side to reduce allowable gap to 0 020 in 0 5 mm maximum Recommended Torque Sequence A LH side top B RH side bottom C RH side top D LH side bottom Fork Carriers d CN NND DANN CES r Confirm fork carriers are behind face of carriage using a straight edge 6054520 R7 m NSTALLATION Flush supply hoses A Connect supply hoses to supply terminals _ M _ _ and connect together using union fittings as shown B Operate auxiliary valves for 30 sec _ _ _ NOU C Remove union fittings FP0726 eps OPEN OPEN Install hoses Sideshift CLOSE CLOSE Sideshift CAUTION Allow for 4 0 in 100 mm Right Forks Forks Len sideshifting movement in each direction rolling hose arrangement recommended FP0858 eps Back Driver s View Remove fork locking pins WARNING Remove locking pins from forks Make sure that forks slide freely on carriage bars Remove Fork 6054520 R7 FP1115 eps I Pin Assembly b
4. f FP1432 eps EE NSTALLATION Install forks WARNING For forks longer than 60 in A Remove capscrews from outer retainer 1500 mm or load centers exceeding section to remove inner retainer section 30 in 760 mm consult Cascade B install forks using a pallet or blocks Keep feet clear of forks C A C Reinstall fork carrier inner retainer section and Fork Carrier Fork Carrier A tighten capscrews to 25 ft lbs 35 Nm Inner Retainer Outer Retainer Capscrews NOTE See illustration below to position inner retainers for various fork widths IMPORTANT Do not lube the fork carrier grease fittings during initial installation See Periodic Maintenance for lube schedule x iN FP0867 eps Wide Inner Retainer Wide Inner Retainer 6052301 Outer Retainer w Spacer Bar 6052316 5 in Hi Fork or or Wide Inner Narrow Inner retainer 100 onde Retainer with Retainer Dearees Shims 6805182 6042443 FORK CARRIER CONFIGURATIONS RH Front Views NOTE Recommended gap between sides of fork and fork retainer is 0 08 0 16 in 2 0 4 0 mm FP1543 eps 10 6054520 R7 NSTALLATION FP0868 eps Install backrest if applicable Cascade Backrest Tighten to 145 ft Ibs 195 Nm For other backrests see OEM recommendations WARNING Truck control handle and A attachment function activation
5. 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 Il 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 powe
6. Centre 1 1 Rambaugh Colony Lal Bahadur Shastri Road Navi Peth Pune 411 030 Maharashtra India Phone 91 020 2432 5490 Fax 491 020 2433 0881 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 465 6795 7555 Fax 65 6863 1368 Part Number 6054520 R7
7. 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 6054520 R7 SIDESHIFTING FORK POSITIONING WITH SOLENOID VALVE A Sideshift Left A Open Spread Forks press knob button B Sideshift Right B Close Forks press knob button Lubrication Fork Positioner Sideshifter is prelubed at the factory and requires no lubrication for installation Use graphite dry lube for fork bars as required Slip Plate Aerosol GraphoKote or equivalent After use lubricate the Fork Positioner Sideshifter as described in the Periodic Maintenance Sec tion in this manual Cycle Fork Positioner functions e Open and close forks several times Sideshift left and right Check for smoothness and equal movement e Check for operation in accordance with ANSI ISO standards e Check for leaks at fittings valve cylinders e Check that rolling hoses supplying fork position are not pinched AUXILIARY VALVE FUNCTIONS Hoist down Tilt forward ac d Hoistup Tilt Back SIDESHIFTING FORK POSITIONING A Sideshift Left B Sideshift Right C Open Spread Forks D Close forks le an Pc p 11 EE NSTALLATION Adjust forks for equ
8. ERATION 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 m I LOAD WEIGHT Center load prior to traveling Limit truck movement PONZA pS i with raised load Load weight must not exceed y combined truck attachment capacity see truck nameplate Raise ldan prior Total fork capacity LH RH fork to sideshifting must be greater than load weight Check capacity stamp on forks Fork Positioner amp Sideshifter Operation AUXILIARY VALVE FUNCTIONS WARNING Truck control handle and attachment A function activation shown here conforms to ASME ANSI B56 1 recommended practices Hoist down Tilt forward Failure to follow these practices may lead to IA c serious bodily injury or property damage End 2 amp user dealer and OEMs should review any 990 deviation from the practices for safe operation C AA AA SUUM ese Qasa SIDESHIFTING amp FORK POSITIONING WITH SIDESHIFTING amp FORK POSITIONING SUPE NADIE A Sideshift Lef A Sideshift Left Sideshift Left TY A Open Spread Forks i P A pen Sprea B Sideshift Right TIT press knob button C Open Spread Forks _ B Sideshift Right d E D Close forks M B Close Fork
9. 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 Indusirial 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 the 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 NSTALLATION Truck Requirements Truck Relief Setting 2200 psi 152 ba
10. _ J SER manva K Series Integral Fork Positioner amp Sideshifter Manual Number 6054520 R7 cascade Cascade is a Registered Trademark of Cascade Corporation uH C ONTENTS Page INTRODUCTION Special Definitions 1 OPERATION Safety Rules 2 Industrial Lift Trucks 2 Handling Loads 3 Fork Positioner Sideshifter Operation 3 Daily Inspection 4 Safe Operation and Maintenance 5 OSHA Regulations 5 INSTALLATION Truck Requirements 6 Recommended Hydraulic Supply 6 Attachment Installation 7 PERIODIC MAINTENANCE 100 Hour Maintenance 13 300 Hour Maintenance 13 1000 Hour Maintenance 13 2000 Hour Maintenance 14 PARTS Recommended Spare Parts 15 Publications 15 Contacting Cascade back cover NTRODUCTION This manual is for the Cascade K Series Integral Fork Positioner amp Sideshifter Contents include an Operator s Guide Installation Instructions Periodic Maintenance and Catalog Number Serial Number Recommended Spare Parts Capacity weight horizontal CG IMPORTANT K Series Integral Fork Positioner amp Sideshifter is metric Supply fittings adapted as required for application NOTE All specifications are shown in US and Metric units where applicable All fasteners have a torque value range of 10 of stated value ID Label E
11. acks Straightness of blade and shank Fork angle Difference in height of fork tips Positioning lock Wear on fork blade and shank Wear on fork hooks 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 Il 209561 Class III 6054520 R7 Hm R ECOMMENDED SPARE PARTS FORK POSITIONER SIDESHIFTER UNITS SERVICED 35K 55K 70K 1 5 6 19 20 50 PART NO PART NO PART NO DESCRIPTION QTY QTY QTY FORK POSITIONER 6055389 6055389 6055389 Oylinder Service Kit 0 4 6 6055390 6055390 6055390 Composite Bearing Service Kit 1 2 4 6055391 6055391 6055391 Bronze Bearing Service Kit 1 2 4 6039245 6039245 6039245 Mounting Shims 4 6 8 SIDESHIFTER 8508374 8508374 8508375 Upper Bearing 8 16 32 8508376 8508376 8508377 Lower Bearing 6 12 24 8508373 8508373 8508373 Lower Hook 0 2 684295 684295 684295 Capscrew 0 4 667225 667225 667225 Washer 0 4 6020048 6020048 6021760 Cylinder Assembly 0 0 6017490 6017490 6017490 Cylinder Service Kit 1 2 P UBLICATIONS cascade PART NO DESCRIPTION and Order Form 6054520 User Manual 6053927 Service Manual 679929 Tool Catalog 673964 Literature Order Form 6054520 R7 GAO0098 eps 15 Do you have questions you need answered right now Call your ne
12. al movement if required NOTE Attachment is factory adjusted for equal fork movement when operated at recommended pressure and flow rate A Locate flow restrictors at each end Loosen jam nuts and screw both flow restrictors in until they bottom Screw each restrictor out lt FP0760 eps CCW 1 2 turn 7 B Open forks fully then close Look for unequal fork movement C On faster fork one that bottoms first screw Flow Restrictor flow restrictor in CW 1 4 turn each side D Repeat Steps B and C until fork movement is Back Driver s View equal Tighten jam nuts FORK LOWER HOOKS CARRIAGE Inspect fork hooks carriage bar clearance NOTE Use go no go Wear Gauge Part No 209560 Class Il or 209561 Class III A Inspect the fork lower hooks and carriage bar If the gauge fits between the carriage bar and lower hook repair or replacement is needed UPPER CARRIAGE BAR B Inspect the upper carriage bar If the gauge arrow touches the carriage bar repair or replacement is needed Cur Cer FORK UPPER HOOKS C inspect the fork upper hooks If the gauge arrow touches the hook repair or replacement is needed 5 5 A d gl CD um FP0832 eps G 12 6054520 R7 m P ERIODIC MAINTENANCE WARNING After completing any service procedure always test the Fork Positioner Sideshifter through five complete cycles to make sure the attachment opera
13. arest 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 Italia S R L European Headquarters Via Dell Artigianato 1 37030 Vago di Lavagno VR Italy 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 9771 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 ot C73C737M Cascade Corporation 2015 Cascade Canada Inc 5570 Timberlea Blvd Mississauga Ontario Canada LAW 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 Namdong 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 464 9 273 9137 02 2015 Cascade do Brasil Praga Salvador Rosa 131 141 Jordan polis S o Bernardo do Campo SP CEP 09891 430 Tel 55 13 2105 8800 Fax 55 13 2105 8899 Cascade India Material Handling Private Limited No 34 Global Trade
14. e manual for repair procedures NOTE Cylinder rod anchors operate with a loose clearance Inspect Sideshifter 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 Refer to service manual for repair procedures 6054520 R7 Backrest Oylinders and hoses Cylinder Rod Anchor Plugs Fork Positioner Mounting Flange Capscrews outside frame Forks N FP0872 eps Fork Carriage Lower Hooks Fork Carriers Bars and Retainers Lubrication Points Eni sm j a E Back Driver s View 13 n P ERIODIC MAINTENANCE 14 2000 Hour After 2000 hours of truck operation in addition to the 100 300 and 1000 hour maintenance forks in use shall be in spected 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 Surface cr
15. operating instructions for the Cascade K Series Integral Fork Positioner amp Sideshifter 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 Fork Positioner amp 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 understand a procedure ask your supervisor Emphasize Safety Most accidents are caused by operator carelessness or misjudgment You must watch for poorly maintained equipment and hazardous situations and correct them 6054520 R7 Integral Carriage Backrest Sideshifter Fork Positioner FP0863 eps PERATION Safety Rules Industrial Lift Trucks No riders No reaching through mast No standing under load ie e O GA0047 eps hu 8 cm SERE O om ee eds O O No parking on ramp No turning on ramp Watch clearances GA0048 eps TRAFFIC a d c co m Je KJ Observe Workers Stops I L VB t o O TET E ER m Slow for Sound horn slow Sound horn Wet floors Bumps Dips two way traffic at intersection slow at corner 2 6054520 R7 P
16. r Recommended 3500 psi 241 bar Maximum Truck Flow Volume Min 9 Recommended Max 9 35K 55K 1 GPM 70K 4 L min 7 5 L min 12 L min 2 GPM 3 GPM Contact Cascade speed Cascade K Series Integral Fork Positioner Sideshifters are compatible with SAE 10W petroleum base hydraulic fluid meeting Mil Spec MIL 0 5606 or MIL 0 2104B Use of synthetic or aqueous base hydraulic fluid is not recommended If fire resistant hydraulic fluid is required special seals must be used Q Flow less than recommended will result in slow fork positioning Flow greater than maximum can result in excessive heating reduced system performance and short hydraulic system life FP0865 eps Auxiliary Valve Functions Check for compliance with ANSI ISO standards Sideshift Tilt Forward Left iSt DON Open Spread Forks i tere Wtr 7K Hoist Up Close Forks Tilt Back Sideshift Right GA0082 eps Recommended Hydraulic Supply Fork Positioning function No 3 hose No 4 fittings with 5 32 in 4 mm minimum ID Sideshifting function No 4 hose No 6 fittings with 3 16 in 5 mm minimum ID Refer to Cascade Hose amp Cable Reel Selection Guide Part No 212199 to select the correct hose reel for the mast and truck A Fork Positioning Sideshifting B C A B Double Internal Reeving
17. red industrial trucks m Truck Operations 1 Trucks shall not be driven up to anyone standing in front of a 2 3 4 Si 5ii Giii 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 fully 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 6054520 R7 at cro
18. s 5 B n E A press knob button Ce hs FP0862 eps 6054520 R7 3 PERATION Daily Inspection Check items shown each day Report problems to your supervisor Refer to the attachment s service manual for troubleshooting and repair procedures Decals for legibility Mounting fasteners for tightness FP0864 eps Backrest fasteners for tightness Forks for wear Cylinders and hoses Lower Hooks for leaks for tightness 4 6054520 R7 AFE OPERATION AND MAINTENANCE OSHA Regulations Trucks and Attachments Specific Regulations from OSHA 1910 178 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 10 A load backrest extension shall be used whenever necessary Standard 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 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
19. ss 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 7iii 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 0 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 partially 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 p Operation of the Truck 1
20. tes correctly before returning it to the job 100 Hour Every time the lift truck is serviced or every 100 hours of truck operation whichever comes first complete the following maintenance procedures 300 Hour Check for loose or missing capscrews worn or damaged hoses and hydraulic leaks Inspect sideshifter lower hooks for wear and proper clearance Adjust if necessary Refer to Installation Section Step 2 If required tighten capscrews as follows Fork Positioner Mounting Flanges 50 ft lbs 65 Nm Fork Carriers 25 ft lbs 35 Nm FP Cylinder Rod Anchor Plugs 50 ft lbs 65 Nm Sideshifter Lower Hooks 120 ft lbs 165 Nm After each 300 hours of truck operation in addition to the 100 hour maintenance perform the following procedures Tighten backrest capscrews Cascade only to 145 ft lbs 195 Nm Apply general purpose lithium based chassis grease to sideshifter upper bearing grease fittings and sideshifter lower bearings as shown Apply a single pump of grease for the fork carrier grease fittings Apply graphite dry lube to fork carriage bars as required Slip Plate Aerosol Cascade Part No 599489 GraphoKote or equivalent 1000 Hour After each 1000 hours of truck operation in addition to the 100 and 300 hour maintenance perform the following procedures Inspect fork carriers for looseness on bearing tubes and cylinder rod anchors for excessive end play Refer to servic
Download Pdf Manuals
Related Search