6054167R6 K-FPK User Manual
Contents
1. FP0174 eps Load weight must not exceed combined truck attachment capacily see truck nameplate Total fork capacity LH RH fork must be greater than load weight Check capacity stamp on forks AUXILIARY VALVE FUNCTIONS Tilt forward Hoist down ac ssh tt Hoistup Back 6054167 R6 WARNING Truck control handle and attachment function activation shown here conforms to ASME ANSI B56 1 recommended practices Failure to follow these practices may lead to serious bodily injury or property damage End user dealer and OEMs should review any deviation from the practices for safe operation SIDESHIFTING FORK POSITIONING A Sideshift Left B Sideshift Right C Open Forks D Close forks TU D FP0696 eps gt C PERATION Daily Inspection Check items shown each day Report problems to your supervisor See Service Manual for troubleshooting and repair procedures Decals for legibility Fasteners for tightness Forks for wear Cylinders and hoses for leaks 1 r T T cl py i r 1E r Y l Fasteners for tightness 6054167 R6 AFE OPERATION AND MAINTENANCE 0SHA Regulations Industrial Trucks and Attachments Specitic Regulations from 0SHA 1912. statement preceded by CAUTION is information that should be acted upon to prevent machine damage WARNING A statement preceded by WARNING 15 information that should be acted upon to prevent bodily injury A WARNING is always inside a ruled box 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 Cascade K Series Fork Positioner Kit 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 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 6054167 R6 Fork Positioner 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
3. N Wide Inner Retainer Wide Inner Retainer w Spacer Bar 6052316 6052301 Outer Retainer 5in 122 mm Fork Wide Inner Narrow Inner Rotate Inner Retainer with Retainer Retainer 180 Shims 6805182 6042443 Degrees 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 Outside FP1543 eps 6054167 R6 _ 8 Install forks 100K 120K 150K 165K NSTALLATION E 1 load centers exceedin Remove capscrews and fork carrier inner A iin 9 retainer sections WARNING For forks longer than 60 in B install forks using a pallet or blocks Keep feet clear of forks Fork Carrier f Inner Retainer C Reinstall fork carrier inner retainer sections and tighten capscrews to 50 ft Ibs 65 Nm Outer Retainer NOTE See illustration below to position inner retainers for various fork wiqths IMPORTANT Do not lube the fork carrier grease fittings during initial installation See Periodic Maintenance for lube schedule ps Wide Inner Retainer Wide Inner Retainer 6059396 Outer Retainer w Spacer Bar 6059395 Rotate Inner Retainer 180 5in n in jJ Degrees me oN Outside Fork or Narrow Inner ER Narrow Inner Retainer Retainer w Spacer Bar 6075350 6069127 Wide Inner Retainer Spacer Bar 60
4. U SER MANUAL K Series Fork Positioner Kit Manual Number 6054167 R6 Cascade Corporation Cascade is a Registered Trademark of Cascade Corporation E C ONTENTS Page INTRODUCTION Special Definitions 1 OPERATION Safety Rules 2 Industrial Lift Trucks 2 Handling Loads 3 Fork Positioner Operation 3 Daily Inspection 4 Safe Operation and Maintenance 5 OSHA Regulations 5 INSTALLATION Truck Requirements 6 Recommended Hydraulic Supply 7 Installation Procedure 8 PERIODIC MAINTENANCE 100 Hour Maintenance 14 300 Hour Maintenance 14 1000 Hour Maintenance 14 2000 Hour Maintenance 15 PARTS Product Identification 16 Recommended Spare Parts 16 Publications 16 6054167 R6 NTRODUCTION This User Manual is for the Cascade K Series Fork Positioner Contents include an Operator s Guide Installation Instructions Periodic Maintenance and Recommended Spare Parts NOTE All specifications are shown in US and Metric units where applicable All fasteners have a torque value range of 10 of stated value IMPORTANT K Series Fork Positioner is metric Supply fittings adapted as required for application 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 CAUTION
5. 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 01 2015 Cascade do Brasil Pra a 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 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 65 6795 7555 Fax 65 6863 1368 Part Number 6054167 R6
6. movement is equal Tighten jam nuts WARNING Truck control handle and attachment function activation shown here conforms to ASME ANSI B56 1 recommended practices Failure to follow these practices may lead to serious bodily injury or property damage End user dealer and OEMs should review any deviation from the practices for safe operation FORK POSITIONING Spread Forks B Close Forks FP0760 eps Flow Restrictor A each side Back Driver s View 6054167 R6 EN NSTALLATION Inspect fork hooks carriage bar clearance NOTE Use go no go Wear Gauge Part No 209560 Class 11 209561 Class Ill or 6104118 Class IV 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 B inspect the upper carriage bar If the gauge arrow touches the carriage bar repair or replacement is needed C Inspect the fork upper hooks If the gauge arrow touches the hook repair or replacement is needed 6054167 R6 FORK LOWER HOOKS CARRIAGE UPPER CARRIAGE BAR 9 OK Dja FORK UPPER HOOKS GN r JA p FP0832 eps 13 m p ERIODIC MAINTENANCE WARNING After completing any service procedure always test the fork positioner through five complete cycles to make sure the attachment operates cor
7. operate this attachment unless you are a trained and authorized lift truck driver WARNING For forks longer than 60 in 1520 mm or load centers exceeding 30 in 760 mm consult Cascade Backrest Sideshifter or Carriage Frame FP0853 eps PERATION Safety Rules Industrial Lift Trucks No riders No reaching through mast C 3 in i m emply RAMPS No standing under load Y GA0047 eps With load D peu O_O La No parking ramp No turning on ramp Watch clearances GA0048 eps el NA TRAFFIC 4 6 b o 4 Observe Workers Stops A L D b o 0 lt Slow for Sound horn slow Sound horn slow Wet floors Bumps Dips two way traffic al intersection at corner 6054167 R6 PERATION Safety Rules Handling Loads CAUTION Do not put side loads on forks Center load prior to traveling Raise load prior to sideshifting Fork Positioner Operation Limit sideshifting with raised load Limit truck movement with raised load Top of load should not extend above backrest aon I LOAD WEIGHT
8. 0 178 dard 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 WARNING The safe operation and maintenance of industrial trucks is regulated by Occupational Safety and Health OSHA regulations 1910 178 and Ameri can National Standards Institute ANSI Safety Stan 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 appropri ate 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 2 All new powered industr
9. 59396 6069113 Bo NOTE Recommended gap between sides of fork and fork retainer is 0 08 0 16 in 2 0 4 0 mm FORK CARRIER CONFIGURATIONS RH Front Views FP1213 eps 6054167 R6 Capscrews 11 9 10 NSTALLATION Lubrication Fork Positioner 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 fork positioner as described in Periodic Maintenance Section in this manual Cycle Fork Positioner functions Open and close forks several times Check for smoothness and equal movement see Step 10 for adjustment Check for operation in accordance with ANSI ISO standards Check for leaks at fittings valve cylinders AUXILIARY VALVE FUNCTIONS 11 12 Tilt forward Hoist down A tte Hoistup Tilt back Adjust forks for equal 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 CCW three turns Open forks fully then close Look for unequal fork movement On faster fork one that bottoms first screw flow restrictor in CW 1 2 turn Repeat Steps B and C until fork
10. es Connect supply hoses to supply terminals and connect together using CINES TENER ENS a union fitting as shown Operate auxiliary valve for 30 sec B C Remove union fitting I I FP0726 eps Install hoses Sideshift CLOSE OPEN Sideshift CAUTION Allow for 4 in 100 mm movement Right Forks Forks Left in each direction for sideshifting rolling hose arrangement recommended Y FP0701 eps Back Driver s View forks Make sure that forks slide freely on carriage bars 6 Remove fork locking pins WARNING Remove locking pins from Remove Fork Pin Assembly R 2 lt lt FP1115 eps FP1432 eps 6054167 R6 9 HS NSTALLATION 10 1500 mm or load centers exceeding 7 Install forks 55K amp 65K WARNING For forks longer than 60 in Remove capscrews and fork carrier inner retainer sections 30 in 760 mm consult Cascade B install forks using a pallet or blocks Keep feet clear of forks Fork Carrier PA Inner Retainer Outer Retainer C Reinstall fork carrier inner retainer sections and tighten capscrews to 25 ft lbs 35 Nm 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 Capscrews
11. ial trucks acquired and used by an employer after February 15 1972 shall meet the design and construction requirements for powered industrial trucks estab lished 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 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 rid ing of trucks is authorized The employer shall prohibit arms or legs from being placed be tween 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
12. igh 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 stack ing or tiering only enough backward tilt to stabilize the load shall be used 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 condi tion 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 gt 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 ndustrial trucks shall not be altered so that the relative positions of the various parts are different from what
13. ngs Apply a single pump of grease for the fork carrier grease fittings e Apply graphite dry lube to fork carriage bars as required D Slip Plate Aerosol GraphoKote or equivalent 1000 Hour After each 1000 hours of truck operation in addition to Forks C T 5 1 5 1 i 5 1 Lubrication Points the 100 and 300 hour maintenance perform the following p procedures nspect fork carriers for looseness on cylinders and cylinder rod anchors for excessive end play see Service FPO725 eps anual for repair procedures NOTE Cylinder rod anchors operate with a loose clearance nspect 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 Back Driver s View 14 6054167 R6 a P ERIODIC MAINTENANCE 2000 Hour After 2000 hours of truck operation in addition to the 100 300 and 1000 hour maintenance forks in use shall be inspected at intervals of not more than 12 months for single shift operations or whenever any defect or permanent deformation is detected Severe applications will require more frequent inspection Fork inspection shall be carried ou
14. rectly 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 Backrest XN i Check for loose or missing capscrews worn or damaged hoses and hydraulic leaks Oylinders and hoses Cylinder Rod e Inspect sideshifter lower hooks for wear and proper Anchor Plugs earance ghten fork positioner mounting flange capscrews 5 65K 50 ft Ibs 65 Nm Fork Positioner 120K 150K 165K 120 ft lbs 165 Nm Mounting Flange Capscrews ghten fork carrier capscrews outside frame L 65K 25 ft Ibs 35 Nm 120K 150K 165K 50 ft lIbs 65 Nm ighten fork positioner cylinder rod anchor plugs 65K 50 ft lbs 65 Nm 120K 150K 165K 100 ft Ibs 135 Nm ighten lower hook capscrews to gt Class II III 120 ft lbs 165 Nm FP0697 eps Fork Carriage Fork Carrier Lower Hooks Class IV 235 ft lbs 320 Nm Bars Capscrews Backside Fork Positioner 300 Hour Grease Fittings After each 300 hours of truck operation in addition to the 100 hour maintenance perform the following procedures Tighten Cascade backrest capscrews to 145 ft Ibs 195 Nm Apply general purpose chassis grease to sideshifter upper bearing grease fittings and sideshifter lower beari
15. sembly and tighten adequate clearance within sideshift or carriage capscrews on one side frame for maximum fork carrier movement EV B Measure gap at opposite side and determine B t installing in a Cascade sideshifter make sure total number of shims required predrilled mounting holes are correct to accept i fork positioner assembly C Install shims with a maximum 4 per side so total C if required grind corner and or mounting face i does not exceed 0 020 m of end bar for clearance NOTE Maximum difference in number of shims D if fitting to an OEM sideshifter or mast carriage per side is 2 contact Cascade for correct mounting hole location K SERIES FORK POSITIONER MOUNTING I Capscrews 1 Use lockwashers and l tighten to Sideshifter Li 55K 65K 50 ft Ibs us 65 Nm 100K 120K 150K 165K 120 ft Ibs 165 Nm Ifrequired Shims grind corner and or mounting face of end bar for clearance Maximum 4 per side to reduce total allowable gap to 0 020 in 0 5 mm maximum Fork Positioner corner and or mounting face of end bar for clearance If required grind Back Driver s View 3 Tighten Capscrews A Tighten capscrews with lockwashers to 55K 65K 50 ft lbs 65 Nm 100K 120K 150K 165K 120 ft Ibs 165 Nm B Install backrest if applicable 8 6054167 R6 _ NSTALLATION 4 Flush supply hos
16. sideshifter frame when purchasing these parts Publications DESCRIPTION and Order Form 6054167 User Manual 6053927 Service Manual 679929 Tool Catalog 673964 Literature Order Form i Le 16 GAO0098 eps 6054167 R6 BLANK 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 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 c CTM Cascade Corporation 2015 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 Namdong Ind Complex 691 8 Gojan Dong Namdong Ku Inchon Korea Tel
17. t 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 cracks 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 11 209561 Class 111 and 6105118 Class IV 6054167 R6 ARTS P Product Identification The assembly part number is stamped on the rear of the LH fork carrier and must be provided when ordering replacement parts Sticker showing operating pressure phone numbers for service amp parts Patent Sticker FP0667 eps mu iS Back Driver s View Assembly Part Number on LH fork carrier Recommended Spare Parts FORK POSITIONER UNITS SERVICED 100K 120K 1 5 6 19 20 50 55K 65K 150K 165K PART NO PART NO PART NO DESCRIPTION QTY QTY QTY 6055389 6055389 6081752 Cylinder Service Kit 0 4 6 6055390 6055390 6081751 Bearing Service Kit Composite 1 2 6055391 6055391 6081749 Bearing Service Kit Bronze 1 6039245 6039245 6059383 Mounting Shims 8 12 16 W Refer to part number stamped on part or supply serial number stamped on
18. than maximum can result in excessive heating reduced system performance and short hydraulic system life GA0028 eps Carriage Mount Dimension A ITA ISO GA0095 eps Minimum Maximum Class 1 14 94 in 380 0 15 00 in 381 0 mm Class l 18 68 in 474 5 mm 18 74 in 476 0 mm Class 23 44 in 595 5 mm 23 50 in 597 0 mm Auxiliary Valve Functions Check for compliance with ANSI ISO standards Tilt Sideshift Forward Left Open Hoist Down Forks sss 55 sa sas m Hoist Up Close Tilt Sideshift Forks Back Right Carriage Clean and inspect carriage bars Make sure that bars are parallel and that ends are flush Grind smooth any protruding welds that may affect Sideshifter lower bearings Repair any damaged notches 6054167 R6 _ NSTALLATION Recommended Hydraulic Supply Fork Positioning function No 3 hose No 4 fittings with 5 32 in 4 mm minimum ID Fork Positioning A Mast Single Internal Reeving Fork Positioning amp Sideshifting amp Mast Double Internal Reeving GA0398 eps 6054167 R6 S NSTALLATION Installation Procedure Check Mounting Location Determine Shimming Required Make sure fork positioner assembly has A Install fork positioner as
19. they were when origi nally received from the manufacturer nor shall they be altered either by the addition of extra parts not provided by the manufac turer or by the elimination of any parts Additional counter weight ing of fork trucks shall not be done unless approved by the truck manufacturer Industrial trucks shall be examined before being placed in ser vice 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 5 NSTALLATION Truck Requirements Truck Relief Setting 2200 psi 152 bar Recommended 3500 psi 241 bar Maximum Truck Flow Volume Min 9 Recommended Max 9 1 GPM 2 GPM 3 GPM 55K 65K 4L min 7 5L min 12 L min 100K 120K 1 GPM 4 GPM 5 GPM 150K 165K 4 L min 16 L min 20 L min Cascade K Series 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 Contact Cascade Flow less than recommended will result in slow fork positioning speed Flow greater
20. 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 6054167 R6 6 10 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 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 7 7iii 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 When ascending or descending grades in excess of 10 percent loaded trucks shall be driven with the load upgrade 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 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 h
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