6807533R2_35A Integral SS User Manual
Contents
1. GA0158 eps 6807533 R2 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 be installed in mast per OEM 1 Integral Sideshifter carriage should specifications and procedures Union Fitting 2 Flush supply hoses GAO0171 eps 3 Connect hoses and Solenoid wiring 7 5 Amp Fuse Control Switch Valve Sideshift Right Solenoid Coil Ss Unlock Pins e o Sideshift Left m 18 gauge wire SS1006 eps Lock Pins ES LES aly 22 AN Coil SS0947 eps 6807533 R2 EN NSTALLATION Install forks WARNING If the fork locking pin is not Remove capscrew from fork loading slot in center fully engaged the fork could become of lower carriage bar Use pallet or blocks as disengaged from the carriage necessary to raise forks to installation height Keep ES 9 feet clear of forks when installing Tighten capscrew to a torque of 120 ft Ibs 165 Nm Fork Loading Fork Locking SS1007 eps Check Sideshifter bearing lubrication Bearings are prelubed at the factory with break in grease No additional lubrication is required during installation NOTE Afte2. 35A Integral Sideshifter ATTACHMENTS SERVICED PART NUMBER DESCRIPTION 1 5 6 19 20 50 BASE UNIT 6806962 Upper Lower Bearing 8 16 32 8509290 Thrust Bearing 8 16 32 6807172 Pin Lock Bearing 2 4 8 VALVE 6008166 Solenoid Valve 1 2 4 6050419 Solenoid Coil 1 2 4 CYLINDER 6021760 Cylinder Assembly 0 1 2 6019928 Oylinder Service Kit 1 2 4 6807533 R2 ARTS d xe 6807533 R2 Included in Rod Seal Service Kit 6019928 Preloaded in Retainer Seal Carrier Assembly 6017490 Not serviceable order new Cylinder Assembly Not shown see Base Unit page for illustration Quantity as required y Sideshifter Cylinder 1 2 3 Su ji E SS0368 eps 7 5 35A REF QTY PART NO DESCRIPTION 1 1 6021760 Cylinder Assembly 2 2 562132 Rod Seal 3 2 415866 O Ring 70 Duro X Stamped 4 2 562131 Rod Wiper Seal Cylinder Assembly 5 2 6017490 Retainer Seal Carrier Assembly Part Number 6 a Rod Piston Assembly SS0363 eps 7 H Cylinder Shell Front View 2 6016592 Clevis Pin e 2 6016912 Hairpin Cotter v 6016591 Shim Cylinder 10 Do you have questions you need answered right now Call your nearest Cascade Service Department Visit us online at www cascorp com En cas de questions urgentes contacter leservice d entretien Cascade le plus proche Visiter le sit
3. 6 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 6807533 R2 10 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 Tiii 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 0 Loading 1 2 3 4 5 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 back
4. 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 Integral Sideshifters 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 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 Sideshifter Frame Sideshifter Cylinder Fork Stops QL Qoo LO Loy 00 i SS0950 eps Fork Loading Slot Solenoid Valve 6807533 R2 PERATION Safety Rules Industrial Lift Trucks No riders No reaching through mast No standing under load e O GA0047 eps With load SERE RAMPS De e El Motor off park lower load Traveling empty O O El A y lt N No parking on ramp No turning on ramp Watch clear
5. J SER anvar 39A Integral Sideshifter Manual Number 6807533 R2 cascade Cascade is a Registered Trademark of Cascade Corporation 1 NTRODUCTION This User Manual is for Cascade Integral Sideshifters Contents include an Operator s Guide Installation Instructions Periodic Maintenance and Recommended Spare Parts All specifications are shown in US and Metric units where applicable IMPORTANT 35A Sideshifter ports are SAE 9 16 in x 18 UNF for No 6 O ring fittings with 9 32 in 7 mm minimum ID 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 unless you are a trained and authorized lift truck driver 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 CAUTION A statement preceded by CAUTION is information that should be acted upon to prevent machine damage IMPORTANT A statement preceded
6. ances GA0048 eps TRAFFIC s 4 c c Observe Workers Stops l L VB o o EN EN E ws Slow for Sound horn slow Sound horn slow Wet floors Bumps Dips two way traffic at intersection at corner 6807533 R2 PERATION Safety Rules Handling Loads Limit sideshifting Top of load with raised load should not exiend above backrest CAUTION Do not put side loads on forks a 1 X 1 AD WEIGHT Center load prior to traveling COOCOO Limit truck movement FPO174 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 to sideshifting than load weight Check capacity stamp on forks Sideshifter Operation SIDESHIFTING AUXILIARY VALVE A Sideshift Left FUNCTIONS A Lock Pins press button B Sideshift Right B Unlock Pins press button Hoistup Tilt Back 3 6807533 R2 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 Standard for Powered Industrial Trucks ANSI B56 1 When opera
7. e Web 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 37050 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 2 C73C737M Cascade Corporation 201 1 Zijn er vragen waarop u direct een ant woord nodig hebt Neem dan contact op met uwdichtstbijzijnde serviceafdeling van Cascade Of ga naar www cascorp com Per domande urgenti contattare l Ufficio Assistenza Cascade pi vicino Visitate il nostro sito all indirizzo www cascorp com Haben Sie Fragen fiir die Sie sofort eine Antwort ben tigen Wenden Sie sich anlhren n chsten Cascade Kundendienst Besuchen Sie uns online www cascorp com Tiene alguna consulta que deba ser respondida de inmediato Llame por tel fonoal servicio t cnico de Cascade m s cercano Vis tenos en www cascorp com 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 Sparto
8. hour maintenance perform the following procedures Inspect 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 replacement procedure 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 Oylinder and Hoses Fork inspection shall be carried out by trained personnel to detect any damage that might impair safe use Any fork that is defective shall be removed from service Reference ANSI B56 1 2005 Inspect for the following defects e Surface cracks 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 II and 209561 Class III 6807533 R2 8 ARTS Recommended Spare Parts WARNING For the safety of yourself and A others DO NOT install the parts shown in this manual unless you have thoroughly reviewed the appropriate service manual
9. n 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 482 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 Jo o 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 01 2011 Cascade India Material Handling Private Limited No 34 Global Trade Centre 1 1 Rambaugh Colony Lal Bahadur Shastri Road Navi Peth Pune 411 030 Maharashtra India Phone 91 020 2432 5490 Fax 91 020 2433 0881 Part Number 6807533 R2
10. r 600 hours of operation sideshifter bearings should be lubricated with general purpose chassis grease Upper bearing grease areas o A x SS0953 eps Lower bearing grease areas Front View 7 6807533 R2 m P ERIODIC MAINTENANCE 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 Daily WARNING After completing any service maintenance and repair procedures First test with no load then test with a load to make sure the sideshifter operates WARNING If the fork locking pin is not correctly before returning it to the job fully engaged the fork could become disengaged from the carriage 100 Hour Every time the lift truck is serviced or every 100 hours Grease Fittings of truck operation complete the following maintenance procedures Fasteners Check for loose or missing bolts worn or damaged hoses hydraulic leaks and damaged or missing fork stops nspect lower hooks for wear and proper clearance Tighten lower hook capscrews to 50 ft lbs 65 Nm 300 Hour After each 300 hours of truck operation in addition to the 100 hour maintenance perform the following procedures Apply general purpose chassis grease to Sideshifter upper and lower bearing grease fittings 1000 Hour After each 1000 hours of truck operation in addition to the 100 and 300
11. r 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 Trucks shall not be driven up to anyone standing in front of a bench or other fixed object 2 No person shall be allowed to stand or pass under the elevated portion of any truck whether loaded or empty 3 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 4 The employer shall prohibit arms or legs from being placed between the uprights of the mast or outside the running lines of the truck 5i 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 5ii 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 5iii 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
12. ting 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 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 5 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 6 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 fo
13. ustrial 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 l NSTALLATION Truck Requirements Truck Relief Setting 2000 psi 140 bar Recommended 3500 psi 240 bar Maximum Truck Flow Volume o Min Recommended Max 35A 1 GPM 2 GPM 3 GPM 4 L min 7 5 L min 12 L min Cascade Integral 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 O Flow less than recommended will result in slow sideshift speed Flow greater than maximum can result in excessive heating reduced system performance and short hydraulic system life Recommended Hydraulic Supply The Integral Sideshifter requires the hydraulic supply arrangement shown below All hoses and fittings should be No 6 with 7 32 in 7 mm minimum ID GA0157 eps A wast Single Internal Reeving
14. ward 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 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 6 7 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 Ind
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