6047782R1_G-Fork Positioner User Manual_EN
Contents
1. _ H YDRAULIC SUPPLY Recommended Hydraulic Supply Fork Position function No 6 hoses and fittings with 7 mm minimum D Sideshift function No 6 hoses and fittings with 7 mm minimum I D Refer to Cascade Hose amp Cable Reel Selection Guide Part No 212199 to select the correct hose reel for the mast and truck T l Fork Position A Mast Single Internal Reeving Fork Position amp Sideshift A Mast Double Internal Reeving Nj I XY 7 Ay D Sessa gt EM UI GAO0365 eps 7 6047782 R1 EN 1 1 NSTALLATION Attach overhead hoist 2 Remove lower hooks qs VT e S FP0857 eps FP0855 eps Lt y WARNING Make sure overhead oro lego i i Back View hoist has a rated capacity of at least 450 kg Mount on truck carriage Sideshifting Model shown ITA Class Il 15 17 mm ITA Class lll 18 20 mm Engage locator tab with carriage center ITA Class ll 8 9 mm ITA Class III 10 11 mm Truck Upper FP0891 eps Carriage Bar GA0035 eps p 4 Install lower hooks Truck Lower Carriage Bar Clearance FP0900 eps 0 8 mm Min Vs 5 5 1 6 mm Max Tighten capscrews Lower Hook a to 165 Nm 6047782 R1 EN NSTALLATION Flush supply hoses2. A Connect supply hoses to truck supply terminals and connect together using a union fitting as shown B Operate auxiliary valve for 30 sec C Remove union fitting FP0726 eps Install hoses Sideshift Left OPEN CLOSE Sideshift Right if equipped Forks Forks if equipped E 2 di m Le LA a Si OYO OVS ne Front View Install forks A Remove capscrews and fork carrier inner retainers B install forks using a pallet or blocks Keep feet clear of forks C Reinstall fork carrier inner retainers and spacers Tighten capscrews to 35 Nm Capscrews SS0639 eps Add spacers to match fork width Fork Carrier Inner Retainer 6047782 R1 EN u NSTALLATION Install backrest Lubrication The 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 Lubricate as described in the Periodic Maintenance section FP0889 eps AUXILIARY VA
3. Ask your employer for the complete regulations General Requirement 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 Safety Guards If the type of load presents a hazard the user shall equip fork trucks with a vertical load backrest extension in accordance with the following 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 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
4. LVE FUNCTIONS e Open and close forks several times Sideshift if equipped left and right Check for smoothness and equal movement 1 Cycle Fork Positioner functions Hoist down Tilt forward Check for operation in accordance with ISO standards e Check for leaks at fittings valve cylinders GA0005 eps Hoist up Tilt back FORK POSITION FORK POSITION amp SIDESHIFT A Spread Forks B Close Forks A Sideshift Left B GSideshift Right C Spread Forks ill Ii D Close Forks i As a fB FP0899 eps A Ber E Cem FP0890 eps C 6047782 R1 EN 10 11 12 11 NSTALLATION Adjust valve flow controls for equal fork movement if required NOTE Attachment is Factory adjusted for equal fork movement when operated at recommended pressure and flow rate A Open forks fully then close Look for unequal fork movement and note which cylinder is faster B On faster fork one that bottoms first loosen jam nut and screw flow control in CW 1 2 turn C Repeat Step B until fork movement is equal Tighten jam nut Inspect fork hooks and carriage bars 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
5. RUCK REQUIREMENTS JT Truck Relief Setting 160 bar Recommended 210 bar Maximum Truck Flow Volume Min Recommended Max 55G 15 L min 20 L min 35 L min 100G 20 L min 30 L min 40 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 than maximum can result in excessive heating reduced system performance and reduced hydraulic system life GA0131 eps Carriage Mount Dimension A ISO A Minimum Maximum Carriage Clean and inspect carriage bars Class Il 380 0 mm 381 0 mm Bars must be parallel and ends flush Grind Class III 474 5 mm 476 0 mm smooth any protruding welds that may affect Sideshifter lower bearings Repair any dam Class IV 595 5 mm 597 0 mm aged notches GA0028 eps Auxiliary Valve Functions Check for compliance with ISO standards Sideshift Left Tilt Forward Hoist Down Spread Forks eit rj Rd Hoist Up Close Forks Tilt Back Sideshift Right 6047782 R1 EN 6
6. SER MANUAL G Series Fork Positioner Models 55G FPB 55G FPS 100G FBP 100G FPS Manual 6047782 R1 EN Cascade Corporation Cascade is a Registered Trademark of Cascade Corporation jJ ONTENTS Page INTRODUCTION Special Definitions 2 OPERATION Safety Rules 3 Industrial Lift Trucks 3 Handling Loads 4 Fork Position amp Sideshift Operation 4 Daily Inspection 5 Safe Operation and Maintenance 6 TRUCK REQUIREMENTS Truck Settings 7 HYDRAULIC SUPPLY Recommended Hydraulic Supply 8 INSTALLATION Installation Procedures 9 PERIODIC MAINTENANCE 100 Hour Maintenance 13 300 Hour Maintenance 13 1000 Hour Maintenance 13 CONTACTING CASCADE back cover E NTRODUCTION This User Manual is for the Cascade G Series Fork Positioner Contents include an Operation Guide Installation Instructions and Periodic Maintainence All specifications are shown in Metric units where applicable IMPORTANT The G 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 WARNING Rated capacity of the truck attachment combination is a responsibility of the original truck manufacturer and may be less than s
7. 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 Valve pressure adjustment FP0902 eps Left Fork Right Fork Flow Control Flow Control FORK LOWER HOOKS CARRIAGE UPPER CARRIAGE BAR ox G ua FORK UPPER HOOKS Ga gt a ox ds 2 FP0832 eps OL ES 6047782 R1 EN _ P ERIODIC MAINTENANCE WARNING After completing any service procedure always test the Fork Positioner through five complete cycles to make sure the attachment operates correctly before Fork Carrier returning it to the job Capscrews 100 Hour Maintenance Every time the lift truck is serviced or every 100 hours of truck operation whichever comes first complete the following maintenance procedures e Check for loose or missing capscrews worn or damaged hoses and hydraulic leaks e Inspect lower hooks for wear and proper clearance Adjust if necessary see Installation Step 4 e f required tighten fork carrier capscrews to 35 Nm 300 Hour Maintenance OVO After each 300 hours of truck operation in addition to the H
8. d Forks B Close forks EM Hoist up Tilt Back Ae B ee A FB AUXILIARY VALVE FUNCTIONS C FORK POSITION amp SIDESHIFT A Sideshift Left B Sideshift Right C Open Spread Forks D Close forks L oo i us gt A 6047782 R1 EN PERATION Daily Inspection Check items shown each day Report problems to your supervisor See Service Manual for troubleshooting and repair procedures Decals for legibility Upper Hook and Centering Tab for proper engagement Fasteners for tightness FPO905 eps Fasteners for tightness Forks for wear Cylinders and hoses Lower hooks for for leaks proper engagement 6047782 R1 EN AFE OPERATION AND MAINTENANCE Industrial Trucks and Attachments WARNING The safe operation and maintenance A 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 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
9. e load or part of it from falling rearward Traveling 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 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 e
10. gt FP0871 eps 100 hour maintenance perform the following procedures Forks Carriage Bars Tighten backrest capscrews Cascade to 195 Nm Apply general purpose lithium based chassis grease to Front View fork carrier bearing grease fittings Apply graphite dry lube to fork carriage bars as required Slip Plate Aerosol GraphoKote or poluivalent Cylinders Fork Carrier Bearing and Hoses Grease Fittings 1000 Hour Maintenance After each 1000 hours of truck operation in addition to the 100 and 300 hour maintenance perform the following procedures e Inspect fork carriers for looseness on shaft and cylinder rod anchors for excessive end play see Service Manual for repair procedures e Inspect upper and lower bearings for wear If any bearing is worn to less than 2 5 mm thickness replace the entire bearing set see Service Manual for repair procedures e Inspect forks and carriage bars for wear NOTE Cascade fork safety kit 3014162 available with wear calipers inspection sheets and safety poster Also em e available Cascade fork hook amp carriage bar wear gauge ogo ogo ES 209560 CL Il and 209561 CL III ae Upper and Lower Lower Hooks Bearings Back View 6047782 R1 EN 12 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 leserv
11. hown on the attachment as additional information of special significance or to make the job easier WARNING A statement preceded by nameplate Consult the truck nameplate WARNING is information that should be WARNING Do not operate this attachment acted upon to prevent bodily injury A unless you are a trained and authorized lift WARNING is always inside a ruled box truck driver 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 Fork Positioner This Section contains operating instructions for the Cylinders Cascade G Series Fork Positioner It will help you Fork Carriers 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 P g operator carelessness or misjudgement You must watch Sideshift Cylinder f
12. ice d entretien Cascade le plus proche Visiter le site 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 cem eTM Cascade Corporation 2006 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 Haben Sie Fragen f r 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 www cascorp com 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 S
13. nough backward tilt to stabilize the load shall be used Operation of the Truck 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 Maintenance of Industrial Trucks 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 6047782 R1 EN
14. or poorly maintained equipment and hazardous situations if equipped and correct them FP0854 eps Forks 1 6047782 R1 EN PERATION Safety Rules Industrial Lift Trucks No riders No reaching through mast No standing under load De oO e GA0047 eps With load SERE es es C o_O La No parking on ramp No turning on ramp Watch clearances GA0048 eps TRAFFIC s lt A ww 7 H 4 A o Oo gt B c us Slow for Sound horn slow Sound horn slow Wet floors Bumps Dips two way traffic al intersection at corner 6047782 R1 EN PERATION Safety Rules Handling Loads CAUTION Do not put side loads on forks Center load prior to traveling Raise load prior to sideshifting Limit sideshifting with raised load Limit truck movement with raised load Top of load should not extend above backrest A I LOAD 7 WEIGHT FP0174 eps Load weight must not exceed combined truck attachment capacity see truck nameplate Total fork capacity LH RH fork must be greater than load weight Check capacity stamp on forks Fork Position amp Sideshift Operation Hoist down Tilt forward AC kii CI HET V GAO005 eps z FORK POSITION A Open Sprea
15. teel 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 64 9 273 9137 1 2006 cercano Vis tenos en www cascorp com 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 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 6047782 R1 EN
16. trucks Truck Operations 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 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 A load backrest extension shall be used whenever necessary to minimize the possibility of th
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