General Fork Installation
Contents
1. Fork Heal Area FORFORKS UPTO 10mm THICK Pk de cascade O Fork Shank back Hook ia Lip Horizontal 1877 227 22 AC1973 eps Periodic Maintenance The ANSI safety requirements related to lift truck fork inspection repair and testing are listed below ANSI ITSDF B 56 1 2005 6 2 8 Inspection and Repair of Forks in Service on Fork Lift Trucks a b 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 Individual Load Rating of Forks When forks are used in pairs the normal arrangement the rated capacity of each fork shall be at least half of the manufacturer s rated capacity of the truck and at the rated load center distance shown on the lift truck nameplate 6 2 8 1 Inspection Fork inspection shall be carried out carefully by trained personnel with the aim of detecting any damage failure deformation etc which might impair safe use Any fork that shows such a defect shall be withdrawn from service and shall not be returned to service unless it has been satisfactorily repaired in accordance with para 6 2 8 2 a b c a e Surface Cracks The fork shall be thoroughly examined isually for cracks and if considered necessary ubjected to a nondestructive crack detection process2. Write Cascade Corporation 2501 Sheridan Ave Springfield OH 45505 For Technical Support Call 1 800 227 2233 Fax 1 888 329 8207 Internet www cascorp com Write Cascade Corporation P O Box 20187 Portland OR 97294 Sideshifter and Standard Fork Installation 1 Tilt carriage to vertical Place forks on blocks at carriage height for ease of installation Install fork through fork loading slot 2 3 Install Cascade backrest if provided 4 Tighten capscrews to 145 ft lb 195 Nm For other backrests refer to OEM recommendations SS0155 eps A WARNING If the fork locking pin is not fully engaged the fork could become disengaged from the carriage Fork Positioner Fork Installation F Series Fork Positioner For complete installation instructions refer to one of the following manuals F Series Fork Postitioner Installation Instructions Part no 207363 K Series Fork Postitioner User Manual Part no 6045671 L Series Fork Postitioner User Manual Part no 68144594 NOTE Manuals are available at www cascorp com under the support tab Technical Support Manuals link WARNING Customer supplied forks must A have the fork lock pins removed for proper operation on the fork positioner Ifthe forks are removed to be used in Non Fork Positioner applications the fork lock pins must be reinstalled FP1019 eps 1 Remove fork lock pins 2 Remove fork blocks F Ser
3. 5 0 mm 65D 85D 5 85 06 0 in 100D 120D 148 5 1 5 0 mm 150D 200D 8 50 06 0 in 216 0 1 5 0 mm 30G 40G 3 05 06 O in 45G 55G 77 5 1 5 0 mm 65G 3 60 06 0 in 91 5 1 5 O mm 80G 4 70 06 0 in 119 5 1 5 0 mm 100G 5 85 06 0 in 148 5 1 5 0 mm Fork Middle Hooks K s a mw RRO025 eps E Middle Hook Lower RR1072 eps Hook Welding Specifications WARNING Applications that hold a load 1 Preheat weld area full fork width and 6 in 152 mm above A inverted with a 50 or more capacity must use and below hook to 500 F 260 C minimum 600 F Cascade rotator forks 315 C maximum before welding Maximum interpass 5 8 Applications that dump a load when rotator is temperature noula ROLEKCREE 7007 ppa rotated at 45 from vertical can use pallet forks 2 Finish weld middle hook to fork Apply welds in the hook with the installed middle hook weld prep areas using the lower hook as an example of the welds required Note the dimension B no weld area Use the following weld method Attach ground clamp to the fork upright Weld using FCAW Flux Core Arc Welding AWS E100T1 K3 electrode 0 06 in 1 5 mm diameter with 100 CO2 or 75 Ar 25 CO2 30 45 CFH Apply fillet and groove welds using stringer bead technique Minimum weld pass width 0 25 in 6 3 mm maximum weld pass thickness 0 50 in 12 5 mm DCRP weldin
4. Instructions Part no 6073002 NOTE Manuals are available at www cascorp com under the support tab Technical Support Manuals link WARNING Forks must have three hooks A Cascade forks for rotators are already equipped with a middle hook If the rotator is supplied without forks middle hooks are Ae Capscrew Type provided we Bar Type RE Fork Keeper P Fork Keeper 1 Rotate the carriage to the horizontal position Remove the fork keepers from the upper fork carriage bar 2 Release the spring locks on top of the forks 3 Slide the forks into position on the fork carriage bars NOTE If either the fork middle or lower hook clearance is too tight against carriage bar sand or grind the hook tip Do not exceed dimension A as shown in chart on page 5 Do not grind on upper hook 4 Lock each fork in place by pushing the spring lock lever down or twisting the knob down Shake forks to make sure the pin is fully engaged in a fork bar notch 5 Reinstall the keepers Tighten the capscrews to a torque of Capscrew Type 30G 100G 200 ft lbs 270 Nm Bar Type D Series 60 ft lbs 80 Nm Required 45G 65G 65 ft lbs 90 Nm Third Middle Hook Apply Loctite 242 blue to Bar Type capscrews i Threaded holes must be clean and dry before reassembly Sand or grind tip as required 6 Reverse the above procedures for removal WARNING When installing or removing forks ro
5. and including 4 in 100 mm thick Do not use on full or lumber tapered forks Fork calipers measure the thickness of fork arm shank and indicates that a 10 wear factor would be when calipers are applied to the blade cross section A Set the front teeth of the jaws by measuring the thickness of the shank Check that the caliper is held square across the shank for an accurate reading This sets the measure of the fork arm blade B Carefully remove caliper and position the jaws on the fork arm blade approximately 2 in 50 mm out from the inside of the shank e Ifthe inside teeth of the caliper hit the fork it has less than 10 wear and requires no replacement e Ifthe inside teeth of the caliper pass over the fork freely the fork must be taken out of service The fork has 10 wear and 20 reduction in capacity Caliper 2 Fork Arm Shank Scar y Cross Section O 100 a 2 in 50 mm FORK LOWER HOOKS CARRIAGE Repair or Replace UPPER CARRIAGE BAR xH QA Repair or Replace FORK UPPER HOOKS Repair or Replace Qx GA q o b FP0832 eps Fork Arm Blade ascens E Cross Section O 100 e Fork Arm Blade Cross Section 90 A Repair or Replace AC1971 eps Fork Calipers Fork Heel Angle NOTE Some forks are intentionally built with the fork angle either smaller or greater tha
6. cade New Zealand 15 Ra Ora Drive East Tamaki Auckland New Zealand Tel 64 9 273 9136 Fax 64 9 273 9137 12 2014 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 91 020 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 6072127 R5
7. cascade CI CITM Installation Instructions General Fork Installation This manual describes the installation of forks for Rotating Sideshifting and Fork Positioning attachments Middle hooks must be properly welded prior to installation on rotators Refer to the following securing procedures for driver safety and prevent load or equipment damage Fork Locks After moving or installing forks on the sideshifter rotator or truck carriage it is very important that the fork locks be fully engaged into locating notches When loads are handled with side loading conditions or other non recommended uses or practices excessive upper carriage bar notch wear may result on Cascade sideshifters NOTE Non recommended practices are those not adhering to ANSI B56 1 2005 safety standards If you are experiencing rapid carriage notch wear with a Cascade attachment contact Cascade Customer Service Preventive Inspection amp Maintenance To improve safety and efficiency when using forks make sure the following preventive inspection and maintenance is performed by trained personnel 1 Inspect the condition of the upper carriage bar notches during the next normal truck maintenance or service period Perform weld repairs on the carriage bars as necessary Use wear gauge part no 209508 Class II 209507 Class II or 6105257 Class IV to inspect for carriage bar 2 Inspect on a daily basis the condition of the upper carriag
8. e bar notches and the fork locking mechanism Replace any damaged parts 3 Make sure that fork locking pins are fully engaged in the upper carriage bar notches at all times during use Push on the fork heel to confirm that the fork does not disengage from the carriage 4 Make sure that fork stops are in place and functional 5 A third hook is always required on adjustable forks mounted on rotators 6 Inspect forks for fork wear at a minimum every 12 months single shift operations with fork calipers part no 7004851 or fork inspection safety kit part no 3014162 Inspect forks as outlined in Periodic Maintenance section page 9 NOTE Adjust inspection period for multiple shifts WARNING Fork locks must be properly A engaged in a carriage notch for safe operation Improper engagement may result in the fork moving on the carriage and or excessive wear to the carriage notch Worn upper carriage bar slots may allow fork locks to become disengaged from the notch locked position during use resulting in injury or equipment damage Lever Type Fork Keeper Knob Type Fork Lock eae Capscrew Type Fork Keeper P S Bar Type Fork Keeper Carriage Notches Sideshifter Welded 4 Fork Stop Third Hook All rotators with adjustable forks GA0382 eps Part Number 6072127 R5 Cascade Corporation To Order Parts Call 1 888 227 2233 Fax 1 888 329 0234 Internet www cascorp com
9. g current 230 300 amps 29 31 volts Travel speed 8 12 IPM Completely remove slag between passes Slow cool by covering with insulating blanket to 150 F 65 C 3 Inspect welds No undercut overlap cracks of any kind including crater crackers or porosity 4 Clean weld area and repaint Rotator No Weld Model Dimension B Upper 30E 40D 0 56 in nee 55D 14 mm 65D 80D 0 64 in 100D 120D 16 mm 150D 0 87 in 200D 22 mm 30G 40G 0 56 in 45G 55G 14 mm Middle 65G 0 64 in Hook 16 mm 80G 0 47 in 12 mm 100G 0 64 in 16 mm Reference D Series S 7295 S 2978 S 2224 346114 G Series S 22588 S 22566 S 22567 Lower Hook RR1094 eps How To Check Fork Hook amp Carriage Bar Wear NOTE Cascade fork safety kit 3014162 contains wear calipers 7004851 inspection sheets and safety poster Also available fork hook amp carriage bar wear gauges 209560 Class II 209561 Class III and 6105257 Class IV Wear Gauges 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 Fork Calipers Thickness Wear NOTE Use fork calipers on fork up to
10. hat has undergone repairs other than repair or replacement of the positioning lock and or the marking shall only be returned to service after being submitted to and passing the tests described in para 7 27 3 except that the test load shall correspond to 2 5 times the rated capacity marked on the fork 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 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 Cascade Corporation 2014 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 82 32 821 2051 Fax 82 32 821 2055 Cas
11. ies fork carrier retainers K Series Fork Positioner K Series or for carrier stops and retainers L Series 3 Install forks as follows 2 4 F Series Slide forks into position f J Fork Carrier Outer Retainer K amp L Series Install forks using a pallet or blocks Inner Retainer Capscrews Keep feet clear of forks 4 Install fork block or retainers as follows F Series Adjust blocks to provide 1 16 in 1 5 mm clearance with side of fork Tighten capscrew to a torque of 55F 60 ft lbs 80 Nm 100F 120F 118 ft lbs 160 Nm K Series Reinstall fork carrier inner retainers and tighten capscrews to 55K 65K 25 ft lbs 35 Nm 100K 165K 50 ft los 65 Nm L Series Reinstall retainer its hardware and inner FP0694 eps carrier fork stop capscrew with washers Tighten capscrews to 75 ft lbs 100 Nm 5 Install Cascade backrest if equipped Tighten capscrews to 145 ft lb 195 Nm For other backrests L Series Fork Positioner see OEM recommendations Install backrest Inner Carrier Fork Stop Capscrew and Washer FP1967 eps FP0698 eps Rotator Fork Installation Make sure forks are rated for the loads being handled Fork size chosen may reduce rotator rating Refer to the attachment s installation instructions Lever Type Knob Type D Series Rotator Installation Instructions Part no 672327 Fork Lock Fork Lock G Series Rotator Installation
12. n 90 These forks will need to be inspected by other methods Shank A Open the calipers to approximately 90 and place the Ue calipers in the top inside heel area of the fork Indicator B Verify that the lower pieces on the horizontal leg are both touching the top of the blade C Move the calipers towards the shank Verify that the caliper arms are both parallel to the blade and to the upright shank of the fork D Adjust the calipers so that all four points are simultaneously in contact with the fork Gently remove the calipers Look at the indicator lines found at the top of the hinge pin e Ifthe lines on the horizontal leg lie beyond either 93 or 87 indicator lines the forks should be marked to be checked for either permanent deformation possible stress cracks or other defects that impede the safe use of the fork AC1972 eps Fork Calipers Hook Angle A Select the correct Class ITA profile on the caliper for the appropriate ITA hook B insert the caliper up into the hook recess with the corresponding 20 angle face contacting the 20 angle of the hook C Press the vertical face flat against the fork upright shank and move the caliper up into the hook recess The caliper must be held at 90 to the hook e Ifthe horizontal face of the caliper can make contact with the hook s lower lip the hook is worn or deformed Check fork hook welds and fork heel area for cracks
13. pecial attention being paid to the heel and welds ttaching all mounting components to the fork blank his inspection for cracks must also include any special mounting mechanisms of the fork blank to the fork carrier including bolt type mountings and forged upper mounting arrangements for hook or shaft type carriages The forks shall not be returned to service if surface cracks are detected lt IDO q Straightness of Blade and Shank The straightness of the upper face of the blade and the front face of the shank shall be checked If the deviation from straightness exceeds 0 5 of the length of the blade and or the height of the shank respectively the fork shall not be returned to service until it has been repaired in accordance with para 6 2 8 2 Fork Angle Upper Face of Blade to Load Face of the Shank Any fork that has a deviation of greater than 3 deg from the original specification shall not be returned to service The rejected fork shall be reset and tested in accordance with para 6 2 8 2 Difference in Height of Fork Tips The difference in height of one set of forks when mounted on the fork carrier shall be checked If the difference in tip heights exceeds 3 of the length of the blade the set of forks shall not be returned to service until repaired in accordance with para 6 2 8 2 Positioning Lock When Originally Provided It shall be confirmed that the positioning lock is in good repair and correct working orde
14. r If any fault is found the fork shall be withdrawn from service until satisfactory repairs have been effected 1 9 a b Wear 1 Fork Blade and Shank The fork blade and shank shall be thoroughly checked for wear special attention being paid to the vicinity of the heel If the thickness is reduced to 90 of the original thickness the fork shall not be returned to service 2 Fork Hooks When Originally Provided The support face of the top hook and the retaining faces of both hooks shall be checked for wear crushing and other local deformations If these are apparent to such an extent that the clearance between the fork and the fork carrier becomes excessive the fork shall not be returned to service until repaired in accordance with para 6 2 8 2 Legibility of Marking When Originally Provided If the fork marking in accordance with para 7 27 2 is not clearly legible it shall be renewed Marking shall be renewed per instructions from original supplier 6 2 8 2 Repair and Testing Repair Only the manufacturer of the fork or an expert of equal competence shall decide if a fork may be repaired for continued use and the repairs shall only be carried out by such parties It is not recommended that surface cracks or wear be repaired by welding When repairs necessitating resetting are required the fork shall subsequently be subjected to an appropriate heat treatment as necessary Test Loading A fork t
15. tate carriage to horizontal position Use pallets or blocks to raise forks to installation height Keep feet clear of forks when installing Fork keepers must be in place at all times during rotator operation gt RRO780 eps Bar Type Fork Keeper Capscrew Type ga Fork Keeper RRO430 eps 4 Fork Middle Hooks WARNING Rotator forks must have three A hooks Cascade forks for rotators are equipped with a middle hook If the rotator is supplied without forks middle hooks are provided They must be welded using the following procedures Middle hooks on forks are required for rotating attachments Location dimensions and welding specifications are provided The following middle hooks are available Fork Middle Hook Part No Class Il 689279 Class Ill 689281 Class IV 633671 Forks must be rated for the loads being handled WARNING Fork size affects rotator capacity Consult the Cascade attachment s installation manual Verify capacity for truck nameplate Fork Preparation 1 Clean all surfaces to be welded Remove paint oil grease and other contaminants 2 Position the middle hook referring to dimension A Mark the hook position on the fork 3 Tack the hook in four places with 0 25 in 6 mm long welds Recheck dimensions Rotator Hook Spacing Model Dimension A 30E 40D 5 06 06 O in 55D 128 5 1
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