219941R8 F-SS User Manual
Contents
1. _ LoverHook Bearing ime 6 12 2 Paves oavscewmiaxase o 8 1 Cra e e _ capsoremmiexas o 4 8 700580 capscrewnaoxeo o 3 E e o l e a oae Cer or er ao we O o a an a O o e 6 Cua f fmm foyinderassery o ot Kit containing two each of two different style bearings Match the bearing being replaced E Refer to part number stamped on part or supply serial number stamped on sideshifter frame when purchasing parts Four Capscrew Hook applications cascade Service Literature Index and Order Form Publications PART NO DESCRIPTION 219941 220526 ing Information Parts Service and Operator Guide literature is sold through the Cascade Parts Depot Phone janual Part No 673969 679929 Tool Catalog 673964 Literature Order Form corporati GA0377 eps 219941 R8 10 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 ltaly Tel 39 045 89891 11 Fax 39 045 8989 160 ASIA PACIFIC Cascade Japan Ltd 2 23 2 Chome Kukuchi Nishimachi Am2. 100 Hour Every time the lift truck is serviced or every 100 hours Cylinder Upper and of truck operation complete the following maintenance and hoses lower hook procedures for leaks engagement e Check for loose or missing bolts worn or damaged hoses hydraulic leaks and damaged or missing fork Wee stops fy e Inspect lower hooks for wear and proper clearance Adjust if necessary refer to Installation step 4 Tighten lower hook capscrews to Two Capscrew Hooks Class II III 120 ft lbs 165 Nm Class IV 235 ft lbs 820 Nm Four Capscrew Hooks Class Il 65 ft lbs 90 Nm it ft CT SS0915 eps Fasteners 300 Hour After each 300 hours of truck operation in addition to the 100 hour maintenance perform the following procedures e Tighten backrest capscrews Cascade to 145 ft lbs 195 Nm 2000 Hour Continued e Apply general purpose chassis grease to Sideshifter upper and lower bearings Inspect for the following defects e Surface cracks e Straightness of blade and shank 1 000 Hou r e Fork angle After each 1000 hours of truck operation in addition to e Difference in height of fork tips the 100 and 300 hour maintenance perform the following e Positioning lock procedures e Wear on fork blade and shank e Inspect upper and lower bearings for wear If any e Wear on fork hooks bearing is worn to less than 09 in 2 5 mm thickness an replace the entire beari
3. 8 9 mm ITA Class III 39 43 in 10 11 mm ITA Class IV 47 51 in 12 13 mm Truck Upper Carriage Bar 219941 R8 WARNING Check the attachment weight located on the nameplate to make sure the overhead hoist and chains or straps are at least the rated capacity of the attachment SS1062 eps OO0 O090 Four Capscrew Hooks SS0152 eps NSTALLATION 4 Install lower hooks BOLT ON HOOKS Two Capscrew BOLT ON HOOKS Four Capscrew Truck Lower Sideshifter Truck Lower Sideshifter Carriage Bar Peas ete Carriage Bar a Frame Iron Hook Clearance 04 in 1 mm Min 08 in 2 mm Max Bearing ame b 04 in 1 mm Min Bronze Hook Clearance SS1060 eps 08 in 2 mm Max PRUE apa O Clearance touching but not tight Shim to adjust Tighten capscrews to clearance Class II III 120 ft lbs 165 Nm Class IV 235 ft lbs 320 Nm Tighten capscrews to Class Il 65 ft lbs 90 Nm NOTE If frame is equipped with a hydraulic component guard remove the guard to access shims located on the lower fork bar QUICK DISCONNECT HOOKS Reverse guides to reduce hook to carriage clearance Clearance k L 04 in 1 mm Min f Offset on top 08 in 2 mm Max provides max SS1059 eps clearance Class IlIll 62 in 16 mm Tighten capscrews to Class IV Class II III 120 ft Ibs 165 Nm 83 in 21 mm Class IV 190 ft lbs 250 Nm I
4. Safety Rules Industrial Lift Trucks No riders No reaching through mast No standing under load ma fs Traveling empty Motor off park lower load O a8 aO 9 4 Y Y 2 se GA0048 eps TRAFFIC z N ot I TET w Slow for Sound horn slow Sound horn slow Wet floors Bumps Dips two way traffic at intersection at corner t s angie Workers tops Jou AT Ne 219941 R8 PERATION Safety Rules Handling Loads CAUTION Do not put side loads on forks Center load prior to traveling Raise load prior to sideshifting Sideshifter Operation AUXILIARY VALVE FUNCTIONS Hoist down Tilt forward GAO010 eps Hoist up Tilt Back Limit truck movement with raised load Top of load Should not extend above backrest Limit sideshifting with raised load Bas on FPO0017 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 SIDESHIFTING A Sideshift Left B Sideshift Right SS0160 eps 219941 R8 A AFE OPERATION AND MAINTENANCE 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 oper
5. Class II 14 94 in 380 0 mm 15 00 in 381 0 mm bars Make sure that bars are parallel and Class Ill 18 68 in 474 5 mm 18 74 in 476 0 mm ends are flush Grind smooth any protruding Class IV_ 23 44 in 595 5 mm 23 50 in 597 0 mm welds that may affect Sideshifter lower GA0028 eps bearings Repair any damaged notches Recommended Hydraulic Supply The Sideshifter will require one of the hydraulic supply arrangements shown below All hoses and fittings should be at least No 4 with 3 16 in 5 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 Auxiliary Valve Functions Check for compliance with ITA ISO standards Sideshift Left T GA0026 eps RH THINLINE 2 Port Hose Reel Supply Group GA0094 eps Hoist Up Tilt sideshift OR Back Right B mast Single Internal Hose Reeving 5 219941 R8 _ PNSTALLATION 1 Attach overhead hoist Lifting Eye Stamped OR Capacity Weight Eye Bolts Load Center HCG information Stamped Model Serial Number Sticker showing Patents service Phone Numbers 2 DO p SS1063 eps Two Capscrew Hooks 3 Mount Sideshifter on truck carriage ITA Class II 60 66 in 15 17 mm ITA Class III 72 78 in 18 20 mm ITA Class IV 72 78 in 18 20 mm Engage locator tab with center notch ITA Class II 32 36 in
6. 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 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 WARNING Do not operate this attachment unless you are a trained and authorized lift truck driver 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 Cascade F Series Sideshitters It will helo 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 misjudgement You must watch for poorly maintained equipment and hazardous situations and correct them Backrest Upper Hooks Sideshifter Frame Lower Hooks SS0159 eps 219941 R8 PERATION
7. SER MANUAL F Series Sideshifter C ONTENTS Page INTRODUCTION Special Definitions OPERATION Safety Rules 2 Industrial Lift Trucks 2 Handling Loads 3 Sideshifter Operation 3 Safe Operation and Maintenance 4 OSHA Regulations 4 INSTALLATION Truck Requirements E Recommended Hydraulic Supply 5 Installation Procedure 6 PERIODIC MAINTENANCE Daily thru 2000 Hour Maintenance 8 PARTS Recommended Spare Parts 9 Publications 9 Manual Number 219941 R8 Cascade Corporation Cascade is a Registered Trademark of Cascade Corporation NTRODUCTION This user manual is for Cascade F Series Sideshifters It contains an Operation Guide Installation Instructions and Recommended Spare Parts IMPORTANT All hosing and flared fittings on F Series Sideshifters are JIC as standard with face seal as an option NOTE All specifications are shown in Imperial and Metric units where applicable All fasteners have a torque value range 10 of stated value 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 A statement preceded by WARNING is information that should be acted upon to prevent bodily injury A WARNING is always inside a ruled box WARNING
8. agasaki Hyogo Japan 661 0978 Tel 81 6 6420 977 1 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 om Cm TM Cascade Corporation 2012 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 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 Joao 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 04 2012 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 219941 R8
9. ating 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 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 primaril
10. e 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 2000 psi 140 bar Recommended 3500 psi 240 bar Maximum Truck Flow Volume Min 1 GPM 4 L min Recommended Max 2 GPM 3 GPM 7 5 L min 12 L min 55F 65F 100F 120F 1 GPM 4 GPM 5 GPM 150F 165F 4 L min 16 L min 20 L min Cascade F Series Sideshifters are compatible with SAE 10W petroleum base hydraulic fluid meeting Mil Soec MIL O 5606 or MIL O 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 a slow sideshift speed Flow greater than maximum can result in excessive heating reduced system performance and short hydraulic system life GAO095 eps T Carriage Mount Dimension A ITA ISO Minimum Maximum l A ee Carriage Clean and inspect carriage
11. ng set Refer to service manual e Legibility of marking for replacement procedure NOTE Fork Safety Kit 3014162 contains wear calipers inspection sheets and safety poster Also available is fork hook amp carriage wear gauge 209560 Class ll 2000 Hour 209561 Class Ill and 6105257 Class IV 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 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 9 219941 R8 ARTS Recommended Spare Parts Snr 150F UNITSSERVICED _ SERVICED sr esp 100F igor mes eno 2050 PART NO PART NO PART NO PART NO DESCRIPTION aty aty ary Feoaoes 6051249 6051249 6072036 UpperBeerng Composte 8 16 32 Feoaaaee 6052408 6052405 6082297 upper Bearno sore a 8 16 e8547 6067182 6067182 6087162 Lover Bearing Composte 6 12 24 aaeesa 6050041 ose041 6088041 Lower Bearna Brons 4 e 16 Caon zoare costes 6088187 overHook o e wrn oe o ae Peseres LoverHooksearng orouee a 8 16 Pesiert
12. nstall hoses 5 Flush supply hoses Optional Installation Kit 205826 shown for internal reeving GA0046 eps Back Driver s View SS0154 eps 219941 R8 NSTALLATION r Install forks WARNING If the fork locking pin is not fully engaged the fork could become disengaged from the carriage R Install backrest Cascade Backrest a A Tighten to 145 ft lbs 195 Nm For other backrests see OEM ca recommendations L SS0156 eps 219941 R8 Fork Lock Pins SS0914 eps Lubricate lower bearings Lubricate lower bearings with general purpose chassis grease NOTE Upper bearings are prelubed at the Factory with break in grease No lubrication is required during installation Upper bearing l grease fittings I SS0157 eps Lower bearing grease areas E P ERIODIC MAINTENANCE Dai ly WARNING After completing any service Check items shown each day Report problems to your procedure always test the sideshifter supervisor See Service Manual for troubleshooting through five complete cycles First test with maintenance and repair procedures no load then test with a load to make sure the attachment operates correctly before returning it to the job WARNING If the fork locking pin is not fully engaged the fork could become disengaged from the carriage Fork Fork Lock Stops Backrest Pins
13. 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 0 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 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 don
14. vement 219941 R8 6 10 OSHA Regulations Industrial Trucks and Attachments Specific Regulations from OSHA 1910 178 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 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 o 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
15. y for earth moving or over the road hauling 1 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 5i 5ii iii 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 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 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 mo
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