6082563R1 J-Series Integral User Manual
Contents
1. B A Sideshift or Fork Position A Mast Single Internal Reeving Sideshift amp Fork Positioner Non Solenoid B Mast Double Internal Reeving FP1167 eps OR A amp C Single Internal Hose Reeving and RH THINLINE 2 port Hose Reel MI MU Pile Solenoid Adaption on truck TPS nn B Mast Double Internal Reeving B Mast Double Internal Reeving OR on A amp C Single Internal Hose Reeving and RH A amp C Single Internal Hose Reeving and RH THINLINE 2 port Hose Reel TM 2 ae ESSI MORS Heer Solenoid Adaption on attachment Swingshift amp Fork Position A amp C Cable reel with Mast Single Internal Reeving Non Solenoid OR B Mast Double Internal Reeving C 6 N 1 Cable Hose Reel OR Sideshift amp Independent Fork Control A amp C Single Internal Hose Reeving and RH B amp C Single Internal Hose Reeving and THINLINE 2 port Hose Reel RH 6 N 1 Cable Hose Reel Slope Pile amp Fork Position Sideshift amp Swingshift Non Solenoid Non Solenoid B Mast Double Internal Reeving B Mast Double Internal Reeving OR OR A amp C Single Internal Hose Reeving and RH A amp C Single Internal Hose Reeving and RH THINLINE 2 port Hose Reel THINLINE 2 port Hose Reel 6082563 R2 NSTALLATION Truck Requirements Truck Relief Setting 2300 psi 160 bar Recommended 2500 psi 170 bar Maximum Truck Flow Volume Min Recommended Max 15 GPM 25 GPM 35 GPM dens 56 L min 95L min2. 132 L min Cascade J Series Integral attachments are compatible with SAE 10W petroleum base hydraulic fluid meeting Mil Spec fluid is required special seals must be used Contact Cascade Flow less than recommended will result in reduced system performance Flow greater than maximum can result in excessive heating Auxiliary Valve Functions Check for compliance with ANSI ISO standards Sideshifter or Fork Positioner Tilt Forward Open Forks Hoist Pen OR Sideshift Left GAO0387 eps Hoist Up Tilt Back Close Forks OR Sideshift Right Swingshift amp Fork Position Slope Pile amp Fork Position a Left Tilt Forward Slope Pile CCW Hoist Down Open Forks Ae at SALA ar Forks GAO082 eps M Hoist Up Tilt Back Swingshift Right OR Slope Pile CW MIL 0 5606 or MIL 0 2104B Use of synthetic or aqueous base hydraulic fluid is not recommended If fire resistant hydraulic reduced system performance and short hydraulic system life FP1166 eps Sideshift amp Fork Position Sideshift amp Independent Fork Control Sideshift amp Swingshift Sideshift amp Slope Pile Tilt Forward La Hoist Down ri E ia See Lj Adis Open Forks OR Open Left Fork 0R Open Right Fork 0R Swingshift Left 0R Slope Pile CCW E eps a Right Hoist Tilt Back iS Forks OR
3. 6082563 R2 9 10 NSTALLATION Install Forks Use pallets or blocks as necessary to raise forks to installation height Keep feet clear of forks when installing A If equipped remove backrest For reassembly tighten Cascade backrests to 145 ft lbs 195 Nm For other backrests see OEM recommendations B If equipped remove fork shaft retainer capscrews For reassembly tighten capscrews to 50 ft Ibs 65 Nm C Pull the fork shaft out of the attachment enough to install fork into fork carrier D Slide the fork shaft through the fork carrier and fork Check fork shaft and lower frame bar lubrication The fork shaft and lower frame bar is prelubed at the factory with grease No additional lubrication is required during installation NOTE After 300 hours of operation the fork shaft and lower frame bar should be checked for contamination If there is contamination clean fork shaft and lower frame bar Apply chassis grease to the fork shaft and apply chassis grease or Slip Plate or equivalent paint on graphite to the ower frame bar Fork Shaft Retainer Backrest FP1144 eps Fork Shaft HH NI ie li xL npe cai EB Cag l8 FP1183 eps
4. 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 6082563 R2 NSTALLATION Recommended Hydraulic Supply J Series Integral attachments can be operated with any of the hydraulic supply arrangements as shown below Refer to Cascade Hose amp Cable Reel Selection Guide Part No 212199 to select the correct hose reel for the mast and truck Fork Positioning function No 3 hose No 4 fittings with 5 32 in 4 mm minimum ID Sideshifting function No 4 hose No 6 fittings with 3 16 in 5 mm minimum ID
5. Close Left Fork OR Close Right Fork OR Swingshift Right OR Slope Pile CW 6082563 R2 NSTALLATION Attachment Installation dealer responsibility Some of the following steps may or and chains or straps are rated for the weight may not be required but are shown for reference of the attachment Refer to nameplate for Refer to the appropriate OEM Service Manual for service attachment weight and repair procedures IMPORTANT Integral attachment installation is an OEM or WARNING Verify that the overhead hoist Integral attachment carriage and Flush supply hoses additional components should be installed in mast per OEM A Connect supply hoses to supply terminals specifications and procedures and connect together using union fittings as shown B Operate auxiliary valves for 30 sec C Remove union fittings FP1168 eps FP0726 eps NOTE See OEM for installation details on load roller sidethrust roller chain anchor etc Install hoses CAUTION Allow for 6 inches sideshifting movement in each direction rolling hose Forks IN arrangement recommended Some i attachments vary in total sideshift Allow for IN movement in each direction Forks OUT FP1141 eps Sideshift Right Sideshift Left Back Driver s View Sideshifting Fork Positioner shown
6. 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 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 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 7iii 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
7. 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 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 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 This section contains operating instructions for the Cascade J Series Integral attachments It will help you avoid common errors which often cause damage to the equipment or product being handled Backrest This information is intended to simplify operator understanding about effective and safe attachment use and operation Read this information thoroughly Fork before
8. 207 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 cascade cem CTM 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 482 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 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 11 2014 Cascade India Material
9. 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 Part Number 6082563 R2
10. J SE ManuaL J Series Integral Carriages Sideshifter Fork Positioner Sideshifting Fork Positioner Independent Fork Control Swingshift amp Slope Pile Manual Number 6082563 R2 Cascade Corporation un C ONTENTS Page INTRODUCTION 1 Special Definitions 1 OPERATION 1 Safety Rules 2 Industrial Lift Trucks 2 Handling Loads 3 Integral Attachment Operation 4 Daily Inspection 5 Safe Operation and Maintenance 6 OSHA Regulations 6 INSTALLATION 7 Recommended Hydraulic Supply 7 Truck Requirements 8 Auxiliary Valve Functions 8 Attachment Installation 9 INSPECTION amp MAINTENANCE 12 100 Hour Maintenance 12 300 Hour Maintenance 12 1000 Hour Maintenance 12 2000 Hour Maintenance 13 Swing and Slope Attachments 13 Hook Type Fork Positioner Attachments 14 PRODUCT IDENTIFICATION 15 PUBLICATIONS 15 i 6082563 R2 NTRODUCTION This manual is for the Cascade J Series Integral Sideshifter Fork Positioner Sideshift Fork Positioner Independent Fork Control Swingshift and Slope Pile attachments Contents include an Operator s Guide Installation Instructions and Periodic Maintenance 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 Information in this manual is based on general attachments Some functions and features are not shown Contact Cascade for specific information Special Definitions The
11. Lower Frame Bar Front View Sideshifting Fork Positioner shown 6082563 R2 NSTALLATION Cycle Fork Positioner functions e Open and close forks several times Sideshift left and right Check for smoothness and equal movement e Check for operation in accordance with ANSI ISO standards Refer to Integral Attachment Operation on pages 4 and 5 e Check for leaks at fittings valve cylinders 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 cylinder restrictor fittings Loosen jam nuts and screw both flow restrictors in until they bottom Screw each restrictor out counterclockwise three turns B Spread forks fully then close Look for unequal fork movement C On fester fork one that bottoms first screw flow restrictor in clockwise 1 2 turn D Repeat steps B and C until fork movement is equal Tighten jam nuts 6082563 R2 M Slope Pile Right Fork FP1164 eps Swingshift SS0816 eps Fork Positioning Cylinder FP1209 eps A Restrictor Fitting Jam Nut C Flow Restrictor Adjustment Screw 11 uu P ERIODIC MAINTENANCE WARNING After completing any service procedure always test the Fork Positioner Sideshifter through five complete cycles to
12. Top of load Limit truck movement with raised load and sloping with raised load should not extend above backrest En 1 LOAD WEIGHT FP2199 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 NE NTEGRAL ATTACHMENT OPERATION Integral Attachment Operation SIDESHIFT A Sideshift Left B Sideshift Right FORK POSITION A Open Forks B Close Forks Bb A Sideshifl FP2193 eps SIDESHIFT amp FORK POSITION A Sideshift Left B Sideshift Right C Open Forks A Sideshift Left A Sideshift Left B Sideshift Right B Sideshift Right C Swing Left C Slope CCW D Swing Right D Slope CW SIDESHIFT amp INDEPENDENT FORK CONTROL A Sideshift Left B Sideshift Right C Open Left Fork C Open Right Fork Press Knob Button D Close Left Fork D Close Right Fork Press Knob Button AUXILIARY VALVE FUNCTIONS Hoist down Tilt forward D Close Forks C SIDESHIFT amp SWING SIDESHIFT amp SLOPE GA0005 eps Hoist up Tilt Back p wc Slope Pile Swingshift D SS0816 eps E A Sideshift ce P Fork Positi
13. as necessary to clear the road surface 0 Loading 1 p Operation of the Truck 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 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 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
14. hooting and repair procedures Decals for legibility FP1165 eps Backrest Fork Shaft fasteners for tightness Forks for wear Cylinders and hoses for leaks 6082563 R2 5 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 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 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 lateral
15. ly 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 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 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
16. make sure the attachment operates correctly before returning it to the job Fork Shaft Upper Bearing 1 00 Hour Shaft Retainer Every time the lift truck is serviced or every 100 hours enero 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 Check fork shafts for bends damage or wear Replace if bent Consult Cascade if damaged or worn 300 Hour After each 300 hours of truck operation in addition to the 100 hour maintenance perform the following procedures e Tighten Cascade backrest if equipped capscrews to the following torque values M12 Capscrew 75 ft lbs 100 Nm M16 Capscrew 145 ft Ibs 195 Nm FP0736 eps For other backrests see OEM recommendations Sideshift Cyinder Frame Bar Lauer eating e f equipped with zerk fittings apply general purpose Clevis Pin Mounts chassis grease to upper and lower bearings Front View e Inspect frame retainers for wear Replace if necessary Tighten lower frame retainer capscrews to 200 ft Ibs 275 Nm e Inspect fork shaft and front of lower frame bar for grease contamination Remove contaminated grease from fork shaft and lower frame bar Apply a general purpose chassis grease to the fork shaft Apply a general purpose chassis grease or Slip Plate or a Backrest Capscrews pain
17. on Bu Right Fork ca FP1164 eps b Sideshift qo a amp C Left Fork A 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 60825 63 R2 NTEGRAL ATTACHMENT OPERATION SWING OR SLOPE WITH FORK POSITION B dix pef A i m D A Swingshift Left n Slope Pile A Slope Pile CCW L Jl B Swingshift Right ift B Slope Pile CW A swinga B C Open Forks SS0816 eps D Close Forks Ce D AUXILIARY VALVE m FUNCTIONS ic ron Fork Position WARNING Truck control handle and Hoist down Tilt forward A attachment function activation shown WA C here conforms to ASME ANSI B56 1 recommended practices Failure ant to follow these practices may lead 9999 to serious bodily injury or property C damage End user dealer and OEMs Hh BED should review any deviation from the practices for safe operation GA0005 eps a SAS Hoistup Tilt Back uu Daily Inspection Check items shown each day Report problems to your supervisor Refer to Service Manual 6052504 for troubles
18. operating the attachment Be sure you know and understand all operating procedures and safety precautions If you have any questions or don t Cylinder 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 Sideshifler Frame hazardous situations and correct them Integral Carriage Positioner Sideshifter Cylinder P1140 eps Sideshifting Fork Positioner shown Forks 6082563 R2 PERATION Safety Rules Industrial Lift Trucks No riders No reaching through mast No standing under load s Lo aL ee eae RAMPS AS M5 o PS eg 1 No parking on ramp No turning on ramp Watch clearances GA0048 eps MAC TV lt v c dons t Workers Stops J L r o_o TET Sx ges Slow for Sound horn slow Sound horn slow Wet floors Bumps Dips two way traffic at intersection at corner 2 6082563 R2 m PERATION Safety Rules Handling Loads CAUTION Do not put side loads on forks Do not clamp loads 6082563 R2 Center load prior to traveling Raise load prior to sideshifting Limit sideshifting swinging
19. owing defects e Surface cracks Straightness of blade and shank e 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 209561 Class Ill and 6104118 Class IV Swing and Slope Attachments In addition to the previous page maintenance schedule es where applicable the following maintenance procedures a Frame must be completed on swing and slope attachments P Pivot Pins e 300 Hours Apply general purpose chassis grease to pivot pin zerk fittings and cam rollers 1000 Hours Inspect swing and slope frame pivot points for wear 1000 Hours Inspect wedge bearings mechanical swing frame for wear 1000 Hours Inspect swing and slope cylinder pivot pins and clevis pins for wear Replace part as necessary Oylinder Pivot Pins Cam Rollers Bearings 6082563 R2 P Hook Type Fork Positioner 14 Attachments In addition to the previous page maintenance schedule where applicable the following m procedures must be completed on hook typ positioner attachments aintenance e fork e 300 Hours Apply general purpose chassis grease to fork carrier bearings e 300 Hours Tighten capscrews as follows Fork Posi
20. t on graphite equivalent to the lower frame bar if equipped 1000 Hour After each 1000 hours of truck operation in addition to the 100 and 300 hour maintenance perform the following procedures e Inspect sideshift upper and lower bearings for wear If the frame is rubbing the carriage or lower bearing capscrews replace the entire bearing set Refer to Service Manual 6052504 for repair procedures e Inspect sideshift cylinder pivot pins and clevis pins for wear Replace part as necessary e Inspect fork position cylinder anchor nuts for wear ei N o S d S FP1218 eps Replace if necessary NOTE Anchors operate with a loose clearance Fork Positioner e Tighten lower bearing capscrews to 200 ft Ibs 270 Nm Cylinderanchors End en Tighten fork shaft retainers capscrews if equipped to E 49 ft Ibs 66 Nm i A Back Driver s View 12 6082563 R2 Hu 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 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 foll
21. tion Cylinder Lug 15 ft Fork Pad 500 ft lbs 678 Nm Fork Carrier 28 ft Ibs 38 Nm NOTE Apply Loctite 242 to Fork Position Lug and Fork Pad capscrews e 300 Hours Apply general purpose cha or Slip Plate or a paint on graphite equ the fork slider bars bs 20 Nm Oylinder ssis grease ivalent to ERIODIC MAINTENANCE x Fork Slider Bars Lower Fork Carrier Bearings ZA ENS Q Upper Fork Carrier Bearings Fork Position Cylinder Lug Capscrews Fork Carrier Capscrews FP1212 eps Fork Pad Capscrews 6082563 R2 m P RODUCT IDENTIFICATION The product model number and serial number can be found on the nameplate located on the top left surface of the attachment Refer to the nameplate for ordering replacement parts Nameplate o FP1147 eps Back Driver s View Sideshifting Fork Positioner shown p UBLICATIONS cascade PART NO DESCRIPTION and Order Form 6082563 User Manual 6052504 Integral Carriage Service Manual 679929 Tool Catalog 673964 Literature Order Form aa GA0098 eps 6082563 R2 15 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 8
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