User Manual
Contents
1. GAO098 ill 13 Contacting Cascade Users Cascade product literature service literature parts and videos are available through authorized lift truck dealers To find the dealer nearest you contact North America South America Europe Cascade Corporation Cascade N V U S Headquarters European Headquarters 2201 NE 201st P O Box 3009 Fairview OR 97024 9718 1300 El Almere Tel 800 CASCADE 227 2233 Damsluisweg 56 503 669 6300 1332 ED Almere Fax 888 329 8207 The Netherlands Tel 31 36 549291 1 Fax 31 36 5492964 Lift Truck Dealers To order parts service literature or videos North America South America Cascade Parts Sales 2501 Sheridan Ave Springfield OH 45505 Tel 888 CASCADE 227 2233 Fax 888 329 0234 cascade cM Cascade Corporation 2001 12 2001 Part Number 6014809 R 12. 2 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 3 The long or high including multiple tiered loads which may 4 5 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 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 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
3. B U SER MANUAL C Series Integral Sideshifter Manual Number 6014809 R 1 cascade Cascade is a Registered Trademark of Cascade Corporation Q ONTENTS Page INTRODUCTION Special Definitions OPERATION Safety Rules Industrial Lift Trucks Handling Loads Integral Sideshifter Operation Safe Operation and Maintenance OSHA Regulations INSTALLATION Truck Requirements Recommended Hydraulic Supply Installation Procedure INSPECTION amp MAINTENANCE Daily 100 Hour Maintenance 300 Hour Maintenance 1000 Hour Maintenance PARTS Product Identification 9 Base Unit 10 Cylinder Assembly Backrest 12 Recommended Spares Publications 13 N On TOE SE See tee NO O O O O 0 NTRODUCTION This User Manual is for Cascade Integral Sideshifters It contains an Operation Guide Installation Instructions and Parts Manual All specifications are shown in U S and Metric units where applicable IMPORTANT Cylinder ports are 6 SAE O Ring 5625 in dia 18UNF 2B 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 acte
4. Cylinder and hoses Fork Stops Forks Fasteners Lower Hooks SS0386 ill 1000 Hour After each 1000 hours of truck operation in addition to the 100 and 300 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 see Service Manual Inspect forks if equipped for wear NOTE Fork Safety Kit 3014162 is available containing wear calipers inspection sheets and safety poster Also available are fork hook amp carriage wear gauges 209560 CL II and 209561 CL III WARNING For the safety of yourself and others DO NOT install the parts shown in this Manual unless you have thoroughly reviewed the appropriate Service Manual A Sticker showing patent numbers phone numbers for service tip Stamped frame a Stamped cylinder assembly part number LH topside _ ba nu part number Tl N SS0361 ill Back Driver s View 6014809 Rev 1 10 ARTS Base Unit Optional Solid Link Kit 6020173 ac Replaces cylinder if using sideshifting
5. Cylinder Sideshifter Backrest Carriage SS0380 ill Forks 6014809 Rev 1 PERATION Safety Rules Industrial Lift Trucks No riders No reaching through mast No standing under load NY AE wy to of yap AA m HR r Traveling Motor off park lower load empty te e O M k No parking on ramp No turning on ramp Watch clearances GA0048 ill Observe Workers o _I L 4 3 0 0 Ig r w Slow for Sound horn slow Sound horn slow Wet floors Bumps Dips two way traffic at intersection at corner 6014809 Rev 1 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 Limit sideshifting with raised load Limit truck movement with raised load Top of load Should not extend above backrest ae LOAD WEIGHT FP0017 ill 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 AUXILIARY VALVE FUNCTIONS Hoist down Tilt forward GAO010 ill l Hoistup Tilt Bac
6. 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 6014809 Rev 1 6 A safe distance shall be maintained from the edge of ramps or 10 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 7i When ascending or descending grades in excess of 10 percent loaded trucks shall be driven with the load upgrade 7iii 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
7. 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 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
8. 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 manufac turer 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 NSTALLATION Truck Requirements Truck Relief Setting 2000 psi 140 bar Recommended 3500 psi 240 bar Maximum Truck Flow Volume Min 2 Recommended Max 1 GPM 2 GPM 3 GPM 39C 4 L min 7 5 L min 12 L min E 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 re
9. 0 2 683822 Lockwasher M12 21 1 768825 Center Capscrew M12 x 1 75 22 1 678991 Lockwasher High Collar M12 1 D Hydraulic Guard Solid optional 23 1 D Hydraulic Guard Mesh optional 4 4057 Capscrew FH Solid Guard ee 4 643511 Capscrew Hex Mesh Guard 25 4 6229 Washer 26 4 228818 Jam Nut 27 1 6020156 Solid Link optional f Carriage needs replacing order complete Sideshifter Assembly Order part number stamped on frame See Cylinder page for parts breakdown Included in Lower Hook Service Kit 6018267 Included in Solid Link Kit 6020173 Quantity as required Included in Pallet Guard Kit 6018250 Order part number stamped on Hydraulic Guard 7 pPdormx Reference SK 7069 11 12 ARTS Cylinder Assembly Backrest S0368 ill Front View 7 Stamped Part Number Cylinder Assembly SS0383 ill Front View 55C REF QTY PART NO DESCRIPTION 1 1 Cylinder Assembly 2 2 562132 Rod Seal 3 2 415866 O Ring 70 Duro 4 2 562131 Rod Wiper Seal 5 2 6017490 Retainer Seal Carrier Assembly 6 E Rod Piston Assembly 7 _ E Cylinder Shell 2 6016592 Clevis Pin e 2 6016912 Hairpin Cotter x v 6016591 Shim Cylinder x Refer to part number stamped on cylinder top Included in Rod Seal Service Kit 6019928 Preloaded in Retainer Seal Carrier Assembly 6017490 E Not se
10. attachment ee S0420 ill Optional Center Capscrew a S0423 ill S0418 ill Optional Pallet Guard Kit 6018250 D he X SP S0422 ill Optional Hydraulics Guard Stamped Part Number S0421 ill 6014809 Rev 1 ARTS Base Unit 6014809 Rev 1 55C REF QTY PART NO DESCRIPTION 1 1 o nner Carriage Weldment 2 8508374 Upper Bearing Composite 2 8509289 Upper Bearing Bronze optional 2 8508376 Lower Bearing Composite 3 2 8509290 Lower Bearing Bronze optional 4 1 x Frame Weldment 5 1 E Cylinder Assembly 6 2 8508373 Lower Hook 7 4 667225 Washer HD M16 8 2 7403 Grease Fitting 2 601676 Fitting 90 6 6 2 207304 Fitting 90 Long 6 6 2 667222 Fitting 90 5 6 9 2 666984 Fitting 90 4 6 2 604511 Fitting STR 6 6 2 211807 Fitting 90 Face Seal 4 6 2 220832 Fitting STR Face Seal 4 6 10 1 769050 Roll Pin x11 4 684295 Capscrew M16 x 2 12 2 6016592 Clevis Pin 13 2 6016912 Hairpin Cotter o14 Vv 6016591 Shim Cylinder 2 221733 Flow Restrictor 1 5 mm 15 2 206488 Flow Restrictor 1 32 mm 2 209648 Flow Restrictor 1 27 mm 16 2 221906 Safety Decal 17 1 219400 Fork Stop Kit includes 2 stops A18 1 6018251 Pallet Guard A119 2 768557 Capscrew M12 x 1 75 42
11. d 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 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 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 under standing 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 precau tions 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 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
12. iew Lower Hook 2 Tighten bolts to 120 ft lbs 165 Nm Clearance 1 32 in 0 8 mm Min 1 16 in 1 6 mm Max Sideshifting ea Frame gt FRONT SS0365 ill Flush supply hoses 4 Connect hoses Union Fitting Sideshift LEFT Sideshift RIGHT GA0171 il 6014809 Rev 1 Front View NSTALLATION Install forks Install backrest Use blocks as necessary to raise forks to installation height Keep feet clear of forks when installing Cascade Backrest a Tighten to 145 ft Ibs 195 Nm For other NN backrests see OEM oe S03839 ill SS0388 ill recommendations Check Sideshifter bearing lubrication Upper bearing grease fittings Bearings are prelubed at the Factory with break in grease No additional lubrication is required during installation NOTE After 300 hours of operation sideshifter bearings should be lubricated with general purpose lithium based chassis grease SS0382 il Lower bearing grease areas Front View 8 6014809 Rev 1 P NSPECTION amp MAINTENANCE WARNING After completing any service procedure always test the Integral Sideshifter through five complete cycles First test with no load then test with a load to make s
13. k SIDESHIFTING A Sideshift Left B Sideshift Right B 4 S0367 ill 6014809 Rev 1 AFE OPERATION AND MAINTENANCE OSHA Regulations Industrial 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 Ameri can 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 laterally centered 6 The user shall see that all nameplates and markings are in
14. quired special seals may be required Contact Cascade Flow less than recommended will result in slow sideshift speed Flow greater than maximum can result in excessive heating reduced system performance and reduced hydraulic system life GA0158 ill Auxiliary Valve Functions Check for compliance with ITA ISO standards Tilt Forward Sideshift Left Hoist Down Recommended Hydraulic Supply The Integral Sideshifter requires the hydraulic supply ar Hoist Up Tilt Sideshift rangement shown below All hoses and fittings should be at least No 6 with 9 32 in 7 mm minimum I D GA0094 ill Back Right GA0157 ill 6 6014809 Rev 1 NSTALLATION Installation Procedure IMPORTANT Integral Attachment installation is an OEM or dealer responsiblity 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 installed in mast per OEM specifica 1 Integral Sideshifter carriage should be tions and procedures a S0387 ill Check lower hook clearance amp i Mast Carriage xN Front V
15. rviceable order new Cylinder Assembly Not shown see Base Unit page for illustration V Quantity as required 55C Backrest Height 36 in 48 in 60 in 91 5 cm 122 cm 152 5 cm REF QTY PART NO PART NO PART NO DESCRIPTION 1 1 684769 684770 684771 Backrest 31 in 78 7 cm Width 1 1 684772 684773 684774 Backrest 37 in 94 cm Width 1 1 684775 684776 684777 Backrest 41 in 104 cm Width 1 1 684778 684779 684780 Backrest 49 in 124 5 cm Width 1 1 684781 684782 684783 Backrest 61 in 155 cm Width 2 4 200173 Capscrew M16x2 x 35 3 4 684586 Lockwasher M16 Reference S 3370 Ig SS0198 ill 6014809 Rev 1 ARTS Recommended Spare Parts Publications 55C UNITS SERVICED PART NUMBER DESCRIPTION 1 5 6 19 20 50 BASE UNIT AND MOUNTING 8508374 Upper Bearing Composite 8 16 32 8508376 Lower Bearing Composite 6 12 24 8508373 Lower Hook 0 2 4 684295 Capscrew M16 x 2 0 4 8 667225 Washer HD M16 0 4 8 CYLINDER 6020048 Cylinder Assembly 0 0 1 6019928 Rod Seal Service Kit 1 2 4 6014809 Rev 1 Integral Sideshifter PART NO cascade Service Literature Index and Order Form DESCRIPTION 6014809 User Manual Operation Installation Parts 6020275 Service Manual 679929 Tool Catalog 673964 Literature Index Order Form
16. ure the Sideshifter operates correctly before returning it to the job Backrest Daily Check items shown each day Report problems to your supervisor See Service Manual for troubleshooting maintenance and repair procedures NOTE Carriage should be maintained per OEM service specifications 100 Hour Every time the lift truck is serviced or every 100 hours of truck operation whichever comes first complete the following maintenance procedures Check for loose or missing bolts worn or damaged hoses hydraulic leaks and damaged or missing fork stops Inspect lower hooks for wear and proper clearance Adjust if necessary see Step 2 Installation Tighten lower hook capscrews to 120 ft lbs 165 Nm 300 Hour After each 300 hours of truck operation in addition to the 100 hour maintenance perform the following procedures Tighten Cascade backrest capscrews to 145 ft lbs 195 Nm Lubricate Sideshifter upper and lower bearings with general purpose lithium based chassis grease ARTS Product Identification This Section shows replacement parts for Integral Sideshifters The product model number and serial number are stamped on the inside surface of the RH vertical sideplate driver s view and must be provided when ordering replacement parts The cylinder assembly part number is stamped on the LH topside driver s view Stamped model number serial number specifications
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