6800543R1_55A False Carriage User Manual
Contents
1. FORK POSTIONER RATS SERVICED E s em 20 0 PART NO DESCRIPTION am a ar See Ginder Savin Kt s see Bearing Service RECT SESS Bearing Senica Ki Brones T3 seg Moning Shine EE TORS Fork Siop WIE A peta Publications PART NO DESCRIPTION STU Tool Catalog Se erase Order Far 6800543 R1 Blank 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 Cascade Canada Inc Cascade do Brasil U S Headquarters 5570 Timberlea Blvd Fua Jogo Guerra 134 2201 NE 201st Mississauga Ontario Macuco Santos SP Fairview OR 97024 9718 Canada LAW 4M6 Brasil 11015 130 Tel 800 CASCADE 227 2293 905 629 7777 Tel 5 13 2105 8800 Fax 888 329 8207 Fax 905 629 7785 Fax 55 13 2105 8899 EUROPE AFRICA Cascade Italia S R L Cascade Africa Pty Ltd European Headquarters Box 625 Isando 1600 Via DelrArtigianato 1 60 Stoel Road 37050 Vago di Lavagno VR Sparton Kempton Park South Tel 39 045 8989111 Tel 27 11 975 9240 Fax 39 045 8989160 Fax 27 11 394 1147 ASIA PACIFIC Cascade Japan Ltd Cascade Korea Cascade Xiamen Cascade India Material 2 23 2 Chome 121 9L Namdong Ind No 668 Yangguang Rd Handling Private Limited Kukuchi Nishimachi Complex 691 8 Gojan Dong Xinyang Industria2. Back Driver s View FORK LOWER HOOKS CARRIAGE Wear Gauge UPPER CARRIAGE BAR e FORK UPPER HOOKS 6800543 R1 P ERIODIC MAINTENANCE Check tems shown each day Report problems to your procedure always test the Fork Positioner Supervisor See Service Manual for troubleshooting Through five complete cycles to make sure maintenance and repair procedures the attachment operates correctly before returning to the job 100 Hour Every ime the If truck is serviced or every 100 hours of tuck operation whichever comes frst completa the folowing maintenance procedures Chock for loose or missing capscrews wom or damaged hoses and hydraulic Inspectiowor hooks for wear and propor clearance Adjust otk Positioner Tee Sindara ana Tighten fork postioner mounting flange to a equipped torque of 50 ft lbs 65 Nm Tighten fork carrer capscrews to a torque of 25 ft lbs 35 Daily A WARNING Afer completing any service Fork Positioner Mounting Flange Tighten fork postioner cylinder rod anchor plugs to a torque Capsorews cf 50 fs 65 Nm Outside trame Tighten lower hook capscrews to 120 ft lbs 165 Nm Falso Carriages Tighten lower fork stop to 25 fts 35 ne 300 Hour Mer cach 300 hours ot ruck operation in addtion tothe 00 hour maintenance ne folowing procedures Tighten
3. U SER MANUAL 55A False Carriage False Carriage amp Fork Postioner Manual Number 6800543 R1 cascade corporation Casen i eget denk d Cascade Cra C ONTENTS INTRODUCTION Special Dees 1 OPERATION T Safely Rules 2 hdura LR Trucks 2 Handing Loads 3 Fork Position amp Sideshift Operation 3 Safe Operation and Maintenance 4 TRUCK REQUIREMENTS 5 HYDRAULIC SUPPLY INSTALLATION 7 PERIODIC MAINTENANCE Daly T TOO Hour Maintenance S00 Hour Maintenance 11 TO00 Hour Maintenance 2000 Hour Maintenance PARTS Recommended Spare Parts 12 Publications 12 i 6800543 R1 NTRODUCTION 1 This User Manual is for the Cascade 55A False Carriage or Fork Positioner Contents include an Operators Guide Installation Instructions Periodic Maintainence and Parts Manual All specifications are shown in U S and Metric units where applicable IMPORTANT The 55A attachment 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 additional information of special significance or to make the job easier WARNING A statement preceded by WARNING is information that should be WARNING Rated capacity of the truck attachment combination is a
4. 6800543 R1 Truck Carriage OR Integral Sideshifter 0 PERATION Safety Rules Industrial Lift Trucks No riders No reaching through mast No standing under load No parking on ramp No turning on ramp TRAFFIC ER lt gt Observe gt MT H o o lt lt m Slow for Sound hom slow Sound horn slow Wet floors Bumps two way tratic at intersection at comer 2 6800543 R1 0 PERATION Safety Rules Handling Loads Limit sideshining Top of load with raised load should not extend above backrest 1 CAUTION Do not put side loads on forks I EN QU Limit truck movement e with raised toad Load weight must not exceed combined ruckattachment capacity see truck nameplate Raise load prior to sideshifting Total fork capacity LH RH fork must be greater than load weight Check capacity stamp on forks Fork Position amp Sideshift Operation AUXILIARY VALVE SIDESHIFTING SIDESHIFTING amp FUNCTIONS A Sideshit Lot FORK POSITIONING B Sideshitt Right A Sideshift Left Sideshit Right C Spread Forks D Close Forks Holst down Tit forward Jac HER E aa Hoist up Tit Back 6800543 R1 3 AFE OPERATION AND MAINTENANCE OSHA Regulations Industrial Trucks and Attachments Specific Regulations from OSHA 1910 178 Industria trucks is regula
5. It equipped Back Rights 6800543 R1 5 RES H YDRAULIC SUPPLY FORK POSITIONERS Fork Positioning function No 3 hose No 4 fitings with 5 82 in 4 mm minimum LD Fork Positioning Mast Single internal Reeving 6800543 R1 1 NSTALLATION 1 Attach overhead hoist 2 Lower hooks A Remove bolt on lower hooks OR B Pull pin to lower quick disconnect hooks Install pin in lower hole WARNING Make sure overhead hoist has a rated capacity of at least 1000 Ibs 450 ka Liting eye on frame lt Quick Daconnect Lower Hooks Back Drivers Views 3 Mount unit on truck carriage 60 60 in 15 17 mm 72 78 n 1820 mm Engage locator tab nderit Center natch 30 43 in 10 11 mm Truck Upper Cartage Bar Install lower hooks BOLT ON QUICK DISCONNECT Reverse guides to reduce VE Fake Cariage L J F Clearance Bw Tht against lower SE aa gt mar JEE santem Q P gens I Cams EPA Tighten capscrews to 120 tbe 165 Nm Slearance 165 Nm 6800543 R1 7 1 7 Fork Positioner Install forks NSTALLATION CAUTION if installed on a sideshifter allow for 4 in 100 mm movement in each direction for sideshifting roling hose arrangement recommended Install hoses Fork Positioner Flush supply hoses Connect supply hoses to supply terminals and connect toget
6. backrest capscrows Cascade to 145 ibs 195 e Apply general purpose chassis grease to fork carrier grease WA Apply graphite dry iube to fork carriage bars as required Slip Plate Aerosol GraphoKote or equivalent Lubrication Points 1000 Hour Afer cach 1000 hours of tuck operan in addition to the 100 and 300 hour maintenance perform tho cloning procedures Inspect fork carers for looseness on bearing tubes and od anchors for excessiva end play oo Service Manual for repair procedures NOTE Gyindor rod anchors operate with loose clearance 2000 Hour After 2000 hours of tuck operation in addon to the 100 300 and 000 our maintenance forks h use shal be inspected Zeen ol not more 12 mons single hit Operations or whenever any defect EH ic detected Severe applicators wil require more frequent Fork inspection shal be cared out by trained personnel to detect any damage that might impair safe use Any fork that is doloctue shal be removed om serce Rooronce ANSI dict d Z Sagnresofbadeandshak Waw trk blado andshane NOTE Fa Selly 062 1 ses Ma onthe repeater emt lt Diforenco in height of fork tips Legib lty of marking gauge 209580 Class II and 209561 Class 6800543 R1 11 ARTS Recommended Spare Parts
7. examinallon shows any condition adversely affecting the safety of he vehicle Such examinations shall be made at least daly When industrial trucks are used a round he ciock basis hey shall bo examined atr each shift Defects when found shal be immediately reported and ect 6800543 R1 RUCK REQUIREMENTS FORK POSITIONERS Truck Relief Setting 2200 psi 152 bar Recommended 3500 psi 241 bar Maximum Truck Flow Volume Min Recom Max 1GPM 2GPM 3GPM Umi 75Umin I2Umi Cascade 55A Fork Poallioners are compatible with SAE 10W Petroleum base er L02049 Uz or met pr aqueous basa yea ud i nat recommended fire resistant hyoraule fud is requ specia seale must bo used Contact Cascade Flow less than recommended wil in slow fork positioning Speed 3 Flow greater than maximum can result in excessive heating reduced system performance and short hydraulic system le i Carriage Mount Dimension A ITA ISO A Minimum Maximum Carriage Ciean and inspect cariage A tss Assure tat bars are paralel and tat e I 14 94 in 380 0 mm 15 00 in 381 0 mm ends are flush Grind smooth any protruding us that may afectSidectfer tower bearings Repair any damaged notches Auxiliary Valve Functions Check for compliance with TTA ISO standards Sideshitt Lete Spread Forks Host p Close Forks Tit Sideshit
8. ft and right Check for Smoothness and equal movement Check for operation in accordance with ITA ISO standards Check for leaks at fittings valve cylinders SIDESHIFTING amp FORK POSITIONING Sideshitt Left Sideshit Right SIDESHIFTING C Spread Forks A Sideshit Loft D Close Forks B Sideshift Right 6800543 R1 9 1 12 13 10 NSTALLATION Fork Positioner Adjust forks for equal movement if required NOTE Attachment is Factory adjusted for equal fork movement when operated at recommended pressure and flow rate Locate flow restrictrs at each end Loosen jam nuts and screw both flow restrictors in until they bottom Screw each restrictor out CCW three turns Open forks fully then close Look for unequal fork movement faster fork one that bottoms first screw flow restrictor in CW 1 2 tum Repeat Steps B and C until fork movement is equal Tighten jam nuts Inspect fork hooks carriage bar clearance NOTE Use go no go Wear Gauge Part No 209560 Class Il or 209561 Class II A inspect the fork lower hooks and carriage bar Vie gauge fts between the carriage bar and lower hook repair or replacement is needed inspect the upper carriage bar Ifthe gauge arrow touches the carriage bar repair replacement is needed inspect the fork upper hooks If the gauge arrow touches the hook repair or replacement is needed Flow ege each side
9. her using close OPEN a union fiting as shown Forks fos Operate auxiliary valve for 30 sec Remove union fiting Back Drivers View Fork Carrier Imer Retainer Remove capscrows and fork carrier inner retainer sections B Install forks using a pallet or blocks Keep feet clear of forks Reinstall fork carrier inner retainer sections and tighten capscrews to 25 ft lbs 35 Nm NOTE Soo illustration below to position inner retainers for various fork widths A Wide inner Retainer Wide inner Retainer 05230 Outer Retainer wiSpacor Bar 5052316 LT ORS xem Fem oss Retainer Degrees y 6042443 e 6800543 R1 zi 1 NSTALLATION 8 False Carriage Install forks 9 Install backrest Cascade Backrest Totton to Remove tork stop capscrow 185 Nm For other to Insta fo Backrests sos OEM Doch glen to 25 ft lb lt S recommendations 35 Nm Lubrication Fork Positioners prelubed at the Factory and requires no lubrication for installation Use graphite dry lube for fork bars as required Slip Plato Aerosol GraphoKote or equivalent After use lubricate fork positioner as described in Periodic Maintenance Section in this Manual AUXILIARY VALVE FUNCTIONS Open and close forks several times Sideshift 1 1 Cycle Fork Positioner functions f equipped le
10. l Zone No 34 Global Trade Centre Amagasaki Hyogo Namdong Ku Haicang Xiamen City 1 1 Rambaugh Colony Japan 661 0978 Inchon Korea Fujian Province Lal Bahadur Shastri Road Tel 81 6 6420 9771 Tel 82 32 821 2051 PR China 361026 Navi Path Pune 411030 Fax 81 6 64209777 Fax 482 32 821 2058 Tel 86 592 651 2500 Maharashtra India Fax 86 592 851 2571 Phone 491 020 2432 5490 Fax 491 020 2433 0881 Cascade Australia Ply Ltd Cascade New Zealand Sunstream Industries 1446 Ipswich Road 15 Ra Ora Drive Pto Lid Flocklea QLD 4107 East Tamaki Auckland 18 Tuas South Street 5 Australia New Zealand Singapore 637798 Tel 1 800 227 223 Tel 64 9 273 9136 Tol 65 6795 7555 Fax 61 7 33737333 Fax 64 9 278 9137 Fax 65 6863 1368 Ea Cascade Corporation 2009 12 2009 Part Number 6800543 R1
11. nts for powered instil tucks estab chad in he marcan National Standard for Powered Industral Trucks Part II ANSI 66 1 except for vohicles intended primariy for earth moving or over the road hauling Operator Training Only rained and authorized operators shal be to operat a powered industrial tuck Methods shal be devised to train operators in he salo operato of powered tucks m Truck Operations 1 Trucks shal not bo driven up to anyone standing In front of a bench or other xed abject 2 No person shall be alowed to stand or pass under the elevated partan of any tuck whether loaded or amay 8 Unauthorized personal sha not be permitied to ide on powered induct l trucks A safe piace to ride shall be provided where rid ing of trucks is authorized 4 The employer shal prohibit ams or logs from being placed be ho uprights ol he mast or outside the running Ines of the ck 8 When a powered industrial ruck let unattended load engaging means shall be lowered cont shall be neutralized power hal bo shut off and brakes set Whos shal ba blocked If he racks parked on an 80 powered Industral ruck is unattended when the operator is 25 foot or more away fom tho vehicle which remains n hie view or whenever the operator leaves the vehicle and is not in his ev 68 When the operator af an industrial truck s mounted and within 25 feat of ha tuck sl in Ne view he engaging means
12. o stabilize bet 6 Exam care shal bo used when titing te load forward or backward particulary when high itg forward with bad engaging means elevated shall be prohibited except lo pick up a load An elevate load shal not be ited forward except when the load is n a deposit poston ove a rack or stack When stack Ing o tering only enough backward it to stabilize the bad shall be uted p Operation of the Truck 1 tf at any ime a powered instal truck ls found 1o bo nod of repal defective orn any way unsafe he tuck shal be taken out qf service unti thas been restored lo sale operating a Maintenance of Industrial Trucks 4 Any poworoperaled Industral ruck not in sale operating condition shall be removed from serce Al pais shall be made by authorized personnel All parts of any such industrial tuck requiring replacement shall be replaced by paris equivalent as to safety wih those used Inthe original design 6 industrial tucks shal not bo altered so that the eave positione of he various parts aro diferent rom what they were when originally rected fom he manufacturer shall hay be altered aer by the addon of exa parts not provided by the manutac turer or by the elimination d any parts Additonal counterweight ing ot Tork tucks shal not be done unless approved by the ruck manufacturer 7 Industral tucks shal be examined baloro being placed in service and shall not be placed service it he
13. responsibilty of the original truck manufacturer and may be less than shown on tho attachment nameplate Consult the tuck nameplate WARNING Do not operate this attachment unless you are a trained and authorized lift truck driver acted upon to prevent bodily Injury 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 0 PERATION This Section contains operating instructions for the Cascade 55A False Carraige or Fork Positioner It wil help 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 Fork Fork Positioner and Sideshifter use and operation Read False this information thoroughly before operating the Carriage Attachment Be sure you know and understand all operating procedures and safety precautions Ifyou have any questions or dont understand a Fark procedure ask your supervisor Positioner Emphasize Safety Most accidents are caused by operator carelessness or misjudgement You must watch for poorly maintained equipment and hazardous situations and correct them
14. shal be fly lowered contis outalzed and Ine brakes set to Prevent movement 6 A sale distance shall be maintained trom the edge of ramps or Platforms while on any dock or platform or freight car Trucs shall not be used for opening or closing freight doors 10 load backrest extension shal be used whenever necessary to Minimize the paslbaty of the load or part of it from taling rear ward 0 Traveling 4 The driver shal bo required to slow down and sound the horn at cross isles and other locations where vision obstructed II ho load beng obstructs forward view ha driver shall bo required o rave wih tn load waling 7 When ascending or descending grades in excess f 10 percent loaded tucks shal be driven wih e load upgrade T8 On al grades the kad and load engaging means shall bo tited back appscabo and raised as far as necessary to clear ho road surface 6 Loading 1 Oniy sable or safely arranged loads shall be handled Caulon shall bo exercised when handing aflcenter leads which cannot bo centered 2 Orly loads within the rated capacity of the ruck shall handled 8 The long or high including muliple iered loads which may affect capac y shall be adjusted 4 Trucks equipped wit attachments shall be operat as partlaly loaded truck when not handing a cad 6 A load engaging means shal be placed under the load as far as possibla ine mast shall be ch ted backward t
15. ted by Occupational Safety and Health OSHA regulations 1910 178 and Ameri can National Standards Institute ANSI Safety Stan dard for Powered Industrial Trucks ANSI B56 1 When operating and maintaining industria tucks equipped with attachments you should pay particular attention to the folowing sections ofthese regulations You should bo familar with all sections of hese regulations Ask your employer for the complete regulations WARNING Tha safe operation and maintenance of a General Requirement 4 Modifications and adders which affect capacity and safe poration shal be performed by to customer or user wihout manufactures prior writen approval Capacity operation and maintenance instruction plates tags or decals shall be changed according the truck is equipped wih front end attachments other than factory installed attachment ho user shall request hal he tuck be marked to idanty he attachments and show tho appropri ate weight of he truck and atachmert combination at maximam vation win load lateral centered 6 The user shall see that al nameplates and markings ara place and maintained in a legible coin e Safety Guards 2 ihe ype of bad prosents a hazard tha usar shall fork true with a vertical ead backrest extension n accordance wih a2 folowing a2 Al naw powered industrial ruck acquired and used by an employer ater Februar 15 1972 shal meet the design and construction raqureme
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