A-Series Fork Positioner/ Sideshifter Manual Number 1849482-R2 cascade. corporation ‘Cazador Tadonte Catease CrpeaionONTENTS -C Page INTRODUCTION Special Definitions 7 OPERATION Safety Puls 2 Industrial Lift Tucks 2 Handling Loads 3 Sideshitter Operation 3 Safe Operation and Mainienancs 4 ‘TRUCK REQUIREMENTS 5 HYDRAULIC SUPPLY 6 INSTALLATION 7 PERIODIC MAINTENANCE Dail 3 100-Hour Maintenance 3 300-Hour Maintenance 13 1000-Hour Maintenance 13 2000-Hour Maintenance 4 PARTS Recommended Spare Paris 15 Publications 15 NTRODUCTION ‘This user manual is for the Cascade A-Series Fork Positioner/Sideshifter. Contents include an Operator's Guide, Installation Instructions, Periodic Maintenance and Perts Manual Foik postoner nameplate with stariped model number, serial number, part number and spectications Sideshiter stamped mode! number, serial number, ‘customer pert number Sy NOTE: All specifications are shown in US. and (Metric) units where applicable, All fasteners have a torque value range of 10% o! stated value IMPORTANT: Series Fork PosiionerSideshiter is metic. Supply fitings adepted as required for application. Slicker showing patent ‘numbers, phone ‘numbers for sorvico ‘Stamped capacity, ‘weigh, horizontal CG 1849482-R2al | NTRODUCTION Special Definitions The statements shown appeer throughout this Manual where spacial emphasis is required. Read all WARNINGS and CAUTIONS before proceeding with any work. sare aeaer a OHTENT ONT oe Ponds Wann: Ries capciy of tect as additional information of special significance or to make fe olert RaEe waradecuiey td ie tebboae be less than shown on the attachment nameplate, Consult the truck nameplate. WARNING: Do not operate this attachment Unless you are a trained and authorised if tnuck driver. WARNING ~ A statement preceded by A 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. a 0 PERATION This Section contains operating instructions for the Cascade A-Series Fork Postioner/Sideshifter. It will help You avoid common errors which often cause damage 10 the equipment or product being handled. Frame / Backrest This information is intended to simply operator Understanding about effective and safe Fork Postioner/ Sideshitter 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. Valve Emphasise Safety! Nost accidents are caused by Fork Cores operator carelessness or misjudgoment. You must watch for poorly maintained equipment and hazardous situations and correct them. Cylinders / Bearing Ways 1849482-R2 10 pPERA TION = i Safety Rules — Industrial Lift Trucks No riders ‘No reaching through mast ‘No standing under load ‘No parking on ramp ‘No turning on ramp Watch clearances TRAFFIC _— <= ote = i. es a ~~ Nae — Slow for Sound horn, slow | Sound horn, slow Wet floors Bumps Dips two-way tratic | at intersection | at comer 2 1849482-R2: 0 PERATION Safety Rules —- Handling Loads Limit sideshitting with raised load. » he ji ee i Load weight must not exceed combined truck/attachment capacity (see truck nameplate). Raise load prior to sideshting. Total fork capacity (LH + RH fork) must e greater than load weight. Fork Positioner/Sideshifter Operation heck capacity stamp on forks. ‘AUXILIARY VALVE WARNING: Truck contro! handle and attachment FUNCTIONS A function activation shown here conforms to ASME/ANSI B56.1 recommended practices. Holet down Tit forward 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 1849482-R2 3AFE OPERATION AND MAINTENANCE OSHA Regulations - Industrial Trucks and Attachments (Specitic Regulations from OSHA 1910.178) WARNING: The sate operation and maintenance of A ‘neal uct rept by Osoupaton Say and Heaith (OSHA) regulations 1910.178 and Amex Can National Standards Inettute (ANS!) Safety Sta- ard for Powered Industrial Trucks, ANSI BS6.1. When operating and maintaining indusial trucks equipped wih attachments you shoul pay particular attention fo te folowing sections of these regulations. You shouldbe familar with all sections ofthese regulations. Ask your employer for the complete regulations. (2) General Requirement (6) Nocictions and addons which fect capacty and sale ‘operation shal nt be performed bythe customer or use witout maruiaciurers prior wnten approval. Capacity operation and maintenance instruction plats, tags or decals stl be changed accordingly. ithe tuckis equipped wih rontend attachments other than factory insalld atachmenis, the use hal equest thatthe buck tbe marked to identi the attachments and show the appropr- ate weight ofthe tuck and attachment combination et maxrum ‘elevation wth oad aterly centre. (6) The use shal se that ll nameplates and markings aein place and maintained ina agile condition. (@) Safety Guards (2) the typeof oad presents a hazard, the user shal equip fork ‘tuck wih a verical oad backrest extensonin accordance with (2X2) folowing (2X2) All new powered indus tucks aoquied and used by an employer ater February 15,1872 shal mee he design and constuction requirements or powered incusta trucks estab lished nthe “American Natonal Sandard for Powered Industrial “Tuoks, Part, ANS! B56. except for vehicles intended primary for earh moving or over the-oad hauling (i) Operator Training Only trained and authorized operators shall be permited io operatoa Powered industrial truck, Methods shall be devised to train operators in the safe operation of powered indus tucks. (00) Truck Operations (1) ‘Tucks shall not be civen up to anyane standing i rot of a bench o other fed object, (2) No person shall be lowed o stand or pass under the elevatoc Portion of any ruck, whether loaded or empty, (2) Unauthorized personnel shal not be permited tarde on powered industrial tucks. safe pane to ride shal be provided where id- ing of rcks is authorized (4) The empoyer shal prchiit arms olegs rom being placed be- ‘ween the uprights of the mast cr outside the runing lines ofthe ‘nck. (6i) When a powered industrial ruck islet unattended, load engaging ‘means shal be fly Invered, contos shal be neutralzed, power ‘sal be shutoff and brakes set. Wheels shall be blocked if the ‘tuck is patked on an incine 6) (Gi. A powered industial tuck is unattended when the operator is 25, feet or more away fom the vehicle which remain nhs view, cr ‘whenever the operator leaves the vehicle anit snot in his view (Gi) When the operator ofan industal ruck is dtsmaunted and within 25 eet ofthe tuck sil nhs view, the load engaging means shal be fully lowered, contol neutralized and the brakes set 10 prevent movement (6) Asate distance sha be maintained rom the edge of ramps or platforms while on any elevated dock or platorm cr right car, Trucks shall not be used for opening or closing freight doors. (10) load backrest extension shall be used whenever necessary to minimize the possibly of he load or part of it rom fling rearward (0) Traveling (4) The dtver shal be requited to stow coun and sound te horn at ross isles and oer locatons where vision is obstructed. the load being cared obstructs foward view, the diver shall be requted to travel wth te oad trang, (7i) When ascercing or descending grades in excess oi 10 percent, loaded trucks shal be driven wih the oad upgrade. (Ti) On ll grades te load and load engaging means shall be tited backif appicable, an raised ony as far as necessary to clear the toad suave (0) Loading (1) Oni stable or safely arranged lads shal be handled. Caution shallbe exercised when handing of-cener ads which cannot be centred (2) Oniy loads win the rated capacity ofthe tuck shal be handle. (3) The long or high (including multiple-iered) loads which may alfect capacity shall be acjusted. (4) Trucks equipped with attachments shall be operated as partially Icaded trucks when not handing a load (6) Aload engaging means shall be placed unde: the load as far as possible; the mast shal be careful tiled backward to stabilze the lad. Extreme care shal be used vhen iting the load forward or backward, particularly when high ering, Tiing forward with nad ‘engaging means elevate shal be pichbited except to pick up load, An elevated load shall not be tited forward except when the load is in a deposit postion over a rack or stack. When slacke ing oterng, only enough backward tit to stabize the load shall beused 6) (0) Operation of the Truck (1) Hat any time @ powered industial truck is found tobe in need of repair, defective, or in any way unsafe the ruck shal be taken ‘ut of service unlit has been resicred to safe operating condi- tion (a) Maintenance of Industrial Trucks (1) Any power operated industia tuck notin sale operating ‘condition shal be removed fram sence. All repairs shall be made by authorized personnel ‘Al parts of any such industial ruck requiring replacement shall be replaced only by pars equivalent as to saaty wih those used in the original design, Industal tucks shall not be atered so thatthe relative postions ‘ofthe various pars are diferent from what they were when ofgi- nal recelve fam the manufacturer, nor shall hey be altered ether bythe aditon of extra pants not provided by the manulac- Ture or bythe elimination of any pars. Additional couneraveigh- ing of fork trucks shall not be done unless approved by the tuck manufacture, Industial tucks shal be examined before being placedin ser vice and shall not be placed in sevice if the examination shows any condition adversely affecting the safety othe vehicle. Such ‘examinations shal be made al least dally. When industial trucks ate used ona round-the-clock bass, they shal be examined ater tech shit Detects when found shal be immediately feported and comecte. 6) ) 0) 1849482-R25 ; | F auc REQUIREMENTS Truck Relief Setting 2300 psi (160 bar) Recommended 2600 psi (180 bar) Maximum Truck Flow Volume ° Min.@ Recommended Max.® 3GPM —-4GPM_— SGM Fork Position (14 min.) (15min) (19 Limin,) 1GPM GPM. 3 GPM bream! (4Umin) — (7-5Limin) (12 Limin,) {© Cascade A-Series Fork PosiionerSideshifier are compalble with ‘SAE TOW petroleum base hydrauic fluid meeting Mil Spec. MIL-O- ‘5606 oF MIL-0-21048. ‘Use of synthetic or aqueous base hydraulic fluid snot recommended. If fire resistant hyeraui fi i require, ‘special seals must be used. Contact Cascade. @ Flow less than recommended will result in slow fork postoning speed. @ Flow greater than maximum can result in excessive healing, reduced system perfomance and shor hydraulc sysiem He. in (A) ITA (ISO) ly rors ops | Carriage Mount Dimen: A Minimum Maximum Classi 14.94 in. (380.0mm) 15.00 in. (381.0 mm) Class Ill 18.68 in. (474.5 mm) 18.74 in. (476.0 mm) Class IV_23.44 in, (595.5 mm) 23.50 in, (597.0 mm) Auxiliary Valve Functions ‘Check for compliance with ANSI(SO) standards: un Forward Let Close Tit Sideshitt Forks Back Fight 1849482-R2 Carriage —Ciean and inspect carriage bars. Make sure that bars are parallel and that ends are fish. Grind smooth any protruding welds that may affect Sideshiter lower bearings. Repair any damaged notches.jy YORAULIC SUPPLY sH. Fork Positioning function: No. 3 hoseINo. 4 fitings with 5(82-in (4 mm) minimum LD, Sideshifting function: No. 4 hose/No. 6 fitings with 3/16:n. (5 mm) minimum LD. Refer to Cascade Hose & Cable Ree! Selection Guide, Part No. 2121860 select he covrect hose rea forthe mas and truck, Fork Positioning/Sideshifting ‘A Mast Double Internal Reeving Solenoid Adaption ‘A. Mast Single Internal Reeving with RF Hydraulic Control 1849482-R2(ocated on the nameplate) to make sure the ‘overhead hoist and chains or straps are at ( WARNING: Check the attachment weight least the rated capacity ofthe attachment. 2 Remove bolt-on lower hooks ITA Class il 60.66 in. (15-17 mm) ITA Ciass ll ~.72-78 in. (18-20 mm) TTA Class V—.72.78in. (18-20 mm) 3 Mount unit on truck carriage Engage locator tab on sideshiter with center notch ITA Class tl 32-36:n. (8.9 mm) ITA Class Il ~ 39-49 in. (10-11 mm) ITA Giass IV — 47-51 in. (12-13 mm) ‘Truck Upper Carriage Bar 4 Install bolt-on lower hooks Truck Lower Sideshitter eran Lt fl ‘Clearance: 1182 in. (0.8 mm) Min. 6 in. (1.6 mm) Max. Frrai¢sce Tighten bots to: Cass IM ~ 120 fos, (165 Nem) 1849482-R2 (Class IV ~ 235 f-tos. (320 Nm) 7iNSTALLATION 5 Flush supply hoses A. Connect supply hoses to supply terminals and connect together using a union fiting as shown. B Operate auxiliary vave for 30 sec. Remove union fitting Install hoses CAUTION: Allow for 4inches movementin ‘each direction for sidestiing (roling’ hose arrangement recommended), Back (Driver's) View Remove fork locking pins WARNING: Remove locking pins {rom forks. Make sure that forks side freely on carriage bars. Frisseps TT] I Close Fert Sion ight Sesh ot Remove Fork Pin Assembly 1849482-R2a / NSTALLATION Install Forks A. Disconnect oylinder rod-end anchors from fork carriers and retract cylinder rods. B tate fork carers up to provide clearance fo ork instalation, WARNING: Remove locking pins from forks. Assure that forks slide freely on sideshitter carriage bars. © Intl fork using bot ok soto engage forks with sideshifter carriage. D. Line up forks with fork carriers on frame and rotate fork carriers down into position over forks. Assure fork spacer plates are in place if required, E Reconnect cylinder rod anchors using two hardened washers and sel-locking nut (see ilystration below). Adjust nut to provide 1/82 in. (1 mm) clearance in joint. Use flats on cylinder rod end to prevent turning, IMPORTANT: Joint must function with a loose operating clearance. Lubricate with chassis grease. Cylinder Rod End Wrench Fat Frcs Fo Sac: at (it required) D ‘Fostoa Sideshiter Assembly 1849482-R2 Hardened Washers (2) Sl-Locking Nut Backrest Fork Positioner Frame Fork Carrier— f “aarion : Lubrication Fork Positioner/Sideshifter is prelubed at the Factory and requires no lubrication for instalation. Use graphite dry lube for fork bars as required (‘Sip Plate Aerosol, "GraphoKote' or equivalent), After use, lubricate fork positioner and sideshifter as described in Perioaic Maintenance Section in this Manual. Cycle Fork Positioner functions ‘© Open and close forks several times. ‘Sideshift (if equipped) left and right Check for smoothness and equal movernent ‘+ Check for operation in accordance with ‘ANSI (ISO) standards. * Check for leaks at fitings, valve, oylinders, ‘Check that rong hoses supplying fork position are not pinched. 11 function activation shown here conforms to ‘ASME/ANSI B56.1 recommended practices. Failure to follow these practices may lead to serious bodiy injury or property damage. End user, dealer and OEMs should review any deviation trom the practices for safe operation. ( WARNING: Truck control handle and attachment AUXILIARY VALVE FUNCTIONS Tit Hoist down cle Hoist up Tit back (NON-SIDESHIFTING ‘SIDESHIFTING ‘SIDESHIFTING WITH AA Spread Forks A Sideshift Left btaachemindaes B Close Forks B Sideshit Right A Sieshit Left © (notusea) © Spread Forks A pales tale a D (press knob button) (not used) D Close Forks B Sicesnit Right B Chose Forks B A =F c — SoS 10 1849482-R2. {J ssmuation 12 13 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 tow estctrs on righthand cylinder (only one (1) flow restrictor used). B Open forks fully, then close. Look for unequal fork movement. C Loosen restrictor jam nut and adjust until Fight hand fork moves equally with lft hand fork. Tighten jam nut Inspect fork hooks, carriage bar clearance NOTE: Use go/no-go Wear Gauge Part No. 200560 {Class i), 209561 (Class Ill) or 6104118 (Class IV). A. Inspect the fork lower hooks and cartiage bar. ifthe gauge fits between the carriage bar and lower hook, repair or replacements needed. B Inspect the upper carriage bar. Ifthe 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. 1849482-R2 accu ea Fow A Restctr Fiting res Back (Driver's) View: FORK LOWER HOOKS, CARRIAGE Wear Gauge OK A UPPER CARRIAGE BAR FG ea ae oss25e abl12 iss! P ERIODIC MAINTENANCE WARNING: AVter completing any service procedure, always test each function through five complete cycles. First test with no load, then test witha load to make sure the attachment operates Correctly before returning ito the job. 100-Hour Maintenance Every time the lift truck is serviced or every 100 hours of truck operation, whichever comes first, perform the following maintenance procedures: + Check for loose or mising bots, worn or damaged hoses and hycrauti leaks. 500-Hour Maintenance Alter each 500 hours of truck operation, in addon tothe 100-hour maintenance, perform tne folowing procedures + Tighten treme and backrest mounting capscrens to 115-128 ft-lbs. (155-170 Nm). «Tighten lower nook capscrews Class Il / Ill = 120 ft-lbs. (165 Nm). Class IV - 235 ft.-Ibs. (320 Nm). + Apply grapite dry lube to fork cartier bearings (Sip Plate’, 'GraphoKote’ or equivalent). + Apply chassis grease to fork cline fod ancnors + oply chassis grease to sdeshtter upper bearing areas fitings, and lowe at bearings + Check fork hooks and carriage bars for wea’ using a wear gauge (Cascade Part No. 209509 far Class I, 203507 for Class Ill and 6104118 for Class IV). 1000-Hour Maintenance Ater each 1000 hours of ttuck operation, in addition to the 100 and 500-hour maintenance, perform the following procedures: ‘© Inspect fork carrier bearings for wear and replace if necessary ‘Inspect fork cylinder rod anchor washers for wear and replace if necessary ‘+ Inspect thickness of sideshifter (if equipped) upper ‘and lower bearing sets. If any bearing in the sat is worn to less than 3/32 in. (2.5 mm) thickness, replace entre bearing set (see Service Manual Frame and Backrest Mounting Capscrews (4) Front View Fork Carter Cylinder Rod Bearings (2) ‘Anchors (2) REESE iT Sideshiter Grease Fittings (2) Sideshiter Lower Mounting Hook Lower Bearings (2) Capscrews (4) Back (Driver's) View 1849482-R2~ ill P ERIODIC MAINTENANCE 2000-Hour ‘Nor 2000 hours of truck operation in addon tothe 4100, 300 and 1000-hour maintenance, forks in use shall de 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 equire more requert inspection Fork inspection shall be carried out by trained personnel {0 detect any damage that might impair sae use. Any fork thats delectve snl be removed trom service. Relerence ANSI B56.1-2005, Inspect forthe faliowing detects © Surface cracks + Straightness of blade end shank + Fork angle + Diflerence in height of fork ips + Positioning lock + Wear on fork blade an shank + Wear on fork hooks * Legibility of marking NOTE: Fork Safety Kit 3014162 contains wear calipers, inspection sheets and safely postr. also avalable is fork hook & carriage wear gauge 209560 (Class I), 209561 (Class II) and 6104118 (Class IV). 1849482-R2 1314 ay P ARTS Recommended Spare Parts FORK POSITIONER /SIDESHIFTER UNITS SERVICED 55a Pa toon | 12,1508, 1s | 619 | 2050 PARTINOL | PAHE.NO: | PARTNO: | panto, DESCRIPTION ary. | ary. | ary. FORK POSITIONER wis | una |_ ins 11170 | Oyinder Service Kit 0 4 6 wings | 111763_| 171183 | 111183 | Oyinder, Gland Nut oO 2 [4 107760 | 6107750 | 6707750 | 6107750 _| Bearing, ForkEye Bronze 4 8 16 SIDESHIFTER 2eere2 | eosia49 | 051249 | 6079636 | Uppe: Bearing-Composte 8 6] 2 eon616 | 6052405 | 6082405 | 6082297 _| Upper Bearing-Brene 4 3 | 6 emorie | eosrie2 | 6057162 [6057162 _| Lower Bearing-Composte 6 [| 2 [| = 2ess7o__| eoseoa1_| 056041 | 6058041_| Loner Bearing-Bronze 4 a | 6 2081@6 | 204186 | 204766 | 6089167 | Lower Hook 0 2 4 7s2008 | 752903 | 752908 = __| Capscrew, MIB A5 0 4 8 = = = 768580 | Capscrew, M20 x60 0 4 8 ree | a7e000 | 676090 — | Na mi: 0 a 8 = = = rasa00 _ | Nut, 420 0 4 8 eareas | eereas | areas | t6a19 | Washer 0 4 8 : . 7 | Ovinder Assembly ° 0 1 2isaes | 219866 | s64409_| S64a08 | Cylinder Service Ki 1 2 4 'W Refer to partrumber stamoed on part or supply serial number stamped on sidesiter frame winen purchasing those parts, 1849482-R21849482-R2 suit PAGE INTENTIONALLY LEFT BLANK 15Do you have questions you need answered right now? Call your nearest Cascade Parts Department. Visit us online at www.cascorp.com AMERICAS Cascade Corporation Cascade Canada Inc. Parts Sales 5570 Timberlea Blvd, 2501 Sheridan Ave. Mississauga, Ontario Springfield, OH 45505 Canada LaW 446 Tel: 888-CASCADE (227-2283) Tel: 905-629-7777 Fax: 888-329-0234 Fax: 905-629-7785 EUROPE-AFRICA Cascade Malla S.R.L. Cascade (Africa) Pty. Ltd. European Headquarters PO Box 625, Isando 1600 Via DelArtigianato 1 60A Steel Road 37050 Vago di Lavagno (VR) Sparton, Kempton Park ttaly South Africa Tel 39-045-2989111 Tel: 27-11-975.9240 Fax: 39-045-8989160 Fax: 27-11-894-1147 ASIA-PACIFIC Cascade Japan Ltd, Cascade Korea 2.23, 2.Chome, 4218 9L Namdong Ind. Kukuchi Nishimachi ‘Complex, 691-8 Gojan-Dong ‘Amagasaki, Hyogo Namdong-Ku Japan, 661-0978 Inchon, Korea Tel: 81-6-6420-971 Tel: +82-32-821-2051 Fax: 81-6-6420-9777 Fax: +82-32-621-2055 Cascade Australia Pty.Ltd. Cascade New Zealand 36 Kiln Road 16 Ra Ora Drive Darra, QLD 4076 East Tamaki, Auckland Australia New Zealand Tek: 1-800-207-223 Tol: +64-9-273-9136 Fax: +61 7 3373-7333, Fax: +64-9-273.9137 =o Cascade do Brasi Rua Jogo Guerra, 134 ‘Macuco, Santos - SP Brasil 11015-130 Tel: 55-13-2105-8800 Fax: §5-13-2105-8899 Cascade-Xiamen No. 668 Yangguang Re. Xinyang Industrial Zone Haicang, Xiamen City Fujian Province PR. 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 © Cascade Corporation 2012 08.2016 Cascade India Material Handling Private Limited No 34, Global Trade Centre 111 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 1849482-R2