cascade corporation L Series User manual

cascade
corporation
SER MANUAL
U
Cascade is a Registered Trademark of Cascade Corporation
Original Instructions
Number 6814459-R6 EN
L-Series
Fork Positioner/
Sideshifter

i6814459-R6 EN
ONTENTS
C
Page
INTRODUCTION
Special Definitions 1
OPERATION
Safety Rules – Industrial Lift Trucks 2
Safety Rules – Handling Loads 3
Auxiliary Valve Operation 4
Safe Operation and Maintenance 5
INSTALLATION
Truck Requirements 6
Hydraulic Supply 7
Attachment Installation 8
PERIODIC MAINTENANCE
Daily, 1000-Hour 17
2000-Hour 18
NAMEPLATE ICONS 19

1
6814459-R6 EN
NTRODUCTION
I
PERATION
O
FP1955.eps
This user manual is for the Cascade L-Series Fork
Positioner/Sideshifter. 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: L-Series Fork Positioner/Sideshifter 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
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 proceeded by NOTE is information
that is handy to know and may make the job easier.
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 L-Series Fork Positioner/Sideshifter. 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
understanding about effective and safe Fork Positioner/
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 a supervisor.
Emphasize Safety! Most accidents are caused by
operator carelessness or misjudgment. You must
watch for poorly maintained equipment and hazardous
situations and correct them.
Backrest
Sideshifter
Fork
Positioner
Forks

26814459-R6 EN
PERATION
OSafety Rules – Industrial Lift Trucks
FP1530.eps
FP1531.eps
No riders No reaching through mast
No parking on ramp No turning on ramp Watch clearances
No standing under load
Motor off, park, lower load Traveling
empty
Tilt
Observe
Wet floors
Workers Stops
Bumps Dips Slow for
two-way traffic
Sound horn, slow
at intersection
Sound horn, slow
at corner
Raise
8 cm
With Load
No Load
RAMPS
P P
P
STOP
TRAFFIC

3
6814459-R6 EN
PERATION
O
FP1532.eps
Safety Rules – Handling Loads
CAUTION: Do not put
side loads on forks.
Do not clamp loads. Limit sideshifting
with raised load
Center load
prior to
traveling
Top of load
should not extend
above backrest
Raise load prior
to sideshifting
LOAD
WEIGHT
Limit truck movement
with raised load
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.
Limit mast tilting
with raised load.

46814459-R6 EN
PERATION
O
FP1977.eps
FP1977.eps
FP1977.eps
FP1977.eps
WARNING: Truck control handle and attachment
function activation shown here conforms to
ISO 3691 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.
BD
C
A
GA0005.eps
AUXILIARY VALVE
FUNCTIONS
Hoist Down
Hoist Up
Tilt Forward
Tilt Back
SIDESHIFTING/
FORK POSITIONING
ASideshift Left
BSideshift Right
COpen Forks
DClose Forks
FORK POSITIONING
AOpen Forks
BClose Forks
SIDESHIFTING/
FORK POSITIONING
WITH SOLENOID VALVE OR
RF VALVE
ASideshift Left
AOpen Forks
(press knob button)
BSideshift Right
BClose Forks
(press knob button)
SIDESHIFTING/FORK POSITIONING
WITH SEQUENCE VALVE
ASideshift Left – Open Forks
BSideshift Right – Close Forks
AA
A
B
B
B
C
A
A
A
C
A
A
A
D
B
B
B
D
B
B
B
Auxiliary Valve Functions

5
6814459-R6 EN
AFE OPERATION AND MAINTENANCE
SIndustrial Trucks and Attachments
WARNING: When operating and maintaining industrial
trucks equipped with attachments, you should pay
particular attention to the following information. You
should be familiar with this information for truck and
attachment operation. Ask your employer for complete
operation information.
General Requirement
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.
Safety Guards
If the type of load presents a hazard, the user shall equip fork
trucks with a vertical load backrest extension in accordance with
the following.
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 II, 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.
Truck Operations
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 7
meter 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
7 meter of the truck still in his view, the load engaging means shall
be fully lowered, controls neutralized and the brakes set to prevent
movement.
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.
Traveling
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.
Loading
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.
Operation of the Truck
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.
Maintenance of Industrial Trucks
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 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.

66814459-R6 EN
NSTALLATION
I
GA0137.eps
Truck Requirements
Truck Relief Setting
152 bar Recommended
241 bar Maximum
Truck Flow Volume ➀
Min. ➁Recommended Max. ➂
25L 4 L/min. 8 L/min. 12 L/min.
32L-70L 4 L/min. 16 L/min. 20 L/min.
➀Cascade L-Series Fork Positioners 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 required,
special seals must be used. Contact Cascade.
➁Flow less than recommended will result in slow fork positioning
speed.
➂ Flow greater than maximum can result in excessive heating,
reduced system performance and short hydraulic system life.
Carriage Mount Dimension (A) ITA (ISO)
Minimum Maximum
Class II
Class III
Class IV
380.0 mm
474.5 mm
595.5 mm
381.0 mm
476.0 mm
597.0 mm
Carriage –Clean and inspect carriage
bars. Make sure that bars are parallel
and that ends are flush. Grind smooth
any protruding welds that may affect
sideshifter lower bearings. Repair any
damaged notches.
GA0082.eps
Auxiliary Valve Functions
Check for compliance with ISO
standards:
Hoist Down
Hoist Up
Tilt
Forward
Tilt
Back
Sideshift
Left
Sideshift
Right
Open
Forks
Close
Forks
A
GA0028.eps

7
6814459-R6 EN
NSTALLATION
IHydraulic Supply
Fork Positioning Function: No. 3 hose/No. 4 fittings with 4
mm minimum ID.
Sideshifting Function: No. 4 hose/ No. 6 fittings with 5 mm
minimum ID.
Refer to Cascade Hose & Cable Reel Selection Guide, Part
No. 212199 to select the correct hose reel for the mast and
truck.
AB
Fork Positioner – Standard
Non-Sideshifting
A or B RH or LH THINLINETM 2-port hose reel groups
Sideshifting
A & B RH & LH THINLINETM 2-port hose reel groups
Fork Positioner – Sequence Valve
A or B RH or LH THINLINETM 2-port hose reel groups
Fork Positioner – Solenoid Adaption
A or B RH or LH THINLINETM 2-port hose reel groups
GA0083.eps

86814459-R6 EN
NSTALLATION
I
FP1959.eps
Attachment Installation
1
2
3
Attach overhead hoist
Remove bolt-on lower hooks
Remove bolt-on lower hooks
Lifting eye on
attachment frame
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.
ITA Class II – 15-17 mm
ITA Class III – 18-20 mm
ITA Class IV – 18-20 mm
ITA Class II – 8-9 mm
ITA Class III – 10-11 mm
ITA Class IV – 12-13 mm
Engage locator
tab on sideshifter
with center notch
Truck Upper
Carriage Bar
FP1957.eps
FP1958.eps

9
6814459-R6 EN
NSTALLATION
I
FP1864.eps
4Install bolt-on lower hooks
Truck Lower
Carriage Bar
Tighten capscrews to a double torque of:
Class II/III – 225 Nm
Class IV – 320 Nm
5Flush supply hoses
A Connect supply hoses to supply terminals and
connect together using a union fitting as shown.
B Operate auxiliary valve for 30 sec.
C Remove union fitting.
FP0726.eps
Sideshifting: Sideshifting:
Bronze Hooks Iron Hooks
0 Clearance, touching 2.5 mm Min.
but not tight. 5.0 mm Max.
Non-sideshifting:
Tight against
carriage bar.

10 6814459-R6 EN
NSTALLATION
I
6Install hoses
CAUTION: Allow for 100 mm (25L/32L/46L) or 150 mm
(55L/70L) movement in each direction for sideshifting
('rolling' hose arrangement recommended).
Standard
Internal Hose Reeving
Sideshift Left
OPEN Forks
Sideshift Right CLOSE Forks
Checked Option Non-Sideshifting
Internal Hose Reeving
OPEN Forks CLOSE Forks
Back (Driver's) View
Back (Driver's) View
FP1963.eps
FP1960.eps

11
6814459-R6 EN
NSTALLATION
I
OPEN Forks
OR
Sideshift Left
OPEN Forks,
Sideshift Left
CLOSE Forks
OR
Sideshift Right
CLOSE Forks,
Sideshift Right
Back (Driver's) View
Back (Driver's) View
Sequence Valve
RH High Termination
RH Hose Reel
Radio Frequency Option OR Solenoid
Internal Hose Reeving
FP1981.eps
FP1982.eps
6Install hoses (continued)

12 6814459-R6 EN
NSTALLATION
I
Sideshift
Right Sideshift
Left
CLOSE Forks
OPEN Forks
Fork Position Sideshift
SSR Manifold Layout Shown
Back (Driver's) View
Checked Option Sideshifting with High Termination
LH & RH Hose Reels
Sideshift
Right Sideshift
Left
CLOSE Forks
OPEN Forks
Fork Position Sideshift
SSR Manifold Layout Shown
Back (Driver's) View
High Termination
LH & RH Hose Reels
6Install hoses (continued)
FP1964.eps
FP1966.eps
Sideshift Cylinder
Manifold Labels:
'SSR' on top of the manifolds
indicates sideshift supply
connections on right side of
the attachment.
'SSL' on top of the manifolds
indicates sideshift supply
connections on left side of
the attachment.

13
6814459-R6 EN
NSTALLATION
I
FP1967.eps
7Install forks
A Remove inner carrier fork stops, retainers and
their hardware.
B Install forks using a pallet or blocks. Keep feet
clear of forks.
C Reinstall retainer, its hardware and inner carrier
fork stop capscrews with washers. Tighten
capscrews to 100 Nm.
NOTE: See illustration below to position
retainers for various widths.
A
B
C
Retainer
Capscrew
Retainer
Inner Carrier Fork
Stop - Capscrew
and Washer
FP2107.eps FP2108.eps
Install retainers for
minimum clearance
with inside of forks
Install retainers for
minimum clearance
with outside of forks
Position forks
against outer
fork stops
Position forks
against inner
fork stops
FP2109.eps
Retainer
Outer Fork Stop
(nonremovable)
Inner Fork Stop
(removable)
Front View
CAUTION: Install forks
at minimum In to In OR
maximum Out to Out
positions only.
MAXIMUM OUT TO OUT MINIMUM IN TO IN

14 6814459-R6 EN
FP1976.eps
8Install backrest (if equipped)
Cascade Backrest –
Tighten to 195 Nm.
NSTALLATION
I

15
6814459-R6 EN
WARNING: Truck control handle and attachment
function activation shown here conforms to
ANSI/ITSDF B56.1 (ISO 3691) 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.
BD
C
A
GA0005.eps
AUXILIARY VALVE
FUNCTIONS
Hoist Down
Hoist Up
Tilt Forward
Tilt Back
9Cycle Fork Positioner functions
• Open and close forks several times. Sideshift
(if equipped) left and right. Check for
smoothness and equal movement.
• Check for operation in accordance with ANSI
(ISO) standards.
• Check for leaks at fittings, valve and cylinders.
• Check for rolling hoses supplying fork position
are not pinched.
FP1977.eps
FP1977.eps
FP1977.eps
FP1977.eps
SIDESHIFTING/
FORK POSITIONING
ASideshift Left
BSideshift Right
COpen Forks
DClose Forks
FORK POSITIONING
AOpen Forks
BClose Forks
SIDESHIFTING/
FORK POSITIONING
WITH SOLENOID VALVE OR
RF VALVE
ASideshift Left
AOpen Forks
(press knob button)
BSideshift Right
BClose Forks
(press knob button)
SIDESHIFTING/FORK POSITIONING
WITH SEQUENCE VALVE
ASideshift Left – Open Forks
BSideshift Right – Close Forks
AA
A
B
B
B
C
A
A
A
C
A
A
A
D
B
B
B
D
B
B
B
NSTALLATION
I

16 6814459-R6 EN
10 Inspect fork hooks, carriage bar
clearance.
NOTE: Use go/no-go Wear Gage Part No. 209560
(Class II), 209561 (Class III) or 6104118 (Class IV).
A Inspect the fork lower hooks and carriage bar.
If the gauge fits between the carriage bar and
lower hook, repair or replacement is needed.
B Inspect the upper carriage bar. If the 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.
FP0832.eps
FORK LOWER HOOKS, CARRIAGE
UPPER CARRIAGE BAR
FORK UPPER HOOKS
OK
OK
OK
Wear
Gauge
NSTALLATION
I

17
6814459-R6 EN
PERIODIC MAINTENANCE
FP1978.eps
Daily
Check items shown each day. Report problems to your
supervisor. Refer to service manual for troubleshooting,
maintenance and repair procedures.
1000-Hour
Every time the lift truck is serviced or every 1000 hours
of truck operation, whichever comes first, complete the
following maintenance procedure:
• Check for loose or missing capscrews, worn or
damaged hoses, and hydraulic leaks.
• Inspect sideshifter lower hooks for wear and proper
clearance. Adjust if necessary. Refer to installation
Step 4.
• Tighten fork positioner mounting flange capscrews to
165 Nm.
• Tighten retainer capscrews and inner carrier fork stops
to 100 Nm.
• Tighten cylinder anchor bar capscrews to 65 Nm.
• Tighten fork positioner cylinder rod anchor plugs to 135
Nm.
• Tighten lower hook capscrews to:
Class II/III – 225 Nm
Class IV – 320 Nm
• Tighten frame carrier stop capscrews to 90 Nm.
• Tighten Cascade backrest capscrews to 195 Nm.
• Apply general-purpose chassis grease to sideshifter
upper bearing grease fittings, fork carrier grease
fittings, and sideshifter lower bearings.
• Apply graphite dry-lube to fork carriage bars as
required ('Slip Plate Aerosol', 'GraphKote' or equivalent).
• Inspect carrier arm bars and bearings for wear or
damage. If bearing thickness is less than 1.5 mm,
replace both bearings.
• Inspect sideshifter upper and lower bearings
for wear. If any bearing is worn to less than 2.5
mm thickness replace the entire bearing set.
Refer to service manual for repair procedures.
Backrest
Fork Carrier
Retainer
Capscrews
Inner Fork Carrier
Capscrews
Lower Hooks
Mounting
Flange
Capscrews
Backrest
Capscrews
Frame
Carrier Stop
Capscrews
Forks
Cylinder
Anchor Bar
Capscrews
Lubrication Points
Back (Driver's) View
Cylinders
and hoses
FP1979.eps
WARNING: After completing any service
procedure, always test the fork positioner
through five complete cycles to make sure
the attachment operates correctly before
returning it to the job.

18 6814459-R6 EN
ERIODIC MAINTENANCE
P
2000-Hour
After 2000 hours of truck operation, in addition to the
250, 500 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 following defects:
• Surface cracks
• Straightness of blade and shank
• 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 & carriage wear gauge 209560 (Class II),
209561 (Class III) and 6105257 (Class IV).