cascade
corporation
SER MANUAL
U
Cascade is a Registered Trademark of Cascade Corporation
80R & 100R
Integral Mount
Sideshifter, Sideshifting
Fork Positioner
Number 6914838 EN
Original Instructions
CONTENTS
i
6914838 EN
INTRODUCTION
This manual is for the Cascade 80R and 100R Integral
Sideshifter/Fork Positioner. Contents include an Operator's
Guide, Installation Instructions and Periodic Maintenance.
IMPORTANT: The 80R and 100R Integral Fork Positioner/
Sideshifter is metric. Supply fittings can be adapted as
required for your application.
NOTE: All specifications are shown in Metric units where
applicable. All fasteners have a torque value range of
±10% of stated value.
Catalog Number, Serial Number
Capacity, weight, horizontal CG
Page
INTRODUCTION i
Special Definitions 1
OPERATION 1
Safety Rules – Industrial Lift Trucks 2
Safety Rules – Handling Loads 3
Sideshift & Fork Position Operation 3
Daily Inspection 4
Safe Operation and Maintenance 5
INSTALLATION
Truck Requirements 6
Hydraulic Supply 6
Attachment Installation 7
PERIODIC MAINTENANCE
Daily 11
1000-Hour 11
2000-Hour 11
RESIDUAL HAZARDS 12
NAMEPLATE ICONS 13
IN0013.eps
1
6914838 EN
IN0015.eps
INTRODUCTION
This section contains operating instructions for the
Cascade 80R and 100R Integral Sideshifter/Fork
Positioner. 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 Attachment
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.
Emphasize Safety! Most accidents are caused
by operator carelessness or misjudgment. You
must watch for poorly maintained equipment and
hazardous situations and correct them.
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.
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.
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.
Forks
Backrest
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.
OPERATION
Frame
Sideshift
Cylinder
Weighted Emission Sound Pressure Level - Weighted
emission sound pressure level (LA) does not exceed 70
dB(A).
Measured Value of Whole Body Vibration - Measured
value of whole body vibration (m/s
2
) does not exceed 0,5
m/s
2
.
Measured Value of Hand-Arm Vibration - Measured value
of hand-arm vibration (m/s
2
) does not exceed 2,5 m/s
2
.
Fork Shaft
2
6914838 EN
FP2948.eps
FP2947.eps
OPERATION
Safety Rules – Industrial Lift Trucks
No standing under load No reaching through mast No riders
Motor off, park, lower load
With load
Tilt
Raise
No load
Traveling
empty
8 cm
P
P
TRAFFIC
No parking on ramp
Watch clearances
No turning on ramp
P
STOP
RAMPS
Slow for
two-way trafc
Sound horn, slow
at intersection
Wet oors
Bumps Dips
Workers Stops
Sound horn,
slow at corner
Observe
3
6914838 EN
FP2955.eps
IN0016.eps
OPERATION
Safety Rules – Handling Loads
SIDESHIFTING &
FORK POSITIONING
A Sideshift Left
B Sideshift Right
C Open Forks (if equipped)
D Close forks (if equipped)
Limit truck movement
with raised load.
Top of load should
not extend above
backrest.
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.
CAUTION: Do not put
side loads on forks.
Center load prior
to traveling.
Limit sideshifting
with raised load.
LOAD
WEIGHT
B
D
C
A
GA0005.eps
Hoist down
Tilt forward
Hoist up Tilt Back
Sideshift & Fork Position Operation
Raise load prior
to sideshifting.
B
C
A
C
D
D
AUXILIARY VALVE
FUNCTIONS
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.
4
6914838 EN
IN0017.eps
OPERATION
Daily Inspection
Check items shown each day. Report problems to your
supervisor. Refer to the attachment’s service manual for
troubleshooting and repair procedures.
Cylinders, Valve and
Hoses for leaks
Fasteners
for tightness
Decals and
Nameplate
for legibility
Forks for wear
5
6914838 EN
SAFE OPERATION AND MAINTENANCE
Industrial 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.
INSTALLATION
6
6914838 EN
IN0019.eps
IN0018.eps
Truck Requirements
GA0082.eps
Auxiliary Valve Functions
Check for compliance with ANSI (ISO) standards:
Sideshift
Left
Hoist Up
Tilt Back
Tilt Forward
Sideshift
Right
Hoist Down
Open Forks (if equipped)
Close Forks (if equipped)
Hydraulic Supply
Fork Positioning and Sideshift function: No. 8 hose/
No. 8 fittings with 10 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.
A
Fork Positioning & Sideshifting
A Mast Double Internal Reeving
OR
C Mast Single Internal Reeving and Hose Reel
B
Truck Relief Setting
152 bar Recommended
241 bar Maximum
Truck Flow Volume
➀
Min.
➁
Recommended
Max.
➂
80R/100R-IFS
80R/100R-ISS
4 L/min. 7.5 L/min. 12 L/min.
➀ Cascade R-Series Integral Attachments 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.
➁ Flow less than recommended will result in slow fork positioning
and sideshift speed.
➂ Flow greater than maximum can result in excessive heating,
reduced system performance and short hydraulic system life.
Sideshifting
A Mast Single Internal Reeving
OR
B Hose Reel
C
INSTALLATION
7
6914838 EN
Integral attachment should be
installed in the mast per OEM
specifications and procedures.
IMPORTANT: Integral attachment installation is an OEM
or dealer responsibility. 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.
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.
Attachment Installation
1
FP0726.eps
2
Flush supply hoses
A
Connect supply hoses to supply terminals
and connect together using union fittings as
shown.
B Operate auxiliary valves for 30 sec.
C Remove union fittings.
Install supply hoses
3
Fittings are male No. 8 JIC 37°.
Sideshift
Left
Sideshift
Right
IN0010.eps
IN0014.eps
80R 100R
IN0029.eps
Sideshift
Left
Sideshift
Right
Close
Forks
(if equipped)
Open
Forks
(if equipped)
Close
Forks
(if equipped)
Open
Forks
(if equipped)
INSTALLATION
8
6914838 EN
4
Install forks (if required)
Shaft Mount Forks
A
Remove the backrest (if equipped).
B Remove the cover plate.
C Remove the fork shaft end cover.
D Pull the shaft out of the frame far enough to allow
installing the fork tube on the shaft.
E Engage the fork lower hook with the lower
carriage bar. Insert the shaft through the fork
tube. Fully engage the shaft in the frame and
install the end plate. Tighten the end plate
capscrews to the torque of 66 Nm.
F Fasten the cylinder rod end to the fork tube
anchor. Tighten the nut to 320 Nm.
G Reinstall the cover plate. Tighten capscrews to
the torque of 38 Nm.
H Reinstall the backrest. Tighten capscrews to the
torque of 66 Nm.
FP1364.eps
Carrier Mount Forks
A
Remove capscrews and fork carrier outer retainers.
B Remove locking pin from fork upper hook, if equipped.
C Install forks using a pallet or blocks. Keep feet clear of
forks.
D Reinstall fork carrier retainers and tighten capscrews to
165 Nm (lube torque).
RH Fork Carrier
Retainer
Capscrew
B
A,D
C
IN0022.eps
200 mm
Wide Forks
IN0023.eps
B,G
A,H
F
C
D
E
Attachment Installation
Carrier Mount Forks
Shaft Mount Forks
INSTALLATION
9
6914838 EN
IN0016.eps
5
Cycle Attachment functions
• Open and close forks several times (if equipped).
Sideshift left and right. Check for smoothness and
equal fork movement. Equalize fork movement if
required by adjusting the valve speed controls.
• Check for operation in accordance with ISO
standards.
• Check for leaks at fittings, valve and cylinders.
SIDESHIFTING &
FORK POSITIONING
A Sideshift Left
B Sideshift Right
C Open Forks (if equipped)
D Close forks (if equipped)
B
D
C
A
GA0005.eps
Hoist down
Tilt forward
B
C
A
C
D
D
AUXILIARY VALVE FUNCTIONS
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.
Hoist up Tilt Back
IN0032.eps
RH Fork
Speed Control
LH Fork
Speed Control
INSTALLATION
10
6914838 EN
6
Inspect fork or carrier hook
clearance
NOTE: Use go/no-go Wear Gauge Part No.
209560 (Class II) or 209561 (Class III).
Inspect the fork or carrier lower hooks. If the
gauge fits between the lower hook and frame,
repair or replacement is needed.
FORK OR CARRIER LOWER HOOK
Wear
Gauge
FP2931.eps
Attachment Installation
7
Sideshifters–Position forks
Remove hairpin cotter and clevis pin from frame.
Position forks to required position. Reinstall clevis
pin to fully engage top hole in fork. Install hairpin
cotter.
IN0033.eps
11
6914838 EN
IN0021.eps
IN0020.eps
PERIODIC MAINTENANCE
Daily
Check items shown each day. Report problems to your
supervisor. Refer to service manual for troubleshooting,
maintenance and repair procedures.
• Check for loose or missing capscrews, worn or
damaged hoses, and hydraulic leaks.
1000-Hour
Every time the lift truck is serviced or every 1000 hours
of truck operation, whichever comes first, complete the
following maintenance procedure:
• Apply chassis grease to the frame upper and lower
grease fittings and fork or carrier bearing grease
fittings.
• Tighten fork carrier retainer capscrews to 165 Nm.
• Tighten the fork position cylinder rod anchor nuts to
320 Nm.
• Tighten the fork position cylinder base anchor nuts to
450 Nm.
• Tighten the sideshift cylinder capscrews to 105 Nm.
• Inspect the fork or carrier upper and lower bearings
for wear or damage. If bearing thickness is less than
1.5 mm, replace the bearings.
Fork or Carrier
Bearing Grease
Fittings
Cylinder Rod
Anchor
Fork Position
Cylinders
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.
Frame
Upper
Grease
Fittings
Cylinder
Base
Anchors
Lower
Bearings
Valve
Upper
Bearings
Frame
Lower
Grease
Fittings
Sideshift
Cylinder
IN0031.eps
Fork Carrier
Retainer
Capscrews
12
6914838 EN
2000-Hour
After 2000 hours of truck operation, in addition to the
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).
PERIODIC MAINTENANCE
RESIDUAL HAZARDS
• Hazard of crushing between the lift truck’s front structure
and the mast when completely tilted backwards.
• Hazard of shearing between the lift truck’s front structure
and mast components that move vertically with the mast
completely tilted backwards.
• Hazard of shearing between the attachment frame and
forks.
• Hazard of crushing during fork service procedures.
• Hazard of crushing during cylinder service procedures.
• Hazard of crushing during installation and periodic
maintenance operations.
The attachment has been designed to prevent risks during
movement, installation and operation. There are, however,
some residual hazards:
13
6914838 EN
+
7
@
123
+
A2-Z
Cascade Corporation • www.cascorp.com • Icons & Patents: www.cascorp.com/support 6095754
3500 lb
1586 kg
24 in
610 mm
9.1 in
220 mm
6.5 in
165 mm
1115 lb
505 kg
2300 psi
159 bar
45E–PHS–462
PTL1086133–2
6086329
2010
3500 lb
1586 kg
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AMERICAS
Cascade Corporation
U.S. Headquarters
2201 NE 201st
Fairview, OR 97024-9718
Tel: 800-CASCADE (227-2233)
Fax: 888-329-8207
Cascade Canada Inc.
5570 Timberlea Blvd.
Mississauga, Ontario
Canada L4W-4M6
Tel: 905-629-7777
Fax: 905-629-7785
Cascade do Brasil
Praça Salvador Rosa,
131/141-Jordanópolis,
São Bernardo do Campo - SP
CEP 09891-430
Tel: 55-13-2105-8800
Fax: 55-13-2105-8899
EUROPE-AFRICA
Cascade Italia S.R.L.
European Headquarters
Via Dell’Artigianato 1
37030 Vago di Lavagno (VR)
Italy
Tel: 39-045-8989111
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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
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 Korea
121B 9L Namdong Ind.
Complex, 691-8 Gojan-Dong
Namdong-Ku
Inchon, Korea
Tel: +82-32-821-2051
Fax: +82-32-821-2055
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
Cascade India Material
Handling P Ltd
Sy no 271/8, Ingawale Patil
Estate,
Godown No.9,10 & 11, Bhugaon,
Off Paud Road, Tal Mulshi, Dist
Pune 411 042
Cascade Australia Pty. Ltd.
1445 Ipswich Road
Rocklea, QLD 4107
Australia
Tel: 1-800-227-223
Fax: +61 7 3373-7333
Cascade New Zealand
15 Ra Ora Drive
East Tamaki, Auckland
New Zealand
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Sunstream Industries
Pte. Ltd.
18 Tuas South Street 5
Singapore 637796
Tel: +65-6795-7555
Fax: +65-6863-1368
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