E-Series Sideshifters
Contents
1. SS0278 ill Hose end in drain bucket Front View S ERVICE a a 41 Sideshifter Removal seen OD soest non 1 Remove the forks from the Sideshifter A 2 Remove the backrest from the Sideshifter For reassem bly Cascade backrests tighten the capscrews to 145 ft lbs 195 Nm Refer to the truck service manual for truck manufacturer s backrest WARNING Before disconnecting hoses relieve pressure in the Attachment hydraulic system Turn the truck off and move the truck control handle several times in both directions 3 Disconnect the hoses from the cylinder Tag hoses for ea reassembly Front View ied 4 Remove the lower mounting hooks and inspect for wear Mark see illustration opposite Replace if beyond wear limit Lower Mounting animun Hooks on rear 46 mm SS0254 ill 5 Attach a 1000 Ib 450 kg capacity overhead hoist to Cylinder Anchor the Sideshifter frame and lift away from the truck car Bracket Assembly riage The anchor bracket cylinder assembly will remain on the truck carriage 6 For installation reverse the above procedures with the following exceptions Clean and inspect carriage bars for damage and smoothness Assure that bars are parallel and that ends are flush Repair any protruding2. Fastener torque values for the E Series Sideshifter are shown in the table below in both U S and Metric units All torque values are also called out in each service section throughout the Manual Ref Fastener Size Ft Ibs Nm 1 Lower hook to frame 4 M 16 120 165 5 8 in 2 Backrest to frame 4 M 16 145 195 3 Pallet Guard to frame 2 M 16 145 195 12 SS0279 ill 205849 Rev 3 Do you have questions you need answered right now Call your nearest Cascade Service Department AMERICAS Cascade Corporation U S Headquarters 2201 NE 201st Fairview OR 97024 9718 Tel 800 CASCADE 227 2233 Fax 888 329 8207 EUROPE AFRICA Cascade Italia S R L European Headquarters Via Dell Artigianato 1 37030 Vago di Lavagno VR Italy Tel 39 045 8989111 Fax 39 045 8989160 ASIA PACIFIC Cascade Japan Lid 2 23 2 Chome Kukuchi Nishimachi Amagasaki Hyogo Japan 661 0978 Tel 81 6 6420 9771 Fax 81 6 6420 9777 Cascade Australia Pty Lid 1445 Ipswich Road Rocklea QLD 4107 Australia Tel 1 800 227 223 Fax 61 7 3373 7333 cascade CI CITM Cascade Corporation 1999 Cascade Canada Inc 5570 Timberlea Blvd Mississauga Ontario Canada L4W 4M6 Tel 905 629 7777 Fax 905 629 7785 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 Cascade Korea 121B 9L Namdong
3. S ERVICE MANUAL E Series Sideshifter Manual Number 205849 R 3 cascade Cascade is a Registered Trademark of Cascade Corporation O ONTENTS INTRODUCTION Section 1 Page Introduction 1 1 Special Definitions 1 2 PERIODIC MAINTENANCE Section 2 100 Hour Maintenance 2 1 500 Hour Maintenance 2 2 1000 Hour Maintenance 2 3 2000 Hour Maintenance 2 4 MDINININO TROUBLESHOOTING Section 3 General Procedures 3 1 Truck System Requirements 3 1 1 Tools Required 3 1 2 Troubleshooting Chart 3 1 3 Plumbing 3 2 Hosing Diagram 3 2 1 Hydraulic Schematic 3 2 2 Sideshift Function 3 3 O1 BIB BIO 0 09 00 SERVICE Section 4 Sideshifter Removal 4 1 Bearings 4 2 Lubrication 4 2 1 Service 4 2 2 Cylinder 4 3 Cylinder Removal 4 3 1 Cylinder Disassembly 4 3 2 Cylinder Inspection 4 3 3 Cylinder Reassembly 4 3 4 O O 0 00 00 NI NI NI SPECIFICATIONS Section 5 Specifications 5 1 11 Hydraulics 5 1 1 Auxiliary Valve Functions 5 1 2 11 Truck Carriage 5 1 3 11 Fastener Torque Values 5 1 4 12 205849 Rev 3 NTRODUCTION 1 1 1 2 Introduction This Manual provides Periodic Maintenance Troubleshooting Service and Specifications for E Series Sideshifters In any communication about the Sideshifter refer to t
4. 6 8 JIC No 4 No 6 Reducer and No 8 JIC O Ring Diagnostic Quick Disconnects Male Straight Thread O ring Coupler No 4 Part No 212282 No 5 Part No 210378 G amp G No 6 Part No 678592 Female JIC Thread Coupler No 4 Part No 210385 No 5 Part No 678591 ACO127 ill NOTE Diagnostics Kit 394382 includes all of the above BovBLEsHooTING 32 Plumbing 3 2 1 Hosing Diagram 2 Port Hose Reel or IHR Sideshift Cylinder Hose Terminal Truck Auxiliary Valve S0032 ill SIDESHIFT LEFT SIDESHIFT RIGHT Pressure EEE Return ER E 3 2 2 Hydraulic Schematic Sideshift Cylinder LI Flow Restrictors 2 SSR SSL f k X Truck Auxiliary Valve Truck Relief Valve Truck Pump Truck Tank SS0179 ill 205849 Rev 3 T BOQUBLESHOOTING 33 Sideshift Function There are six potential problems that could affect the sideshifting function Inadequate upper bearing lubrication or worn bearings see Section 4 2 e Incorrect hydraulic pressure or flow from lift truck e External leaks e Lower mounting hooks installed with incorrect clearance see Section 4 1 Step 6 Worn or defective cylinder seals see Section 4 3 e Cylinder fittings or flow restrictors plugged incor rect type or not installed properly see Section 4 3 3 3 2 Supply Circuit Test 1 Check the pressur
5. Ind Complex 691 8 Gojan Dong Namdong Ku Inchon Korea Tel 82 32 821 2051 Fax 82 32 821 2055 Cascade New Zealand 15 Ra Ora Drive East Tamaki Auckland New Zealand Tel 64 9 273 9136 Fax 64 9 273 9137 10 99 Cascade do Brasil Rua Jo o Guerra 134 Macuco Santos SP Brasil 11015 130 Tel 55 13 2105 8800 Fax 55 13 2105 8899 Cascade Xiamen No 668 Yangguang Rd 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 India Material Handling Private Limited No 34 Global Trade Centre 1 1 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 205849 R 3
6. wear gauge 209560 and fork wear calipers 686093 2000 Hour Maintenance After each 2000 hours of truck operation in addition to the 100 500 and 1000 hour maintenance perform the following procedures Replace upper and lower bearing sets See Section 4 2 2 Upper Bearing Grease Fittings Es Lower Bearing Grease Areas CLO SS0259 ill Lower Mounting Hooks on rear Front Driver s View Forks S0258 ill Backrest Mounting Capscrews 4 205849 Rev 3 T BovsLEshoorina 3 1 3 1 1 3 1 2 3 1 3 General Procedures Truck System Requirements Truck hydraulic pressure should be within the range shown in Specifications Section 5 1 PRESSURE TO THE SIDESHIFTER MUST NOT EXCEED 3500 psi 245 bar Truck hydraulic flow should be within the volume range shown in Specifications Section 5 1 Hydraulic fluid supplied to the Sideshifter must meet the requirements shown in Specifications Section 5 1 Tools Required In addition to a normal selection of hand tools the following are required 20 GPM 80 L min inline flow meter Cascade Flow Meter Kit part no 671477 3000 psi 200 bar pressure gauge Cascade Pressure Gauge Kit part no 671212 Assorted fittings lines drain hoses and quick couplers as required Troubleshooting Chart Determine All T
7. welds or Q damaged notches by grinding filing or welding Clean all bearing areas of built up dirt and grease asii al Inspect Sideshifter bearings for wear and replace as necessary see Section 4 2 2 aR e Install and adjust lower hooks as shown below Sideshifter Frame RN CAUTION Lower hook clearance must be adjusted bper as shown for proper sideshifter operation a Lubricate both upper and lower Sideshifter bearings Arrangement with general purpose lithium based chassis grease SS0050 ill 6 BOLT ON QUICK CHANGE Reverse guides to reduce hook to carriage clearance Sideshifter ps Truck Carriage ER SA E 7 Ea EM j l Clearance i i Clearance E ea Ci 1 32 in 0 8 mm Min 4 1 32 in 0 8 mm Min vee D 1 16 in 1 6 mm Max 1 16 in 1 6 mm Max 5 8 in 16 mm XQ Sosi offset on top uid Tighten bolts to provides max Tighten capscrews to 120 ft lbs 165 Nm clearance 120 ft lbs 165 Nm 6 205849 Rev 3 Service 42 Bearings 4 2 1 Bearing Lubrication Lubricate both the upper and lower Sideshifter bearings with general purpose lithium based chassis grease every 500 hours of operation NOTE 60E 100E models must be sideshifted to expose the grease fittings 4 2 2 Bearing Service 1 Remove the Sideshifter from the truck as described in Section 4 1 2 Remove and inspect the upper bearings If either bearing is worn to less than 1 16 in 1 5 mm thick on the back surface replace both be
8. 0 bar Recommended 3500 psi 240 bar Maximum Truck Flow Volume Min 2 Recommended Max 1 GPM 2 GPM 3 GPM 95E 60E 4 L min 7 5 L min 12 L min A ene 1 GPM 4 GPM 5 GPM p 4 Limin 15 L min 19 L min Cascade E Series Sideshifters are compatible with SAE 10W petroleum base hydraulic fluid meeting Mil Spec MIL 0 5606 or Hr MIL 0 2104B Use of synthetic or aqueous base hydraulic fluid is not recommended If fire resistant hydraulic fluid is required 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 GA0090 ill Hoses and Fittings All supply hoses and fittings should be at least No 4 with 3 16 in 5 mm minimum 1 D 5 1 2 Auxiliary Valve Functions Check for compliance with ITA ISO standards Tilt Forward z Sideshift Left A Hoist Down GA0094 ill Hoist Up Tilt Sideshift Back Right 5 1 3 Truck Carriage GA0091 ill g Carriage Mount Dimension A ITA ISO A Minimum Maximum Class Il 14 94 in 380 0 mm 15 00 in 381 0 mm Class Ill 18 68 in 474 5 mm 18 74 in 476 0 mm GA0028 ill 205849 Rev 3 11 S PECIFICATIONS 5 1 4 Torque Values
9. arings 3 Measure the exposed thickness of the lower bear ings If less than 1 16 in 1 6 mm replace both bearings NOTE Sideshifter serial numbers 55E SS 001 through 148 use 12 mm thick lower bearings or optional 15 mm thick bearings Serial numbers 55E SS 149 and higher use 19 mm thick lower bearings 55E lower bearing part numbers are listed below 55E Lower Bearing 12mm _ 208387 55E Lower Bearing 15mm 204188 55E Lower Bearing 19mm 207209 4 For reassembly reverse the above procedures with the following exceptions Clean all bearing areas of built up dirt and grease Clean all parts prior to reassembly Serial Numbers 55E SS 001 through 148 Apply grease to the lower bearing pockets to hold lower bearings in place All Other Serial Numbers Tap lower bearings firmly into bearing pockets Lower 4 Bearing Pocket Lower Bearings 3 205849 Rev 3 S0264 ill Upper bearing grease fittings 3 Tom Lower bearing grease areas g SS0262 ill Upper Bearings 1 16 in 1 6 mm Min back surface S0036 ill S0209 ill Upper Bearing Arrangement S0263 ill S Envice a3 Cylinder 43 1 Cylinder Removal WARNING Before removing hoses or A hydraulic components relieve pressure in the Attachment hydraulic system Turn the truck off and move the auxiliary control han
10. dle several times in both directions 1 Disconnect the hoses from the cylinder ports 2 Remove the lower mounting hooks 3 Attach a suitable overhead hoist to the sideshifter carriage Remove the carriage from the truck The anchor bracket cylinder assembly will remain on the truck carriage 4 Remove the anchor bracket cylinder assembly from the truck carriage Service the cylinder as described in Section 4 4 CLO S0208 ill 5 Inspect the sideshifter bearings for wear as described in Section 4 2 2 Steps 2 3 and 4 2 6 For reassembly reverse the above procedures with the following exceptions Clean the upper hook and lower bearing pockets of any built up dirt and grease Clean all parts prior to reassembly Locate the upper bearings correctly in the anchor bracket cutouts see illustration e Install and adjust the lower mounting hooks as Cylinder Anchor described in Section 4 1 Step 6 Bracket Assembly Lubricate the Sideshifter bearings as described in Section 4 2 1 SY PSs EN gt N Upper Bearing Arrangement Sideshifter Bearings SS0263 ill 8 205849 Rev 3 Service 4 3 2 Cylinder Disassembly 1 Clamp the cylinder anchor bracket assembly in a soft jawed vise Do not clamp on the cylinder shell 2 Center the cylinder rod in the cylinder Remove the spiral snap rings from the re
11. e supplied by the truck at the carriage hose terminals Pressure must be within the range shown in Specifications Section 5 1 PRESSURE TO THE SIDESHIFTER MUST NOT EXCEED 3500 PSI 245 BAR 2 Check the flow volume at the carriage hose terminal Flow must be within the range shown in Specifications Section 5 1 3 Sideshift fully to the left and hold the lever in the SIDESHIFT LEFT position for a few seconds Release the lever and check for external leaks at fittings hoses and cylinder rod ends 3 3 3 Sideshift Circuit Test 1 Sideshift fully to the right Turn the truck off and relieve Attachment system pressure Disconnect the SIDESHIFT LEFT supply hose from the truck hose terminal and route to a drain bucket Cap the supply fitting 2 Start the truck and actuate the SIDESHIFT RIGHT lever for 5 seconds If there is substantial hydraulic flow out of the drain hose the sideshift cylinder seals are defective and require service Refer to Section 4 4 2 If there is no hydraulic flow out of the hose check for plugged or incorrectly installed flow restrictor washers and fittings If there is still no hydraulic flow the problem is not hydraulic see Section 3 3 205849 Rev 3 WARNING Before disconnecting hoses relieve pressure in the Attach ment hydraulic system Turn the truck off and move the truck auxiliary control handle several times in both directions Sideshift Left Hose
12. embly 10 1 Polish the piston and retainer chamfer angle with emery cloth This allows the seals to slide over the chamfer easier Wash all components with cleaning solvent Lubricate all new seals and rings with petroleum jelly or STP Note the direction of the U cup seals If the seals are installed backward they will not work properly For proper seal placement see the illustration below Install the new seals on the piston and retainer Hook one side of the seal in the groove and push it over the piston or retainer 5 Apply a thick film of petroleum jelly or STP to the inside of the cylinder shell piston seals and retainers 6 Insert the rod assembly into the cylinder shell If resistance is encountered tap the rod end witha rubber mallet 7 Tap the retainers into the shell far enough to install the retaining rings in their grooves 8 Pull the rod out to one side to the fully extended position This will position the retainer so the spiral snap ring can be installed Repeat for the retainer on the other end Latest Configuration S0046 ill Latest Configuration 3 o Optional Spacers NS S0281 ill NOT 7 Retainer Shell Piston 8 7 each end of cylinder s0211 ill 7 8 205849 Rev 3 Ei S PECIFICATIONS 51 Specifications 5 1 1 Hydraulics Truck Relief Setting 2300 psi 16
13. he product I D number stamped on the back surface of the left vertical bar driver s view as shown IMPORTANT All hosing and flared fittings on E Series attachments are JIC as standard with face seal as an option NOTE Specifications are shown in both U S and Metric units Imprinted information showing Decal containing capacity model number serial number and WARNING patent numbers attachment specifications and phone number to call for service Back Driver s View 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 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 205849 Rev 3 P ERIODIC MAINTENANCE 2 1 2 2 2 3 2 4 WARNING Afte
14. he Facts It is important to gather all the facts about the problem before beginning any service procedures The first step is to talk to the equipment operator Ask for a complete description of the malfunc tion Guidelines below can then be used as a starting point to begin troubleshooting Sideshift Circuit Attachment will not sideshift Attachment sideshifts slowly To correct these problems see Section 3 3 205849 Rev 3 WARNING Before servicing any hydraulic component relieve pressure in the Attach ment system Turn the truck off and move the truck auxiliary control handle several times in both directions After completing any service procedure always test the Attachment through several cycles First test the Attachment empty to bleed any air trapped in the system to the truck tank Then test the Attachment with a load to be sure it operates correctly before returning to the job Stay clear of the load while testing Do not raise the load more than 4 in 10 cm off the floor while testing Flow Meter Kit 671477 2 No 8 12 JIC O Ring Flow Meter S o oa GA0013 ill 2 No 6 8 JIC Reducer Pressure Gauge Kit 671212 Pressure No 6 and No 8 Gauge No 6 6 Hose JIC Swivel Tee i ip eS ofS uy GA0014 ill F No 4 6 Pipe JIC No
15. r completing any service procedure always test the Sideshifter through 5 complete cycles First test empty then test with a load to make sure the attachment operates correctly before returning it to the job 100 Hour Maintenance Every time the lift truck is serviced or every 100 hours of truck operation whichever comes first complete the following maintenance procedures e 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 Section 4 1 Step 7 Usea torque wrench and tighten lower hook capscrews to 120 ft lbs 165 Nm 500 Hour Maintenance After each 500 hours or 4 weeks of truck operation which ever occurs first in addition to the 100 hour maintenance perform the following procedures e Tighten backrest capscrews Cascade to 145 ft lbs 195 Nm For truck manufacturer s backrest refer to truck service manual Apply general purpose lithium based chassis grease to Sideshifter upper and lower bearings 1000 Hour Maintenance After each 1000 hours of truck operation in addition to the 100 and 500 hour maintenance perform the following procedures Inspect thickness of upper and lower bearing If any bearing in the set is worn to less than 3 32 in 2 5 mm thickness replace entire bearing set see Section 4 2 2 e Inspect forks for wear Use Cascade fork bar
16. tainers see illustration 3 Tap the retainers into the shell approximately 2 in 50 mm Remove the retaining rings by prying one end up and working the ring out of the groove Service Tool Kit 674424 includes two double ended brass tools that make seal and retaining ring removal easy and won t damage the cylinder components with nicks or scratches CAUTION Do not scratch the cylinder bore Ss0049 ill 4 Remove the rod assembly from the cylinder See the illustration below 5 Clamp the rod assembly in a soft jawed vise or between two blocks of wood to remove the seals Pry the seals up with a brass tool Cut to remove CAUTION Do not scratch the seal grooves SS0039 ill 4 3 3 Cylinder Inspection Inspect all components for nicks or burrs Minor nicks or burrs can be removed with 400 grit emery cloth NOTE Minor nicks are those that will not bypass oil under pressure If nicks cannot be removed with emery cloth replace the part Inspect the outside of the shell for deformities that could weaken the shell s performance when under pressure Replace if necessary Make sure the cylinder fittings and flow restrictors are the correct type and are installed as shown 2 34 tora 3 2 S0042 ill Re UR IMPORTANT Fittings must bottom against flow restrictors in cylinder ports for proper hydraulic flow characteristics 205849 Rev 3 9 Flow Restrictors S ERVICE 4 3 4 Cylinder Reass
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