U

SER MANUAL

E-Series

Sideshifter

Manual Number 218197 R-2

cascade

姞

Cascade is a Registered Trademark of Cascade Corporation

C

ONTENTS

INTRODUCTION

Special Definitions

OPERATION

Safety Rules

Industrial Lift Trucks

Handling Loads

Sideshifter Operation

Safe Operation and Maintenance

OSHA Regulations

INSTALLATION

Truck Requirements

Recommended Hydraulic Supply

Installation Procedure

INSPECTION & MAINTENANCE

Daily

100-Hour Maintenance

500-Hour Maintenance

1000-Hour Maintenance

PARTS

Product Identification

Base Unit

Cylinder

Recommended Spare Parts

Publications

Contacting Cascade

Page

9

10

11

back cover back cover back cover

9

9

9

9

6

6

7

2

3

3

4

4

5

5

2

I

NTRODUCTION

This User Manual is for Cascade E-Series Sideshifters.

It contains an Operation Guide, Installation Instructions, and

Parts Manual. All specifications are shown in U.S. and

(Metric) units where applicable.

IMPORTANT:

All hosing and flared fittings on F-Series

Sideshifters are JIC as standard, with face seal as an option.

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 preceded by NOTE is information that is handy to know and may make the job easier.

O

PERATION

This Section contains operating instructions for Cascade

E-Series Sideshifters. 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 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 your supervisor.

Emphasize Safety!

Most accidents are caused by operator carelessness or misjudgement. You must watch for poorly maintained equipment and hazardous situations and correct them.

Backrest

Cylinder

Forks

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.

Fork Stops

Upper

Hooks

Lower

Hooks

SS0127.ill

218197 Rev. 2

O

PERATION

Safety Rules – Industrial Lift Trucks

No riders No reaching through mast No standing under load

GA0047.ill

P P

Motor off, park, lower load

P

Traveling empty

Tilt

Raise

3 in.

(8 cm)

With load

No load

RAMPS

No parking on ramp

TRAFFIC

Observe

Workers

STOP

Stops

No turning on ramp Watch clearances

GA0048.ill

Slow for two-way traffic

Sound horn, slow at intersection

Sound horn, slow at corner Wet floors

218197 Rev. 2

Bumps Dips

3

O

PERATION

Safety Rules – Handling Loads

Limit sideshifting with raised load.

Top of load should not extend above backrest

4

CAUTION: Do not put side loads on forks.

Center load prior to traveling.

LOAD

WEIGHT

Raise load prior to sideshifting.

Limit truck movement with raised load.

Sideshifter Operation

AUXILIARY VALVE

FUNCTIONS

GA0010.ill

Hoist down

Tilt forward

A

Hoist up Tilt Back

B

SIDESHIFTING

A

Sideshift Left

B

Sideshift Right

B

Load weight must not exceed combined truck/attachment capacity (see truck nameplate).

FP0017.ill

Total fork capacity (LH + RH fork) must be greater than load weight.

Check capacity stamp on forks.

SS0129.ill

A

218197 Rev. 2

S

AFE OPERATION AND MAINTENANCE

OSHA Regulations – Industrial Trucks and Attachments

(Specific Regulations from OSHA 1910.178)

WARNING:

The safe operation and maintenance of industrial trucks is regulated by Occupational Safety and Health (OSHA) regulations 1910.178 and American National Standards Institute (ANSI) Safety Standard for

Powered Industrial Trucks, ANSI B56.1. When operating and maintaining industrial trucks equipped with attachments you should pay particular attention to the following sections of these regulations. You should be familiar with

all

sections of these regulations.

Ask your employer for the complete regulations.

(a)

General Requirement

(4) 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.

(5) 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.

(6) The user shall see that all nameplates and markings are in place and maintained in a legible condition.

(e)

Safety Guards

(2) If the type of load presents a hazard, the user shall equip fork trucks with a vertical load backrest extension in accordance with

(a)(2) following.

(a)(2) 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.

(l)

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.

(m)

Truck Operations

(1) Trucks shall not be driven up to anyone standing in front of a bench or other fixed object.

(2) No person shall be allowed to stand or pass under the elevated portion of any truck, whether loaded or empty.

(3) 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.

(4) The employer shall prohibit arms or legs from being placed between the uprights of the mast or outside the running lines of the truck.

(5i) 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.

(5ii) A powered industrial truck is unattended when the operator is 25 feet 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.

(5iii) When the operator of an industrial truck is dismounted and within 25 feet of the truck still in his view, the load engaging means shall be fully lowered, controls neutralized and the brakes set to prevent movement.

(6) 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.

(10) A load backrest extension shall be used whenever necessary to minimize the possibility of the load or part of it from falling rearward.

(n)

Traveling

(4) 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.

(7i) When ascending or descending grades in excess of 10 percent, loaded trucks shall be driven with the load upgrade.

(7iii) 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.

(o)

Loading

(1) Only stable or safely arranged loads shall be handled. Caution shall be exercised when handling off-center loads which cannot be centered.

(2) Only loads within the rated capacity of the truck shall be handled.

(3) The long or high (including multiple-tiered) loads which may affect capacity shall be adjusted.

(4) Trucks equipped with attachments shall be operated as partially loaded trucks when not handling a load.

(5) 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.

(6) 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.

(p)

Operation of the Truck

(1) 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.

(q)

Maintenance of Industrial Trucks

(1) Any power-operated industrial truck not in safe operating condition shall be removed from service. All repairs shall be made by authorized personnel.

(5) 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.

(6) 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.

(7) 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.

218197 Rev. 2 5

6

I

NSTALLATION

Truck Requirements

Truck Relief Setting

2300 psi (160 bar) Recommended

3500 psi (240 bar) Maximum

Truck Flow Volume

➀

Min.

➁

Recommended

55E, 60E

100E

1 GPM

(4 L/min.)

1 GPM

(4 L/min.)

2 GPM

(7.5 L/min.)

4 GPM

(15 L/min.)

Max.

➂

3 GPM

(12 L/min.)

5 GPM

(19 L/min.)

➀ Cascade E-Series Sideshifters 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 may be required. Contact Cascade.

➁ Flow less than recommended will result in slow sideshift speed.

➂ Flow greater than maximum can result in excessive heating, reduced system performance and reduced hydraulic system life.

A

GA0028.ill

Carriage Mount Dimension (A)

ITA (ISO)

Minimum Maximum

Class II

14.94 in. (380.0 mm) 15.00 in. (381.0 mm)

Class III

18.68 in. (474.5 mm) 18.74 in. (476.0 mm)

Recommended

Hydraulic Supply

The Sideshifter will require one of the hydraulic supply arrangements shown below. All hoses and fittings should be at least No. 4 with 3/16 in. (5 mm) minimum I.D. Refer to

Cascade Hose & Cable Reel Selection Guide, Part No.

212199 to select the correct hose reel for the mast and truck.

GA0131.ill

Carriage –

Clean and inspect carriage bars. Assure that bars are parallel and that ends are flush. Grind smooth any protruding welds that may affect Sideshifter lower bearings. Repair any damaged notches

Auxiliary Valve Functions

Check for compliance with

ITA (ISO) standards:

Tilt

Forward

Hoist Down

Sideshift

Left

GA0094.ill

Hoist Up Tilt

Back

Sideshift

Right

A

B

GA0026.ill

A

RH THINLINE

姠 2-Port Hose Reel Supply Group

OR

B

Mast Single Internal Hose Reeving

218197 Rev. 2

I

NSTALLATION

Installation Procedure

Attach overhead hoist

1

Model / Serial

Number Plate

Lifting eye

WARNING:

Make sure overhead hoist has rated capacity of at least

1000 lbs. (450 kg).

2

Remove bolt-on lower hooks

SS0004.ill

SS0130.ill

Back (Driver's) View

3

Mount Sideshifter on truck carriage

ITA Class II –

.60-.66 in. (15-17 mm)

ITA Class III –

.72-.78 in. (18-20 mm)

Engage locator tab with center notch

Remove cylinder retaining clips after mounting.

ITA Class II – .32–.36 in. (8-9 mm)

ITA Class III – .39–.43 in. (10-11 mm)

Truck Upper

Carriage Bar

Back (Driver's) View

4

Install lower hooks

BOLT-ON

Truck Carriage

Clearance:

1/32 in. (0.8 mm) Min.

1/16 in. (1.6 mm) Max.

Tighten bolts to

120 ft.-lbs. (165 Nm).

218197 Rev. 2

Sideshifter

F

Clearance:

1/32 in. (0.8 mm) Min.

1/16 in. (1.6 mm) Max.

QUICK-DISCONNECT

Reverse guides to reduce hook-to-carriage clearance.

5/8 in. (16 mm) offset on top provides max.

clearance.

SS0005.ill

SS0251.ill

Tighten capscrews to

120 ft.-lbs. (165 Nm)

7

I

NSTALLATION

5

Flush supply hoses

6

Install hoses

Optional Installation

Kit 205826 shown for internal reeving.

GA0046.ill

SS0007.ill

8

7

Install forks

cascade a s c a d e

SS0171.ill

9

Lubricate lower bearings

Lubricate the lower sideshifter bearings with general-purpose lithium-based chassis grease.

IMPORTANT:

Upper bearings are prelubed at the Factory with break-in grease. No lubrication is required for installation.

8

Install backrest

c a s c a d e

Cascade Backrest–

Tighten to 145 ft.-lbs.

(195 Nm). For other backrests, see OEM recommendations.

Upper bearing grease fittings

SS0010.ill

Lower bearing grease areas

SS0011.ill

218197 Rev. 2

I

NSPECTION & MAINTENANCE

WARNING:

After completing any service procedure, always test the Sideshifter through five complete cycles. First test with no load, then test with a load to make sure the attachment operates correctly before returning it to the job.

Daily

Check items shown each day. Report problems to your supervisor. See Service Manual for troubleshooting, maintenance and repair procedures

100-Hour

Every time the lift truck is serviced or every 100 hours of truck operation, whichever comes first, complete the following maintenance procedures:

•

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 Step 4, Installation). Tighten lower hook capscrews to 120 ft.-lbs (165 Nm).

500-Hour

After each 500 hours of truck operation, in addition to the

100-hour maintenance, perform the following procedures:

•

Tighten backrest capscrews (Cascade) to

145 ft.-lbs. (195 Nm).

•

Apply general-purpose lithium-based chassis grease to

Sideshifter upper and lower bearings.

Backrest

Cylinder and hoses for leaks

Forks

SS0127.ill

Fork Stops

Upper and lower hook engagement

Fasteners

1000-Hour

After each 1000 hours of truck operation, in addition to the

100 and 500-hour maintenance, perform the following procedures:

• Inspect upper and lower bearings for wear. If any bearing is worn to less than 1/16 in. (1.5 mm) thick, replace the entire bearing set. See Service Manual for replacement procedure.

• Inspect forks for wear.

NOTE:

Fork Safety Kit 3014162 is available containing wear calipers, inspection sheets and safety poster. Also available is fork hook & carriage wear gauge 209560 (CL II), and 209561 (CL III).

P

ARTS

Product Identification –

This Section shows replacement parts for E-Series Sideshifters. The product serial number is located on the nameplate on the back surface of the left vertical bar (driver's view) and must be provided when ordering replacement parts.

WARNING:

For the safety of yourself and others, DO NOT install the parts shown in this Manual unless you have thoroughly reviewed the appropriate Service Manual.

Imprinted information showing model number, serial number and attachment specifications.

Decal containing capacity

WARNING, patent numbers and phone number to call for service.

Back (Driver's) View

SS0110.ill

9 218197 Rev. 2

P

ARTS

Base Unit

Optional

Quick Disconnect

Lower Hooks

!

@

$

#

Backrests

SS0104.ill

8

9

1

2

1

0

3

10

%

^&

5

4

SS0137.ill

Refer to the Product Price List for further information on Cascade backrests. Contact your dealer for other OEM backrests.

7 6

SS0105.ill

55E 60E/100E

REF QTY PART NO.

PART NO.

DESCRIPTION

3

3

2

3

1

1

3

★ 4

★ 5

5

★ 6

★ 7

8

▼

1

▼

▼

▼

▼

4

2

2

4

4

1

▼

204187

204137

■

—

208387

204188

207209

553857

204186

225570

667225

639121

●

672018

804065

■

208350

—

—

—

553857

204186

225570

667225

639121

●

Upper Bearing, Composite

Upper Bearing, Bronze

Cylinder/Anchor Assembly

Lower Bearing

Lower Bearing, 12 mm ◆

Lower Bearing, 15 mm ◆

Lower Bearing, 19 mm ◆

Nut, 5/8 UNC, G5

Lower Hook

Lower Hook, Bronze (optional)

Washer

Capscrew, 5/8 UNCx1.50, G5

Frame

9

10

10

10

10

11

12

2

2

2

2

2

2

7403

601676

667222

666984

211807

675514

678832

7403

601676

667222

666984

211807

675957

678832

Grease Fitting

Fitting, JIC 6-6

Fitting, JIC 5-6

Fitting, JIC 4-6

Fitting, Face Seal Adpt 4-6

Q.D. Hook

Pin, Q.D.

13

14

15

16

2

2

4

2

683182

675515

205857

680253

779019

675958

208355

202346

Capscrew

Guide

Retainer

Washer

17 2 765329 763169 Capscrew

◆

NOTE:

Sideshifter serial numbers 55E-SS-001 through 147 use 12 mm thick lower bearings or optional 15 mm thick bearings. Serial numbers

55E-SS-148 and higher use 19 mm thick lower bearings.

● If frame needs replacing, order complete sideshift assembly.

★ Included in Lower Hook Service Kit 204182.

■ See Cylinder page for parts breakdown.

▼ Quantity as required.

Reference: S-3816, S-6015, S-6038.

218197 Rev. 2

P

ARTS

Cylinder

1 2 3 4 5 6 7 8 9 0

@ $ #

Cylinder Assembly Width

@

SS0102.ill

!

SS0065.ill

218197 Rev. 2

55E 60E 100E

REF QTY PART NO.

PART NO.

PART NO.

DESCRIPTION

● 1

2

3

● 4

● 5

● 6

7

● 8

● 9

10

●11

12

13

14

2

1

2

1

2

2

2

2

—

2

2

2

2

2

562132

562055

563278

564141

562792

208378

564226

—

■

563487

205848

205840

205841

205842

—

205845

—

205847

205843

—

205846

—

—

206370

205844

—

562131

562951

562942

—

218228

—

—

—

—

583970

—

583971

—

—

583972

—

583973

—

—

—

—

562131

562951

562942

—

218228

562132

562055

563278

564141

562792

208378

564226

—

■

563487

—

—

—

—

—

—

584001

—

—

584002

—

—

584003

—

—

584004

564408

3154

564403

615131

2789

564406

564401

564404

564407

564402

—

564226

—

■

564409

Cylinder Assembly, 24.4 in. (620 mm) wide

Cylinder Assembly, 26.2 in. (665 mm) wide

Cylinder Assembly, 28.9 in. (735 mm) wide

Cylinder Assembly, 31.9 in. (810 mm) wide

Cylinder Assembly, 34.1 in. (865 mm) wide

Cylinder Assembly, 35.2 in. (895 mm) wide

Cylinder Assembly, 36.0 in. (915 mm) wide

Cylinder Assembly, 38.3 in. (975 mm) wide

Cylinder Assembly, 40.1 in. (1040 mm) wide

Cylinder Assembly, 40.2 in. (1020 mm) wide

Cylinder Assembly, 45.1 in. (1145 mm) wide

Cylinder Assembly, 48.0 in. (1220 mm) wide

Cylinder Assembly, 48.1 in. (1220 mm) wide

Cylinder Assembly, 48.8 in. (1240 mm) wide

Cylinder Assembly, 52.0 in. (1320 mm) wide

Cylinder Assembly, 55.2 in. (1400 mm) wide

Wiper Seal

Snap Ring

Retaining Ring

Back-Up Ring

O-Ring

Rod Seal

Rod/Piston Assembly

Bearing Ring

Piston Seal

Retainer

Rod End Cap

Speed Control Washer

Spacer

Cylinder Shell

Service Kit

● Included in Service Kits 563487 (55E & 60E) and 564409 (100E).

■ Not serviceable, order new cylinder assembly. Reference: S-3816, S-4019, S-4060, S-6105.

11

P

ARTS

Recommended Spare Parts

55E

PART NUMBER

60E

PART NUMBER

100E

PART NUMBER

204187

■

204186

639121

553857

667225

672018

208350

204186

639121

553857

667225

■

563487

562055

■

563487

562055

■ See specific parts page for part number.

Publications

672018

208350

204186

639121

553857

667225

■

564409

564401

DESCRIPTION

BASE UNIT AND MOUNTING

Upper Bearing

Lower Bearing

Lower Hook

Capscrew

Nut

Washer

CYLINDER

Cylinder Assembly

Cylinder Service Kit

Rod

T

OOLS

S

cascade 䊛

ANU

AL

ERVICE M

Service Literature Index and Order Form

Ordering Information

Parts, Service and Operator Guide literature is sold through the Cascade Parts Depot.

please enclose a check payable to Cascade Corporation.

FAX:

513-325-9270

Mail:

Cascade Corporation

P.O. Box 360

Springfield, Ohio 45501

Phone:

513-322-1199

M aster Service Manual

Part No. 673969

Includes all Service manuals listed in a 3-ring binder for $140.00.

U

SER MANUAL

1-5

UNITS SERVICED

6-19 20-50

0

0

8

6

0

0

0

1

0

16

12

2

4

4

4

0

2

0

PART NO.

218197

205849

679929

673964

55E/60E/100E

DESCRIPTION

User Manual (Operator Guide, Installation, Parts)

Service Manual

Tool Catalog

Literature Index Order Form

32

24

4

8

8

8

1

4

1 cascade 姞

Cascade is a Registered Trademark of Cascade Corporation

GA0098.ill

Contacting Cascade

Customers –

Cascade product literature, service literature, parts and videos are available through authorized lift truck dealers. To find out the dealer nearest you, contact:

Cascade Corporation

U.S. Headquarters

2201 NE 201st

Fairview, OR 97024-9718

Tel: 800-CASCADE (227-2233)

503-669-6300

FAX: 888-329-8207

Lift Truck Dealers –

To order parts, service literature or videos:

Cascade Parts Sales

2501 Sheridan Ave.

Springfield, OH 45505

Tel: 888-CASCADE (227-2233)

FAX: 888-329-0234 c

䊚 Cascade Corporation 1999

9-99 Part Number 218197 R-2