F-Series Sideshifters
S
ERVICE MANUAL
F-Series
Sideshifter
Number 220526-R6
cascade
corporation
Cascade is a Registered Trademark of Cascade Corporation
C
ONTENTS
INTRODUCTION, Section 1
Introduction
Special Definitions
PERIODIC MAINTENANCE, Section 2
100-Hour Maintenance
300-Hour Maintenance
1000-Hour Maintenance
2000-Hour Maintenance
TROUBLESHOOTING, Section 3
General Procedures
Truck System Requirements
Tools Required
Troubleshooting Chart
Plumbing
Hosing Diagram
Hydraulic Schematic
Sideshift Function
SERVICE, Section 4
Sideshifter Removal
Bearings
Lubrication
Service
Cylinder
Removal, Inspection, Replacement
Rod Seal Replacement
SPECIFICATIONS, Section 5
Specifications
Hydraulics
Auxiliary Valve Functions
Truck Carriage
Torque Values
i
Page
1
1
2
2
2
2
3
3
3
3
4
4
4
5
6
7
7
7
8
8
9
10
10
10
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11
220526-R6
I
1.1
NTRODUCTION
Introduction
This manual provides Periodic Maintenance,
Troubleshooting, Service and Specifications for F-Series
Sideshifters.
In any communication about the Sideshifter, refer to the
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 F-Series
attachments are JIC as standard, with face seal as an
option.
NOTE: Specifications are shown in both U.S. and
(Metric) units. All fasteners have a torque value range of
±10% of stated value.
Stamped cylinder
assembly part number
(opposite side).
Stamped model number,
serial number, specifications.
Stamped capacity,
weight, load center,
HCG information
Sticker showing patent
numbers, phone
numbers for service.
SS0793.eps
Back (Driver's) View
1.2
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.
220526-R6
1
P
ERIODIC MAINTENANCE
WARNING: If the fork locking pin is not
fully engaged, the fork could become
disengaged from the carriage.
WARNING: After completing any service
procedure, always test the attachment
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.
2.1
Fork Lock Pins
Fork
Stops
Backrest
Cylinder
and hoses
for leaks
Upper and
lower hook
engagement
100-Hour Maintenance
Every time the lift truck is serviced or every 100 hours
of truck operation, complete the following maintenance
procedures:
• Check for loose or missing bolts, worn or damaged
hoses, hydraulic leaks, and damaged or missing fork
stops.
Forks
• Inspect lower hooks for wear and proper clearance.
Adjust if necessary, refer to Section 4.1, step 7.
Tighten lower hook capscrews to:
Class II/III – 120 ft.-lbs (165 Nm)
Class IV – 235 ft.-lbs (320 Nm)
2.2
300-Hour Maintenance
Fasteners
SS0915.eps
Upper Bearing
Grease Fittings
After each 300 hours of truck operation, in addition to the
100-hour maintenance, perform the following procedures:
• Cascade Backrests – Tighten backrest capscrews to
145 ft.-lbs. (195 Nm).
• Apply general-purpose chassis grease to Sideshifter
upper and lower bearings.
2.3
1000-Hour
Maintenance
After each 1000 hours of truck operation, in addition to
the 100 and 300-hour maintenance, perform the following
procedures:
• Inspect upper and lower bearings for wear. If any
bearing is worn to less than 3/32 in. (2.5 mm) thickness,
replace the entire bearing set. Refer to Section 4.2-2.
2.4
2000-Hour Maintenance
After 2000 hours of truck operation, in addition to the
100, 300 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.
2
Lower Bearing
Grease Areas
SS0187.eps
Lower Mounting Hooks
Front View
2000-Hour (Continued)
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).
220526-R6
T
3.1
ROUBLESHOOTING
General Procedures
WARNING: Before servicing any
hydraulic component, relieve pressure in
the Attachment system. Turn the truck off
and move the truck auxiliary control lever
several times in both directions.
Truck System Requirements
3.1-1
• Truck hydraulic pressure should be within the range
shown in Specifications, Section 5.1. PRESSURE TO
THE ATTACHMENT MUST NOT EXCEED 3500 psi
(245 bar).
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.
• Truck hydraulic flow should be within the range shown
in Specifications, Section 5.1.
• Hydraulic fluid supplied to the attachment must meet
the requirements shown in Specifications, Section 5.1.
3.1-2
Tools Required
In addition to a normal selection of mechanic’s hand tools,
the following are required:
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 Kits: 671476 (10 GPM – 37 L/min)
671477 (20 GPM – 75 L/min)
(2)No. 8-12 JIC/ O-Ring
• In-line Flow Meter Kit:
10 GPM (37 L/min) – Cascade Part No. 671476.
20 GPM (75 L/min) – Cascade Part No. 671477.
Flow Meter
GA0013.eps
• Pressure Gauge Kit:
5000 psi (345 bar) – Cascade Part No. 671212.
(2) No. 6-8 JIC Reducer
• Assorted fittings, hoses, and quick-disconnect couplers
as required.
Pressure Gauge Kit: 671212
3.1-3
Troubleshooting Chart
Determine All The 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 malfunction. Guidelines below and on the following
pages can then be used as a starting point to begin
troubleshooting.
Pressure
Gauge*
No. 6-6 Hose*
No. 6 and No. 8
JIC Swivel Tee
GA0014.eps
No. 4-6 Pipe/JIC*
No. 6-8 JIC
Reducer
No. 4, No. 6*
and
No. 8 JIC/O-Ring
Quick-Disconnect Couplers
Sideshift Circuit
Male Straight Thread
O-Ring Coupler:
No. 4 (Part No. 212282)*
No. 5 (Part No. 210378)
No. 6 (Part No. 678592)
• Attachment will not sideshift.
• Attachment sideshifts slowly.
To correct these problems, see Section 3.3.
Female JIC Thread
Coupler:
No. 4 (Part No. 210385)*
No. 6 (Part No. 678591)
AC0127.eps
* NOTE:
Diagnostics Kit 394382 includes items marked.
220526-R6
3
T
3.2
ROUBLESHOOTING
Plumbing
3.2-1 Hosing
Diagram
2-Port Hose
Reel or IHR
Sideshift
Cylinder
SSR
Hose
Terminal
SSL
Truck
Auxiliary
Valve
SS0178.eps
SIDESHIFT LEFT
SIDESHIFT RIGHT
Pressure:
Return:
3.2-2Hydraulic
Schematic
Sideshift
Cylinder
Flow Restrictors
SSR
SSL
Truck Auxiliary Valve
Truck Pump
Truck Relief
Valve
Truck Tank
SS0179.eps
4
220526-R6
T
3.3
ROUBLESHOOTING
Sideshift Function
WARNING: Before disconnecting hoses,
relieve pressure in the Attachment hydraulic
system. Turn the truck off and move the
truck auxiliary control handle several times
in both directions.
There are six potential problems that could affect the
sideshifting function:
• Inadequate upper bearing lubrication or worn
bearings. Refer to Section 4.2.
• Incorrect hydraulic pressure or flow from lift truck.
• External leaks.
• Lower mounting hooks installed with incorrect
clearance. Refer to Section 4.1 Step 7.
• Worn or defective cylinder seals. Refer to Section 4.3.
• Cylinder fittings or flow restrictors plugged, incorrect
type, or not installed properly. Refer to Section 4.3.
3.3-2
Supply Circuit Test
1 Check the pressure 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
1
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
RIGHT Hose
Sideshift Circuit Test
1 Sideshift fully to the left.
Turn the truck off and
relieve Attachment system pressure. Disconnect the
SIDESHIFT RIGHT 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 LEFT lever
for 5 seconds:
• If there is substantial hydraulic flow out of the drain
hose, the sideshift cylinder is faulty and requires
replacement. Refer to Section 4.3.
• 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. Refer to Section 3.3.
220526-R6
SS0180.ill
Cap
supply
fitting
Hose end in
drain bucket
2
Front View
5
S
4.1
ERVICE
Sideshifter Removal
1 Remove the forks from the attachment.
2 Remove the backrest from the attachment.
Seal Carriers
4
Sideshift Left
3
Sideshift Right
Cascade Backrests – For reassembly, 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.
reassembly.
SS0175.eps
A Dim.
Tag hoses for
4 If the hydraulic cylinder is to be serviced, loosen the
seal carriers before removing the attachment.
For reassembly, tighten seal carriers to:
Wear
Limit
Mark
Front View
Class II, III
1.81 in.
(46 mm)
Class IV
2.40 in.
(61 mm)
Class II/III – 120 ft.-lbs. (165 Nm)
Class IV – 235 ft.-lbs. (320 Nm)
5
A
Lower Mounting
Hooks (on rear)
SS0254.eps
5 Remove the lower mounting hooks and inspect for
wear. Refer to illustration. Replace if beyond wear limit.
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.
6 Attach an overhead hoist to the attachment and lift
away from the truck carriage.
7 For installation, reverse the above procedures with the
following exceptions:
• Clean and inspect carriage bars for damage and
smoothness. Bars should be parallel and ends flush.
Repair any protruding welds or damaged notches by
grinding, filing or welding.
6
• Clean all bearing areas of built-up dirt and grease.
• Inspect bearings for wear and replace as necessary.
Refer to Section 4.2-2.
• Install and adjust lower hooks as shown below.
CAUTION: Lower bearing clearance must be
adjusted as shown for proper sideshifter operation.
• Lubricate both upper and lower bearings with
general-purpose chassis grease.
7
BOLT-ON
Truck Carriage
Clearance:
.03 in. (0.8 mm) Min.
.06 in. (1.6 mm) Max.
Tighten bolts to:
Class II/III – 120 ft.-lbs. (165 Nm)
Class IV – 235 ft.-lbs. (320 Nm)
6
SS0176.eps
QUICK-CHANGE
Reverse guides to change
hook-to-carriage clearance.
Sideshifter
Clearance:
.03 in. (0.8 mm) Min.
.06 in. (1.6 mm) Max.
Offset on top
provides max.
clearance:
Class II/III –
.62 in. (16 mm)
Class IV –
.83 in. (21 mm)
SS0153.eps
Tighten capscrews to:
Class II/III – 120 ft.-lbs. (165 Nm)
Class IV – 190 ft.-lbs. (250 Nm)
220526-R6
S
ERVICE
4.2
Bearings
4.2-1
Bearing Lubrication
4.2-2
Upper Bearing
Grease Fittings
Lubricate both the upper and lower bearings with
chassis grease every 300 hours or 4 weeks of operation
(whichever occurs first). In contaminated environments
lubricate every week or as required.
Lower Bearing
Grease Areas
Bearing Service
1 Remove the attachment from the truck as described in
Section 4.1 and lay flat on a pallet or workbench.
2 Remove the retainer pins and remove the cylinder/
SS0157.eps
anchor bracket assembly from the frame.
3 Remove the upper bearings by driving them out of the
frame. If any bearing is worn to less than .09 in.
(2.5 mm) thickness, replace all the upper bearings.
IMPORTANT: Use a wood block or plastic hammer
to fully seat new bearings into upper frame. Refer to
illustration. Proper lower hook clearance requires that
upper bearings be fully seated into upper frame.
4 Remove the lower bearings by prying them from the
lower hook mounts. If any bearing is worn to less
than .09 in. (2.5 mm) thickness, replace all the lower
bearings. NOTE: Bronze lower bearings are retained
in place by a roll pin. Remove the bearing by pulling or
prying the pin out far enough to release the bearing.
5 For reassembly, reverse the above procedures.
Upper
Bearings
3
4
.09 in.
(2.5 mm)
min.
Cylinder
Retainer Pins
2
.09 in.
(2.5 mm)
min.
Lower Bearings
SS0183.eps
Retainer Pins
(bronze bearings only)
SS0182.eps
2
SS0185.eps
Cylinder / Anchor
Bracket Assembly
1
220526-R5
Sideshifter
Frame
7
S
ERVICE
4.3
Cylinder
4.3-1
Removal, Inspection and
Replacement
NOTE: The attachment must be removed from the truck
in order to replace the cylinder/anchor bracket assembly
and the cylinder rod seals.
WARNING: Before removing hoses or
hydraulic components, relieve pressure in
the Attachment hydraulic system. Turn the
truck off and move the truck control handle
several times in both directions.
1 Remove the attachment from the truck as described in
Section 4.1 and lay flat on a pallet or workbench.
2 Remove the retainer pins and remove the cylinder/
anchor bracket assembly from the frame. Refer to
illustration on previous page.
3 Inspect the outside of the cylinder shell for damage
that could impair performance or cause leaks under
pressure. If damage is found, replace the complete
cylinder assembly. IMPORTANT: Make sure cylinder
fittings and flow restrictors are installed as shown.
4 Inspect the cylinder rods for damage.
If bent or
scored, replace the complete cylinder assembly.
5 Inspect the anchor bracket and centering tab for
damage. If damage is found, replace the complete
cylinder assembly.
6 For reassembly, reverse the above procedures with the
following exceptions:
• Replace the cylinder retainer pins with new pins.
Cylinder / Anchor
Bracket Assembly
5
Centering Tab
Flow Restrictor
(each end of cylinder)
SS0191.eps
4
Cylinder rod
8
IMPORTANT: Fittings must bottom
against flow restrictor in cylinder port for
proper hydraulic flow characteristics.
3
Cylinder shell
220526-R6
S
4.3-2
ERVICE
Rod Seal Replacement
NOTE: The attachment must be removed from the truck to
replace the cylinder rod seals.
Cylinder/Anchor
Bracket Assembly
1 Loosen the seal carriers, then remove the attachment
3
Rod Seal
Carriers
4
from the truck as described in Section 4.1.
2 Remove the cylinder/anchor bracket assembly from the
attachment as described in Section 4.3-1.
3 Clamp the cylinder/anchor bracket in a soft-jawed vise.
CAUTION: Do not clamp on the cylinder shell.
SS0164.eps
4 With the cylinder rod centered, unscrew the seal
carriers from each end of the cylinder. Slide the seal
carriers off the cylinder rod. NOTE: If installing new
seal carriers loaded with seals, proceed to Step 8.
5 Remove the seals and O-ring by prying them out with a
brass O-ring tool as shown.
CAUTION: Do not scratch the seal grooves.
6 Clean the seal carrier and cylinder rod with cleaning
solvent. Break any sharp edges on the cylinder
rod end. Lubricate the new seals and O-rings with
petroleum jelly.
7 Install the seals into the seal carrier grooves.
Form the
seals into a ‘kidney’ shape to ease placement into the
bore. Note the direction of the U-cup seals: Pressure
seals are installed with the lip toward the center of
the cylinder (see illustration below).
5
8 Apply a thick film of petroleum jelly to the inside of the
Seal Removal Tool
(Part No. 674424)
seal carrier and carefully slide onto the cylinder rod.
Screw the seal carriers into the cylinder shell
9 For reassembly, reverse the above procedures with the
following exceptions:
• After the sideshifter is remounted on the truck,
tighten the seal carriers to 120 ft.-lbs. (165 Nm).
U-Cup Pressure Seal
O-Ring
SS0166.eps
Wiper
Seal
7
RC0488.eps
SS0163.eps
220526-R5
8
Rod
Seal Carrier
9
S
5.1
5.1-1
PECIFICATIONS
Specifications
Hydraulics
Truck Relief Setting
Iron Lower Hooks and
Composite Bearings
2000 psi (140 bar)
3500 psi (240 bar)
Bronze Upper and
Lower Bearings
2600 psi (180 bar)
3500 psi (240 bar)
Recommended
Maximum
Truck Flow Volume ➀
Min. ➁
Recommended
Max. ➂
55F, 65F
1 GPM
(4 L/min.)
2 GPM
(7.5 L/min.)
3 GPM
(12 L/min.)
100F, 120F,
150F, 165F
1 GPM
(4 L/min.)
4 GPM
(16 L/min.)
5 GPM
(20 L/min.)
➀ Cascade F-Series Sideshifters are compatible with SAE 10W petroleum base hydraulic fluid meeting Mil. Spec. MIL-0-5606 or MIL-02104B. 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 a slow sideshift speed.
➂ Flow greater than maximum can result in excessive heating, reduced
system performance and short hydraulic system life.
GA0090.eps
Hoses and Fittings
All supply hoses and fittings should be at least No. 4 with
3/16 in. (5 mm) minimum I.D.
5.1-2
Auxiliary Valve Functions
Check for compliance with ITA (ISO) standards:
Tilt
Forward
Sideshift
Left
Hoist Down
GA0387.eps
5.1-3
Hoist Up
Tilt
Back
Sideshift
Right
Truck Carriage
Carriage Mount Dimension (A) ITA (ISO)
A
Class II
Class III
Class IV
Minimum
Maximum
14.94 in. (380.0 mm)
18.68 in. (474.5 mm)
23.44 in. (595.5 mm)
15.00 in. (381.0 mm)
18.74 in. (476.0 mm)
23.50 in. (597.0 mm)
GA0091.eps
GA0028.eps
10
220526-R6
S
5.1-4
PECIFICATIONS
Torque Values
Fastener torque values for the F-Series Sideshifter are
shown in the table below in both U.S. and Metric units.
Torque values are also specified throughout the manual.
NOTE: All fasteners have a torque value range of ±10% of
stated value.
Ref.
Fastener
1
Lower Hooks
2
Backrest
3
Rod Seal Carrier
4
Pallet Guard
Size
Ft.-lbs.
Nm
M16
5/8 in.
120
165
M16
145
195
–
120
165
M16
145
195
2
1
4
220526-R6
3
SS0181.eps
11
Do you have questions you need
answered right now? Call your nearest Cascade Service Department.
Visit us online at www.cascorp.com
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
Fax: 39-045-8989160
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 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
Tel: +64-9-273-9136
Fax: +64-9-273-9137
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
c
© Cascade Corporation 2015
01-2015
Part Number 220526-R6
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