E-Series Sideshifter User Manual
Contents
1. U SER MANUAL E Series ONTENTS Sideshifter Page INTRODUCTION Special Definitions 2 OPERATION Safety Rules 3 Industrial Lift Trucks 3 Handling Loads 4 Sideshifter Operation 4 Safe Operation and Maintenance 5 OSHA Regulations 5 INSTALLATION Truck Requirements 6 Recommended Hydraulic Supply 6 Installation Procedure 7 INSPECTION amp MAINTENANCE Daily 9 100 Hour Maintenance 9 500 Hour Maintenance 9 1000 Hour Maintenance 9 PARTS Product Identification 9 Base Unit 10 Cylinder 11 Recommended Spare Parts back cover Publications back cover Contacting Cascade back cover Manual Number 218197 R 2 cascade Cascade is a Registered Trademark of Cascade Corporation 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 A WAR2. 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 ii 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 218197 Rev 2 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 b
3. t 70 0251 ill Tighten capscrews to 120 ft lbs 165 Nm NSTALLATION Flush supply hoses Install hoses Optional Installation Kit 205826 shown for SS0007 ill 8 Install backrest S0171 ill Cascade Backrest Tighten to 145 ft lbs 195 Nm For other S0010 ill backrests see OEM recommendations A Upper bearing Lubricate lower bearings grease fittings 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 Lower bearing grease areas S0011 ill 8 218197 Rev 2 NSPECTION amp MAINTENANCE WARNING After completing any service Fork Stops A procedure always test the Sideshifter Backrest through five complete cycles First test nae with no load then test with a load to make sure the attachment operates correctly Cylinder before returning it to the job and hoses Upper and for leaks lower hook D a i ly engagement 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 proced
4. 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 manufac turer 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 5 NSTALLATION Truck Requirements Truck Relief Setting 3500 psi 240 bar Maximum Truck Flow Volume 2300 psi 160 bar Recommended Min 2 Recommended Max 1GPM 2 GPM 3 GPM S5E 60E 4 L min 7 5 L min 12 L min ae 1GPM 4 GPM 5 GPM 4 L min 15 L min 19 L min Cascade E Series Sideshifters are compatible with SAE 10W petroleum base hydraulic fluid meeting Mil Spec MIL 0 56
5. 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 Il 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 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
6. 06 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 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 R Carriage Mount Dimension A ITA ISO GA0131 ill GA00238 ill 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 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 amp Cable Reel Selection Guide Part No 212199 to select the correct hose reel for the mast and truck EEEE q GA0026 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 Oe AR Hoist Up Tilt Si
7. 35 2 in 895 mm wide 583971 584001 Cylinder Assembly 36 0 in 915 mm wide 205847 Cylinder Assembly 38 3 in 975 mm wide 205843 Cylinder Assembly 40 1 in 1040 mm wide Z 583972 584002 Cylinder Assembly 40 2 in 1020 mm wide 205846 Cylinder Assembly 45 1 in 1145 mm wide Z 583973 Cylinder Assembly 48 0 in 1220 mm wide _ 584003 Cylinder Assembly 48 1 in 1220 mm wide 206370 Cylinder Assembly 48 8 in 1240 mm wide 205844 Cylinder Assembly 52 0 in 1320 mm wide 584004 Cylinder Assembly 55 2 in 1400 mm wide i 2 562131 562131 564408 Wiper Seal 2 562951 562951 3154 Snap Ring 3 2 562942 562942 564403 Retaining Ring 4 2 615131 Back Up Ring 5 2 218228 218228 2789 O Ring 6 2 562132 562132 564406 Rod Seal 7 1 562055 562055 564401 Rod Piston Assembly 8 2 563278 563278 564404 Bearing Ring 9 1 564141 564141 564407 Piston Seal 10 2 562792 562792 564402 Retainer 11 2 208378 208378 Rod End Cap 12 2 564226 564226 564226 Speed Control Washer 13 2 Spacer 14 E E E Cylinder Shell 563487 563487 564409 Service Kit Included in Service Kits 563487 55E amp 60E and 564409 100E E Not serviceable order new cylinder assembly 218197 Rev 2 Reference S 3816 S 4019 S 4060 S 6105 11 _ p Ants Recommended Spare Parts 55E 60E 100E UNITS SERVICED DESCRIPTION PART NUMBER PART NUMB
8. 6 10 2 211807 211807 Fitting Face Seal Adpt 4 6 11 2 675514 675957 Q D Hook 12 2 678832 678832 Pin Q D 13 4 683182 779019 Capscrew 14 2 675515 675958 Guide 15 2 205857 208355 Retainer 16 2 680253 202346 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 lt n O 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 ARTS Cylinder 0000 ZZZ pa SS0102 ill Cylinder Assembly Width a U U U U TAA 7 C si a 5 a S0065 il 55E 60E 100E REF QTY PART NO PART NO PART NO DESCRIPTION 205848 Cylinder Assembly 24 4 in 620 mm wide 205840 Cylinder Assembly 26 2 in 665 mm wide 205841 Ea Cylinder Assembly 28 9 in 735 mm wide 205842 Cylinder Assembly 31 9 in 810 mm wide 583970 Cylinder Assembly 34 1 in 865 mm wide 205845 Cylinder Assembly
9. ER PART NUMBER 1 5 6 19 20 50 BASE UNIT AND MOUNTING 204187 672018 672018 Upper Bearing 8 16 32 a 208350 208350 Lower Bearing 6 12 24 204186 204186 204186 Lower Hook 0 2 4 639121 639121 639121 Capscrew 0 4 8 553857 553857 553857 Nut 0 4 8 667225 667225 667225 Washer 0 4 8 CYLINDER E a Cylinder Assembly 0 0 1 563487 563487 564409 Cylinder Service Kit 1 2 562055 562055 564401 Rod 0 0 1 E See specific parts page for part number Publications 55E 60E 100E PART NO DESCRIPTION 218197 User Manual Operator Guide Installation Parts 205849 Service Manual 679929 Tool Catalog 673964 Literature Index Order Form 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 cascade cM Cascade Corporation 1999 9 99 Part Number 218197 R 2
10. NING 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 under standing 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 precau tions 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 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 autho
11. deshift GA0094 ill Back Right RHTHINLINE 2 Port Hose Reel Supply Group B Mast Single Internal Hose Reeving 218197 Rev 2 ed f NSTALLATION Installation Procedure A 1 Attach overhead hoist Lifting eye Model Serial Number Plate iT SS0130 ill WARNING Make sure overhead hoist has rated capacity of at least 1000 Ibs 450 kg Remove bolt on lower hooks Back Driver s View ll ss0004 ITA Class II 32 36 in 8 9 mm ITA Class IlI 39 43 in 10 11 mm 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 Truck Upper Carriage Bar Mount Sideshifter on truck carriage ITA Class II 60 66 in 15 17 mm ITA Class Ill 72 78 in 18 20 mm pee Engage locator tab with center notch Ss Back Driver s View Sideshifter F Clearance 1 32 in 0 8 mm Min he i 1 16 in 1 6 mm Max Remove cylinder retaining clips after mounting S0005 ill QUICK DISCONNECT 5 8 in 16 mm offset on top provides max clearance Reverse guides to reduce hook to carriage clearance l
12. e 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
13. orks AUXILIARY VALVE FUNCTIONS Hoist down Tilt forward GA0010 ill l Hoist up Tilt Back SIDESHIFTING A Sideshift Left B Sideshift Right B lt lt 218197 Rev 2 AFE OPERATION AND MAINTENANCE OSHA Regulations Industrial Trucks and Attachments Specific Regulations from OSHA 1910 178 industrial trucks is regulated by Occupational Safety and Health OSHA regulations 1910 178 and Ameri can 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 WARNING The safe operation and maintenance of 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
14. rized lift truck driver Backrest Cylinder Fork Stops 80127 ill Lower 218197 Rev 2 PERATION Safety Rules Industrial Lift Trucks No riders f No reaching through mast No standing under load KR wy 0O 0O o O With Ne Raise 3 in ap No load PS Ale te gs eE g a A e Motor off park lower load Traveling empty O e aaa aay La eee No parking on ramp No turning on ramp Watch clearances GA0048 ill se Mm pot oe Loe Observe Workers Stops 2 L DIE 0 0 up E s Slow for Sound horn slow Sound horn slow Wet floors Bumps Dips two way traffic at intersection at corner 218197 Rev 2 PERATION Safety Rules Handling Loads CAUTION Do not put side loads on forks Center load prior to traveling Raise load prior to sideshifting Limit sideshifting with raised load Limit truck movement with raised load Sideshifter Operation Top of load should not extend above backrest Ans d LOAD WEIGHT FP0017 ill 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 f
15. ures e Check for loose or missing bolts worn or damaged hoses hydraulic leaks and damaged or SS0127 ill Fasteners 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 1 000 Hour ans W After each 1000 hours of truck operation in addition to the 500 Hou r 100 and 500 hour maintenance perform the following procedures Pidka 500 hours of Feri P n addition to the Inspect upper and lower bearings for wear If any bearing 100 hour maintenance perform the following procedures is worn to less than 1 16 in 1 5 mm thick replace the e Tighten backrest capscrews Cascade to entire bearing set See Service Manual for replacement 145 ft lbs 195 Nm procedure Apply general purpose lithium based chassis grease to Inspect forks for wear NOTE Fork Safety Kit 3014162 is Sideshifter upper and lower bearings available containing wear calipers inspection sheets and safety poster Also available is fork hook amp carriage wear gauge 209560 CL Il and 209561 CL Ill _ p Ants Product Identification This Section shows replacement z parts for E Series Sideshifters The product serial number WARNING For the safety of yourself and is located on the nameplate on the back surface of the left others DO NOT instali he partsshown in arte vi this Manual unless you have thoroughl
16. y vertical bar driver s view and must be provided when reviewed the appropriate Service Manual ordering replacement parts 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 218197 Rev 2 9 P ARTS Base Unit Optional Quick Disconnect Lower Hooks SS0104 ill SS0137 ill Refer to the Product Price List for further information on Cascade backrests Contact your dealer for other OEM backrests 10 55E 60E 100E REF QTY PART NO PART NO DESCRIPTION 1 v 204187 672018 Upper Bearing Composite 1 204137 804065 Upper Bearing Bronze 2 1 a E Cylinder Anchor Assembly 3 v 208350 Lower Bearing 3 vy 208387 _ Lower Bearing 12 mm 3 h 204188 Lower Bearing 15 mm 3 v 207209 Lower Bearing 19 mm x4 4 553857 553857 Nut 5 8 UNC G5 5 2 204186 204186 Lower Hook 5 2 225570 225570 Lower Hook Bronze optional 6 4 667225 667225 Washer 7 4 639121 639121 Capscrew 5 8 UNCx1 50 G5 8 1 J J Frame 9 v 7403 7403 Grease Fitting 10 2 601676 601676 Fitting JIC 6 6 10 2 667222 667222 Fitting JIC 5 6 10 2 666984 666984 Fitting JIC 4
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