cascade corporation C Series User manual

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ERVICE MANUAL
S
C-Series
Integral Sideshifter
Manual Number 6020275-R2

ONTENTS
C
i6020275-R2
Page
INTRODUCTION, Section 1
Introduction 1
Special Definitions 1
PERIODIC MAINTENANCE, Section 2
Daily 2
1000-Hour Maintenance 2
2000-Hour Maintenance 2
TROUBLESHOOTING, Section 3
General Procedures 3
Truck System Requirements 3
Tools Required 3
Troubleshooting Chart 3
Plumbing 4
Hosing Diagram 4
Hydraulic Schematics 4
Sideshift Function 5
SERVICE, Section 4
Sideshifter Removal 6
Bearings 7
Bearing Lubrication 7
Bearing Service 7
Cylinders 8
Removal, Inspection, Replacement 8
Rod Seal Carrier Replacement 9
SPECIFICATIONS, Section 5
Specifications 10
Hydraulics 10
Auxiliary Valve Functions 10
Torque Values 11

NTRODUCTION
I
6020275-R2 1
1.1 Introduction
This manual provides the Periodic Maintenance,
Troubleshooting, Service and Specifications for C-Series
Integral Sideshifters.
In any communication about the attachment, refer to
the product catalog and serial numbers stamped on the
nameplate. If the nameplate is missing, the numbers can
be found stamped on the right front surface of the carriage.
NOTE: All specifications are shown in US and (Metric)
units where applicable. All fasteners have a torque value
range of ±10% of stated value.
IMPORTANT: Cylinder ports are #6 SAE O-Ring (.5625 in.
diameter, 18 UNF-2B) on all Integral Sideshifters.
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
your 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 your job easier.
SS0361.eps
Stamped model number,
serial number, specifications
Sticker showing parent numbers
and phone numbers for service
Stamped frame
part number
Stamped cylinder
assembly part
number
(opposite side)
Back (Driver's) View

6020275-R2
ERIODIC MAINTENANCE
P
2
WARNING: After completing any service
procedure, always test the Integral
Sideshifter through five complete cycles.
First test with no load, then test with a
load to make sure the sidehsifter operate
correctly before returning it to the job.
2.1 Daily
Check items shown each day. Report problems to your
supervisor. Refer to Troubleshooting and Service sections
for troubleshooting, maintenance and repair procedures.
NOTE: Carriage should be maintained per OEM service
specifications.
IMPORTANT: Visually check wear on lower hook and
capscrew conditions.
• Check for loose or missing bolts, worn or damaged
hoses, hydraulic leaks and damaged or missing fork
stops.
• Check decals and nameplate for legibility.
2.2 1000-Hour
Every time the lift truck is serviced or every 1000 hours
of truck operation, whichever comes first, complete the
following maintenance procedures:
• Tighten backrest capscrews (Cascade) to 145 ft.-lbs.
(195 Nm). For truck manufacturer's backrest, refer to
truck service manual.
• Inspect lower hooks for wear and proper clearance.
Adjust if necessary, refer to profile lower hook illustration
in Section 4.1. Tighten lower hook capscrews to
120 ft.-lbs (165 Nm).
• Lubricate Sideshifter upper and lower bearings with
general-purpose chassis grease.
• 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 for
replacement procedure.
2.3 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) and 209561
(Class III).
SS0386.eps
Backrest
Cylinder and
Hoses
Fork
Stops
Fasteners
Lower
Hooks
Forks
Grease Fitting
Fork
Locking
Pin
WARNING: If the fork locking pin is not
fully engaged, the fork could become
disengaged from the carriage.

6020275-R2
ROUBLESHOOTING
T
3
3.1 General Procedures
3.1-1 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.
3.1-2 Tools Required
In addition to a normal selection of hand tools, the following
are required:
• Inline Flow Meter Kit:
20 GPM (80 L/min.) - Cascade part no. 671477
• Pressure Gauge Kit:
3000 psi (200 bar) - Cascade part no. 671212
• Assorted fittings, lines, drain hoses and quick-couplers
as required.
3.1-3 Troubleshooting Chart
WARNING: Before servicing any
hydraulic component, relieve pressure in
the system. Turn the truck off and move
the truck auxiliary control valves several
times in both directions.
After completing any service procedure, 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.
Determine All The Facts – It is important that all
the facts regarding the problem are gathered before
beginning service procedures. The first step is to
talk to the equipment operator. Ask for a complete
description of the malfunction. The following
guidelines can then be used as a starting point to
begin troubleshooting procedures:
Sideshift Circuit
• Framewillnotsideshift.
• Framesideshiftsslowly.
To correct these problems, see Section 3.3.
AC0127.eps
GA0013.eps
GA0014.eps
Flow Meter Kit 671477
Pressure Gauge Kit 671212
Diagnostic Quick-Disconnects
No. 8-12 JIC/
O-Ring Flow Meterc
No. 6-8 JIC
Reducer
Pressure
Gauge★
No. 6-6 Hose★
No. 6 and No. 8
JIC Swivel Tee
No. 4-6 Pipe/JIC No. 6-8 JIC
Reducer No. 4, No. 6★
and No. 8
JIC/O-Ring
Male Straigh Thread
O-Ring Coupler:
No. 4 (Part No. 212282)★
No. 5 (Part No. 210378)
No. 6 (Part No. 678592)
Female JIC Thread
QD Coupler:
No. 4 (Part No. 210385)★
No. 6 (Part No. 678591)
★Included in Diagnostics Kit 394382

ROUBLESHOOTING
6020275-R2
T
4
3.2 Plumbing
3.2-1 Hosing Diagram
3.2-2 Hydraulic Schematic
SS0438.eps
SIDESHIFT LEFT
PRESSURE
RETURN
NOTE: For SIDESHIFT RIGHT,
reverse the colors shown. Truck
Auxiliary
Valve
SSL
SSR
Sideshift
Cylinder
2-Port Hose
Reel or IHR
Hose
Terminal
SS0179.eps
Truck Auxiliary Valve
SSLSSR
Sideshift
Cylinder
2-Port Hose
Reel or IHR
Flow Restrictors
Truck Pump
Truck Relief
Valve
Truck Tank

6020275-R2
ROUBLESHOOTING
T
5
3.3 Sideshift Function
There are five 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.
• Lower mounting hooks installed with incorrect
clearance. Refer to Section 4.1, Step 4.
• External leaks due to 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 Fully sideshift to the left. Hold the lever in the
SIDESHIFT LEFT position for a few seconds. Release
the lever and check the external leaks at fittings, hoses
and cylinder rod ends.
3.3-3 Sideshift Circuit Test
1 Fully sideshift to the left. Turn the truck off. Relieve
the 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.
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.
SS0439.eps
1
2
Sideshift RIGHT
Hose disconnected
Cap supply fitting
Hose end in
drain bucket
Sideshifted
LEFT

6020275-R2
ERVICE
S
6
4.1 Sideshifter Removal
NOTE: The following procedure describes removal of
the sideshifting frame only. To remove the cylinder, see
Section 4.3. To remove the integral sideshifting carriage
from the mast, refer to OEM Service Manual procedures.
1 Remove the forks and backrest from the sideshifter
frame. For Cascade backrest reassembly, tighten the
capscrews to 145 ft.-lbs. (195 Nm).
2 Remove the lower mounting hooks and inspect for wear.
For reassembly, adjust hooks as shown below and
tighten to 120 ft.-lbs. (162 Nm).
3 Install an M12 lifting eye in the center threaded hole in
the frame's top bar. Use a 1000 lb. (450 kg) capacity
overhead hoist and lift the frame away from the truck
carriage.
NOTE: Bearings and cylinder will remain on the integral
carriage bars.
4 For installation, reverse the above procedures with the
following exceptions:
• Clean and inspect carriage bars for damage and
smoothness. Make sure that bars are parallel and
that ends are flush.
• Clean all bearing areas of built-up dirt and grease.
• Inspect sideshifter bearings for wear and replace as
necessary. Refer to Section 4.2-2.
• Install and adjust lower hooks as shown below.
CAUTION: Lower hook clearance must be adjusted
as shown for proper sideshifter operation.
• Lubricate both upper and lower sideshifter bearings
with general-purpose chassis grease.
SS0468.eps
SS0448.eps
SS0365.eps
SS0442.eps
2
4
Lower
Mounting
Hooks
Wear
Limit
Mark
Front Views
Lower Hook
3
Minimum
1.8125 in.
(46 mm)
Tighten capscrews to
120 ft.-lbs. (165 Nm)
Clearance:
1/32 in. (0.8 mm) Min.
1/16 in. (1.6 mm) Max.
Sideshifting
Frame
FRONT
Mast
Carriage
Front View Lower
Mounting
Hooks

6020275-R2
ERVICE
S
7
4.2 Bearings
4.2-1 Bearing Lubrication
Lubricate both the upper and lower sideshifter bearings
with chassis grease every 1000 hours or 13 weeks of
operation, whichever occurs first. In contaminated
environments lubricate every week or as required.
4.2-2 Bearing Service
1 Remove the sideshifter frame from the truck carriage as
described in Section 4.1.
2 Remove the upper bearings and check thickness as
shown. Replace all the upper bearings if any bearing is
worn to less than:
A–.10 in. (2.5 mm)
and
B–.08 in. (2.0 mm)
IMPORTANT: Make sure that new upper bearings
are properly seated in upper integral carriage bar, as
shown. Lower hook clearance will not be correct if
upper bearings are installed incorrectly.
3 Remove the lower bearings by prying them from the
lower integral carriage bar. If any bearing is worn to
less than 3/32 in. (2.5 mm) thickness, replace all the
lower bearings.
4 Clean integral carriage bars with solvent and inspect for
damage.
5 For reassembly, reverse the above procedures with the
following exceptions:
• Grease upper and lower bearings with
general-purpose chassis grease.
SS0443.eps
SS0446.eps
SS0445.eps
Upper Bearing
Grease Fittings
Lower Bearing
Grease Areas
Front View
2
34
Lower Bearings
Integral Carriage Bars
Upper Bearings
Check Bearing
Thickness
3/32 in.
(2.5 mm)
min.
Front View
SS1079.eps
A
B

6020275-R2
ERVICE
S
8
4.3 Cylinders
4.3-1 Removal, Inspection and
Replacement
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 Disconnect the hoses from the cylinder and tag for
reassembly. Cap the cylinder fittings.
2 Remove the hairpin clips and clevis pins from the
carriage mounting yokes. Remove the cylinder. Keep
track of shims.
3 Inspect the outside of the cylinder shell for damage
that could impair performance or cause leak under
pressure. If damage is found, replace the complete
cylinder assembly.
NOTE: Internal piston seals are not serviceable.
Replace the complete cylinder.
4 Inspect the cylinder rods for damage. If bent or scored,
replace the complete cylinder.
5 Inspect the carriage mounting yokes for damage.
Repair the yokes or replace the carriage.
6 For reassembly, reverse the above procedures with the
following exceptions:
• Make sure cylinder anti-roll pin is in place.
• Replace rod seal carriers as shown in Section 4.3-2.
• Make sure shims are in place on seal carrier
opposite cylinder roll pin. Shim this side only for a
maximum of 0.5 mm clearance with cylinder in place.
SS0440.eps
SS0467.eps
SS0452.eps
SS0447.eps
1
2
4
6
3
Clevis Pin,
Hairpin Clip
Cylinder
Sideshift LEFT Sideshift RIGHT
6Aint-Roll Pin
Cylinder Rod
Flow Restrictor
(both ports)
Cylinder Shell Seal Carrier
Shims
(as required)
IMPORTANT: Shim cylinder
(end opposite roll pin) for
0.5 mm max. clearance when
mounted in sideshifting frame.
IMPORTANT: Fittings must bottom
against flow restrictor in cylinder port for
proper hydraulic flow characteristics.

6020275-R2
ERVICE
S
9
4.3-2 Rod Seal Carrier
Replacement
NOTE: The rod seal carriers are the only field serviceable
parts on the cylinder and are supplied with the seals
already loaded. The cylinder must be removed from the
carriage to replace the seals.
1 Remove the cylinder from the carriage as described in
Section 4.3-1.
2 Clamp the end of the cylinder in a soft-jawed vise.
CAUTION: Do not clamp on the cylinder shell. Clamp
on the ends of the cylinder only.
3 Unscrew the seal carrier from each end of the cylinder
and slide off the cylinder rod.
4 For reassembly, reverse the above procedures with the
following exceptions:
• Break any sharp edges on the cylinder rod end and
clean with solvent.
• Make sure seals and O-ring are in place. Apply
a thick film of petroleum jelly to the interior bore.
Carefully slide the seal carrier onto the cylinder
rod and screw into the cylinder retainer. Tighten to
240 ft.-lbs. (325 Nm).
SS0450.eps
SS0449.eps
3
2
Rod Seal
Carrier
Cylinder
Assembly
Rod U-Cup
Pressure Seal
O-Ring
Wiper
Retainer
Seal Carrier
4

6020275-R2
PECIFICATIONS
S
10
5.1 Specifications
5.1-1 Hydraulics
GA0176.eps
Truck Relief Setting
2300 psi (160 bar) Recommended
3500 psi (245 bar) Maximum
Truck Flow Volume➀
Min.➁Recommended Max.➂
35C, 55C, 70C 1 GPM
(4 L/min.)
2 GPM
(7.5 L/min.)
3 GPM
(12 L/min.)
➀Cascade Integral Sideshifters are compatible with SAE 10W
petroleum base hydraulic fluid meeting mil. Spec. MIL-0-5606 or
MIL-0-1204B. Use of synthetic or aqueous base hydraulic fluid is
not recommended. If fire resistant hydraulic fluid is required,
special seal must be used. Contact Cascade.
➁Flow less than recommended will result in slow sideshift speed.
➂Flow greater than maximum can result in excessive heating,
reduced system performance and reduced hydraulic system life.
Hoses and Fittings
All supply hoses and fittings should be at least No. 6 with
9/32 in. (7 mm) minimum ID.
5.1-2 Auxiliary Valve Functions
Check for compliance with ANSI (ISO) standards:
GA0126.eps
Hoist Down
Tilt Forward
Sideshift Left
Hoist Up Tilt
Back
Sideshift
Right

6020275-R2
PECIFICATIONS
S
11
Ref. Fastener Location Size Ft.-lbs. Nm
1Lower hooks capscrews M16
5/8 in. 120 165
2Backrest capscrews M16 145 195
3Rod Seal Carrier 1-5/16 in. 240 325
4Pallet Gaurd M16 145 195
5.1-4 Torque Values
Fastener torque values for the C-Series Integral Sideshifter
is shown in the table below in both US and Metric units.
All torque values are also called out in each service section
throughout the manual.
SS0451.eps
1
2
3
4

Cascade Corporation 2012 09-2012 Part Number 6020275-R2
c
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: [phone]
Cascade Canada Inc.
5570 Timberlea Blvd.
Mississauga, Ontario
Canada L4W-4M6
Tel: [phone]
Fax: [phone]
Cascade do Brasil
Rua João Guerra, 134
Macuco, Santos - SP
Brasil 11015-130
Tel: [phone]
Fax: [phone]
EUROPE-AFRICA
Cascade Italia S.R.L.
European Headquarters
Via Dell’Artigianato 1
37030 Vago di Lavagno (VR)
Italy
Tel: [phone]
Fax: [phone]
Cascade (Africa) Pty. Ltd.
PO Box 625, Isando 1600
60A Steel Road
Sparton, Kempton Park
South Africa
Tel: [phone]
Fax: [phone]
ASIA-PACIFIC
Cascade Japan Ltd.
2-23, 2-Chome,
Kukuchi Nishimachi
Amagasaki, Hyogo
Japan, 661-0978
Tel: [phone]
Fax: [phone]
Cascade Korea
121B 9L Namdong Ind.
Complex, 691-8 Gojan-Dong
Namdong-Ku
Inchon, Korea
Tel: [phone]
Fax: [phone]
Cascade-Xiamen
No. 668 Yangguang Rd.
Xinyang Industrial Zone
Haicang, Xiamen City
Fujian Province
P.R. China 361026
Tel: [phone]
Fax: [phone]
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: [phone]
Fax: [phone]
Cascade Australia Pty. Ltd.
1445 Ipswich Road
Rocklea, QLD 4107
Australia
Tel: [phone]
Fax: [phone]
Cascade New Zealand
15 Ra Ora Drive
East Tamaki, Auckland
New Zealand
Tel: [phone]
Fax: [phone]
Sunstream Industries
Pte. Ltd.
18 Tuas South Street 5
Singapore 637796
Tel: [phone]
Fax: [phone]