cascade corporation K Series User manual

Cascade is a Registered Trademark of Cascade Corporation
cascade
corporation
ERVICE MANUAL
S
K-Series
Integral Sideshifting
Fork Positioner
Manual Number 6083966-R4

ONTENTS
C
i6083966-R4
Page
INTRODUCTION, Section 1
Introduction 1
Special Definitions 1
PERIODIC MAINTENANCE, Section 2
100-Hour Maintenance 2
300-Hour Maintenance 2
1000-Hour Maintenance 2
2000-Hour Maintenance 3
TROUBLESHOOTING, Section 3
General Procedures 4
Truck System Requirements 4
Tools Required 4
Troubleshooting Chart 4
Plumbing 5
Hosing Diagram 5
Hydraulic Schematic 5
Fork Position Function 6
Supply Circuit Test 6
Fork Position Circuit Test 6
Sideshift Function 7
Supply Circuit Test 7
Sideshift Circuit Test 7
SERVICE, Section 4
Fork Positioner Removal 8
Removal and Replacement 8
Fork Carrier Configuration 11
Fork Positioner Service 12
Disassembly 12
Inspection 12
Reassembly 13
Sideshifter Frame Removal 14
Bearings 13
Bearing Lubrication 15
Bearing Service 15
Sideshift Cylinder 16
Removal, Inspection and Replacement 16
Rod Seal Carrier 17
SPECIFICATIONS, Section 5
Hydraulics 18
Auxiliary Valve Functions 18
Torque Values 19

NTRODUCTION
I
6083966-R4 1
1. 1 Introduction
This Manual provides the Installation, Periodic
Maintenance, Troubleshooting, Service and Specifications
for Cascade K-Series Integral Fork Positioner.
In any communication about the attachment, refer to the
product ID Label.
IMPORTANT: K-Series Integral Fork Positioner/ Sideshifter
is metric. Supply fittings adapted as required for application.
NOTE: Specifications are shown in both inch and (Metric)
units. All fasteners have a torque value range of ±10% of
stated value.
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.
FP1120.eps
Catolog Number, Serial Number
Capacity, weight, horizantal CG
ID Label
Stamped Fork Positioner
Part Number Back (Driver's) View

6083966-R4
ERIODIC MAINTENANCE
P
2
2.1 100-Hour Maintenance
Every time the lift truck is serviced or every 100 hours
of truck operation, whichever comes first, complete the
following maintenance procedures:
• Check for loose or missing capscrews, worn or
damaged hoses, and hydraulic leaks.
• Inspect sideshifter lower hooks for wear and proper
clearance. To adjust see Service Section 4.3 Step 4..
• If required, tighten capscrews as follows:
Fork Positioner Mounting Flanges – 50 ft.-lbs. (65 Nm)
Fork Carriers – 25 ft.-lbs (35 Nm)
FP Cylinder Rod Anchor Plugs – 50 ft.-lbs. (65 Nm)
Sideshifter Lower Hooks – 120 ft.-lbs. (165 Nm)
2.2 300-Hour Maintenance
After each 300 hours of truck operation, in addition to the
100-hour maintenance, perform the following procedures:
• Cascade Backrest only: Tighten capscrews to
145 ft.-lbs. (195 Nm).
• Apply general-purpose chassis grease to sideshifter
upper bearing grease fittings and sideshifter lower
bearings. Apply a single pump of grease for the fork
carrier grease fittings.
• Apply graphite dry-lube to fork carriage bars as
required ('Slip Plate Aerosol' - Cascade part no. 599489,
'GraphoKote', or equivalent).
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 fork carriers for looseness on bearing tubes,
and cylinder rod anchors for excessive end play.
NOTE: Cylinder rod anchors operate with a loose
clearance.
• Inspect Sideshifter 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 Service
Section 4.3.
• Inspect forks and carriage bars for wear.
NOTE: Cascade fork safety kit 3014162 available with
wear calipers, inspection sheets and safety poster.
Also available, Cascade fork hook & carriage bar wear
gauge 209560 (CL II) and 209561 (CL III).
WARNING: After completing any service
procedure, always test the Fork Positioner/
Sideshifter through five complete cycles
to make sure the attachment operates
correctly before returning it to the job.
FP0861.eps
Back (Driver's) View
Lubrication Points
FP0872.eps
Cylinders
and hoses
Fork Carriers
and Retainers
Fork Positioner
Mounting Flange
Capscrews
(outside frame)
Forks
Fork Carriage
Bars
Lower Hooks
Cylinder Rod
Anchor Plugs
Backrest

6083966-R4
ERIODIC MAINTENANCE
P
3
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.
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).

ROUBLESHOOTING
6083966-R4
T
4
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
(241 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 Specification, 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:
10 GPM (37 L/min) – Cascade Part Number 671476
OR
20 GPM (75 L/min) – Cascade Part Number 671477
• Pressure Gauge Kit:
5000 psi (345 bar) – Cascade Part Number 671212
• Assorted fittings, lines, drain hoses and quick-couplers
as required.
3.1-3 Troubleshooting Chart
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:
Fork Positioning Circuit
• Forks do not move.
• Forks move slowly or unevenly.
To correct one of these problems, see Section 3.3.
Sideshft Circuit
• Attachment will not sideshift.
• Attachment sideshifts slowly.
To correct one of these problems, see Section 3.4.
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.
GA0013.eps
GA0014.eps
AC0127.eps
Flow Meter Kits: 671476 (10 GPM – 37 L/min)
671477 (20 GPM – 75 L/min)
Pressure Gauge Kit: 671212
Quick-Disconnect Couplers
(2) No. 8-12 JIC/
O-Ring Flow Meter
(2) No. 6-8 JIC Reducer
Pressure
Gauge★
No. 4-6 Pipe/JIC★
No. 6-6 Hose★
No. 4, No. 6★
and No. 8
JIC/O-Ring
No. 6 and No. 8
JIC Swivel Tee
No. 6-8 JIC
Reducer
Male Straight Thread
O-Ring Coupler:
No. 4 (Part No. 212282)★
No. 5 (Part No. 210378)
No. 6 (Part No. 678592)
Femail JIC Thread
Coupler:
No. 4 (Part No. 210385)★
No. 6 (Part No. 678591)
★ Included in Diagnostics Kit 394382

6083966-R4
ROUBLESHOOTING
T
5
3.2 Plumbing
3.2-1 Hosing Diagram
FP0757.eps
Fork Position Cylinders
Manifold OPEN
Port
CLOSE
Port
Sideshift
Cylinder
IHR Terminals
Truck Auxiliary
Valve FORK
POSITION
Truck Auxiliary
Valve
SIDESHIFT
SSR
SSL
3.2-2 Hydraulic Schematic
FP0721.eps
Fork Position Cylinders (2)
ManifoldFlow
Restrictors (2)
CLOSE OPEN
Sideshift Cylinder
SSR SSL
IHR
Terminals
Truck
Pump
Truck
Tank
Truck Auxiliary
Valve (SIDESHIFT)
Truck Relief
Valve
Truck Auxiliary Valve
(FORK POSITION)
SIDESHIFT LEFT,
CLOSE FORKS
PRESSURE
RETURN
NOTE: For SIDESHIFT RIGHT,
OPEN FORKS reverse the
colors shown.

ROUBLESHOOTING
6083966-R4
T
6
3.3 Fork Position Function
Five potential problems can affect the fork positioning
function:
• Binding due to bending damage, wear, lack of
lubrication.
• Incorrect hydraulic pressure or flow from truck.
• Flow restrictor fittings plugged or improperly
adjusted.
• Solenoid equipped: Electrical circuits faults, defective
solenoid coil or valve.
• External leaks due to worn or defective cylinder
seals.
3.3-1 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 FORK POSITIONER MUST NOT
EXCEED 3500 psi (241 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 open the forks. Hold the lever in the OPEN position
for several seconds. Release the lever and check for
external leaks at the fittings, tubing, hose, and manifold.
3.3-2 Fork Position Circuit Test
1 If equipped, press the solenoid button. Listen for a
'click' as the solenoid valve. If no sound is heard, check
the fuse, wiring and coil. Repair as necessary.
IMPORTANT: Solenoid-operated valve should be
plumbed so that the solenoid is energized during the
fork-positioning function.
2 Fully open or close the forks. If the forks move
unevenly, slowly or not at all, check flow restrictors for
contamination or improper adjustment. Refer to Section
4.1. Speed should be 3 in. (75 mm) per second at
specified flow rate.
3 If forks still do not move correctly, fully close forks. Turn
the truck off. Relieve the attachment's system pressure.
Disconnect the OPEN supply hose from the truck hose
terminal and route to a drain bucket. Cap the supply
fitting.
4 Start the truck and slowly actuate the CLOSE forks lever
until forks are fully closed. Hold lever for 5 seconds.
• If there is substantial hydraulic flow out of the drain
hose, one of the cylinders has faulty piston seals.
Replace the complete unit or service the piston seals
(see Section 4.2).
• If there is little or no hydraulic flow out of the hose,
the problem is not hydraulic. Refer to Section 3.3.
FP1121.eps
Flow Restrictors
(each end)
2
3
CLOSE Forks
Supply Hose
OPEN Forks
Supply Hose
Cap supply fitting
Hose end in
the bucket
Back (Driver's) View
WARNING: Before removing any
hoses, relieve pressure in the hydraulic
system. With the truck off, open the
truck auxiliary control valve(s) several
times in both directions.

6083966-R4
ROUBLESHOOTING
T
7
3.4 Sideshift Function
Six potential problems can affect the sideshifting function:
• Binding due to bending damage, wear, lack of
lubrication.
• Incorrect hydraulic pressure or flow from truck.
• Flow restrictor orifices plugged, incorrect type, or
improperly installed.
• Solenoid equipped: Electrical circuit faults, defective
solenoid coil or valve.
• Lower mounting hooks installed with incorrect
clearance.
• External leaks due to worn or defective cylinder
seals.
3.4-1 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 FORK POSITIONER MUST NOT
EXCEED 3500 psi (241 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 several seconds. Release
the lever and check for external leaks at the fittings,
hoses and cylinder rod ends.
3.4-2 Sideshift Circuit Test
1 If equipped, press the solenoid button. Listen for a
'click' as the solenoid valve. If no sound is heard, check
the fuse, wiring and coil. Repair as necessary.
IMPORTANT: Solenoid-operated valve should be
plumbed so that the solenoid is not energized during
the sideshifting function (straight-through).
2 Fully sideshift right. Turn the truck off and relieve
the attachment's system pressure. Disconnect the
SIDESHIFT LEFT supply hose from the truck hose
terminal and route to a drain bucket. Cap the supply
fitting.
3 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 is faulty and requires
replacement. Refer to Section 4.5-1.
• If there is little or no hydraulic flow out of the hose,
first check for plugged or incorrectly-installed flow
restrictor washers and fittings. Refer to Section 4.5-1.
If there is still no hydraulic flow, the problem is not
hydraulic. Refer to Section 3.4.
FP1122.eps
Sideshift RIGHT
Supply Hose Sideshift LEFT
Supply Hose
Cap supply fitting
Hose end in
drain bucket 2
WARNING: Before removing any hoses,
relieve pressure in the hydraulic system.
With the truck off, open the truck auxiliary
control valve(s) several times in both
directions.

6083966-R4
ERVICE
S
8
4.1 Fork Positioner
4.1-1 Removal and Replacement
1 Remove capscrews fastening inner fork carriers and
remove forks.
2 If equiped, remove backrest to provide access to
Fork Positioner mounting capscrews. For Cascade
backrests only, tighten capscrews to 145 ft.-lbs.
(195 Nm).
WARNING: Make sure locking pins are
removed from the forks. Forks must slide
freely on sideshifter frame or carriage bars.
WARNING: Before removing any hoses,
relieve pressure in the hydraulic system.
With the truck off, open the truck auxiliary
control valve(s) several times in both
directions.
3 Disconnect supply hoses from Fork Positioner manifold
and tag for reassembly.
FP1123.eps
1
Fork Carrier
Capscrews
Fork Carrier
Outer Section
Fork Carrier
Inner Section
FP0858.eps
Fork Positioner
Assembly
CLOSE
Forks
OPEN
Forks
Manifold

6083966-R4
ERVICE
S
9
4 Remove capscrews fastening Fork Positioner to
sideshifter frame and remove unit through front. Keep
track of shims. For reassembly, shim as necessary,
with a maximum of 4 shims per side. Tighten mounting
capscrews to 50 ft.-lbs. (65 Nm).
CAUTION: Maximum difference in number of shims per
side is 2 and the total allowable gap before tightening
capscrews is 0.020 in. (0.5 mm).
FP1125.eps
K-Series Fork Positioner Mounting
Sideshifter
FRONT
Fork Positioner
Capscrews –
Use lockwashers
and tighten to
50 ft.-lbs. (65 Nm).
Shims –
Maximum 4 per side to reduce
total allowable gap is .020 in.
(0.5 mm) maximum.
4
4
4.1-1 Removal and Replacement (Continued)
FP1416.eps
Recommended Torque Sequence
B
C
D
FRONT
ALH side top
BRH side bottom
CRH side top
DLH side bottom
A
Fork Carriers
Confirm fork carriers are
behind face of carriage
using a straight edge.
RH Side
LH Side

6083966-R4
ERVICE
S
10
5 For installation, reverse the above procedures with the
following exceptions:
• Service fork positioner components. Refer to Section
4.2.
• If necessary, adjust flow restrictors for equal fork
movement as follows:
A Loosen jam nuts and screw both flow restrictors in
until they bottom.
B Fully open and close forks. Look for unequal fork
movement.
C Adjust the flow restrictor for the faster fork by
screwing the flow restrictor inward, CW, 1/2 turn
and test again.
D Repeat procedure until fork movement is equal.
Positioning speed should be 3 in. (75 mm)/second.
Tighten jam nuts.
FP0760.eps
Flow Restrictor (each side)
4.1-1 Removal and Replacement (Continued)

6083966-R4
ERVICE
S
11
FP0867.eps
Fork Carrier
Inner Retainer Capscrews
Fork Carrier
Outer Retainer
WARNING: For forks longer than 60 in.
(1500 mm) or load centers exceeding
30 in. (760 mm), consult Cascade.
FP1543.eps
Narrow Inner
Retainer
(6042443)
Wide Inner
Retainer with
Shims (6805182)
Wide Inner Retainer
w/Spacer Bar (6052316)
Rotate Inner
Retainer 180
Degrees
Wide Inner Retainer
(6052301) Outer Retainer
Outside
5 in.
(122 mm)
Fork
4 in.
(100 mm)
Fork
4 in.
(100 mm)
Fork
5.1 in.
(130 mm)
Fork
3 in.
(80 mm)
Fork
3 in.
(80 mm)
Fork
FORK CARRIER CONFIGURATIONS
RH Front Views
NOTE: Recommended gap between sides of fork and fork retainer is 0.08-0.16 in. (2.0-4.0 mm).
4.1-2 Fork Carrier Configuration
NOTE: Refer to the layouts below to position inner retainers
for various fork widths. Tighten fork carrier inner retainer
capscrews to 25 ft.-lbs. (35 Nm).

6083966-R4
ERVICE
S
12
4.2 Fork Positioner Service
4.2-1 Disassembly
1 Use C-clamps to clamp Fork Positioner face down onto
a benchtop as shown. Use 2 x 4 in. (5 x 10 cm) wood
blocks for clearance and to keep parts in alignment.
FP1189.eps
Anchor
Plug
Keepers
Cylinder
Rod
Tool
6039273
Cylinder
Retainer
FP1190.eps
Tool
6048031
Cylinder
Shell
2 Remove cylinder rod anchor plug. Move fork carrier
toward manifold and remove half-ring keepers. Move
cylinder rod to fully retracted position as shown.
3 Unscrew cylinder retainer using Cascade Socket Tool
6039273 to remove cylinder assembly from manifold.
4 Disconnect hydraulic tubes at manifold. Remove
C-clamp and remove cylinder/fork carrier assembly.
IMPORTANT: If tubes are removed from cylinder head
end, reinstall prior to installation of cylinder/fork carrier
assembly to manifold. Do not bend tubes.
5 Slide fork carrier from cylinder shell. Remove piston/rod
assembly from cylinder shell.
6 Remove all seals, O-ring, wear rings and bearings from
components, as shown.
CAUTION: Do not scratch seal grooves. Use brass seal
removal tools to pry items from grooves.
7 If required, unscrew cylinder shell from head end using
Tool 6048031, as shown. For reassembly, replace
cylinder head end O-ring and apply Loctite 242 (blue)
to threads. Clamp head end in vise and tighten shell to
200 ft.-lbs. (270 Nm).
NOTE: Capscrew (M25 x 1.5 x 60 mm L) and Jam Nut
(M25 x 1.5) may also be used.
5.2-2 Inspection
IMPORTANT: If bending damage is found, Fork Positioner/
Sideshifter assembly should be replaced as a complete
unit.
• Inspect rod, piston and retainer for nicks and burrs.
Remove minor imperfections using 400 grit emery cloth.
• Inspect cylinder bore for minor nicks and burrs.
Remove minor imperfections with a hone (butterfly).
• Inspect cylinder shells for deformities, cracks that could
impair performance or cause leaks under pressure.
• Inspect fork carrier bearings for wear (see 1000 hour
inspection criteria) and replace as necessary.
Piston/ Rod
Assembly
Cylinder
Shell
Fork Carrier

6083966-R4
ERVICE
S
13
4.2-3 Reassembly
1 Lubricate new seals, O-rings and wear rings with O-ring
lube, hydraulic fluid or petroleum jelly.
2 If necessary, use 400-grit emery cloth to break any
sharp edges on the piston, retainer and cylinder shell
chamfer angles and threads to prevent seal damage.
3 Install new seals, O-rings, wear rings and fork carrier
bearings as shown below. See retainer seal loading
technique shown to the right.
NOTE: Fork carrier bearings snap into their respective
grooves. Bronze bearings consist of three separate
segments.
4 Install piston/rod assembly into cylinder shell. Push rod
fully into cylinder.
CAUTION: Make sure piston seal is not damaged by
cylinder shell threads during installation.
5 Slide fork carrier onto cylinder shell with the capscrew
heads facing outwards.
6 Align cylinder assembly to manifold and engage
opposite cylinder rod into fork carrier.
NOTE: Install external spacer on cylinder rod, if
required. Install cylinder retainer through opposite side
of manifold and screw partially into cylinder shell.
7 Make sure cylinder is properly oriented with restrictor
fittings on backside. Engage tubes and screw retainer
fully into shell. Reclamp assembly to bench.
8 Tighten retainer to 120 ft.-lbs. (165 Nm). Tighten
hydraulic tubes at manifold and cylinder head end.
FP0709.eps
FP0710.eps
FP0829.eps
Use flat brass
O-ring tool to seat
seals fully into groove.
3/8 in. (10 mm)
pin punch –
no sharp edge
Lubricate seal and force
partially into groove.
Note Seal Direction.
Twist seal into 'figure 8' or
'half-circle' shape to
insert into retainer.
1/2 in. (12-15 mm)
diameter rod
located flush with
bottom of seal
groove.
3
INSTALLING RETAINER INTERNAL SEALS
FP0703.eps
O-rings
U-Cup Pressure Seal
Note Seal Direction
Wiper seal Wear Ring
Two-Piece
Pressure Seal Wipers Composite or Bronze Bearings
External
Spacer
(if required)
Retainer Piston Fork Carrier
Retainer Manifold Cylinder
Shell
Cylinder
Rod
Inner Fork
Carrier
Outer Fork
Carrier
Internal
Spacer
(if required)
Fork Carrier
Capscrews
O-ring
Head End/
Mounting Foot
Back (Driver's) View – RH Side
3 3
65

6083966-R4
ERVICE
S
14
4.3 Sidesifter Frame Removal
NOTE: To remove the integral sideshifter carriage from the
mast, refer to the 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. (165 Nm).
3 Install an M12 lifting eye to 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 4.4-2.
• 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
SS0442.eps
2Lower
Mounting
Hooks Minimum
1-13/16 in.
(46 mm)
Wear
Limit
Mark
Front Views
3
SS0365.eps
Lower Hooks
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
Mast
Carriage
FRONT
4
Lower
Mounting
Hooks
Front View

6083966-R4
ERVICE
S
15
4.4 Bearings
4.4-1 Bearing Lubrication
Lubricate both the upper and lower Sideshifter bearings
with chasis grease every 300 hours or 4 weeks of operation
(whichever comes first). In contaminated environments,
lubricate every week or as required.
4.4-2 Bearing Service
1 Remove the sideshift frame from the truck carriage as
described in Section 4.3
2 Remove the upper bearings and check thickness as
shown. If any bearing is worn to less than 3/32 in.
(2.5 mm) thickness, replace both upper bearings.
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
then 3/32 in. (2.5 mm) thickness, replace both 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
Upper Bearings
Grease Fittings
Upper Bearings
Grease Areas
SS0363.eps
SS0445.eps
4
3
2
Lower Bearings
Integral Carriage Bars
Upper
Bearings
3/32 in.
(2.5 mm)
min.
Front View
3/32 in.
(2.5 mm)
min.
Front View

6083966-R4
ERVICE
S
16
4.5 Sideshift Cylinder
4.5-1 Removal, Inspection and
Replacement
WARNING: Before removing any hoses,
relieve pressure in the hydraulic system.
With the truck off, open the truck auxiliary
control valve(s) 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 and remove the cylinder.
Keep track of shims.
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.
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 4.5-2.
• 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
SS0447.eps
Sideshift LEFT Sideshift RIGHT Front View
SS0452.eps
Clevis Pin,
Hairpin Clip
Cylinder
2
1
Anti-Roll Pin
Flow Restrictor
(both cylinder ports)
Cylinder Shell
Cylinder Rod
Shims
(as required)
Seal Carrier
6
43
6IMPORTANT: Shim cylinder
(end opposite roll pin) for
0.5 mm maximum clearance
when mounted in sideshifting
frame.
IMPORTANT: Fittings must bottom
against flow restrictor in cylinder port for
proper hydraulic flow characteristics.

6083966-R4
ERVICE
S
17
4.5-2 Rod Seal Carrier
Replacement
NOTE: The rod seal carriers are the only field servicable
parts on the cylinder and are supplied with 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 4.5-1.
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 and apply a
thick film of petroleum jelly to the interior bore. Slide
the seal carrier onto the cylinder rod and screw into
the cylinder retainer. Tighten to 240 ft.-lbs. (325 Nm).
SS0449.eps
SS0450.eps
Rod Seal
Carriers
Rod Pressure Seal
O-Ring
Wiper
Seal Carrier
Retainer 4
Cylinder
Assembly
2
3

6083966-R4
PECIFICATIONS
S
18
FP1127.eps
5.1 Specifications
5.1-1 Hydraulics
Truck Relief Setting
2200 psi (152 bar) Recommended
3500 psi (241 bar) Maximum
Truck Flow Volume ➀
Min. ➁Recommended Max. ➂
35K, 55K,
70K
1 GPM
(4 L/min.)
2 GPM
(7.5 L/min.)
3 GPM
(12 L/min.)
➀Cascade K-Series Integral Fork Positioners 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 must be used. Contact
Cascade.
➁Flow less than recommended will result in slow fork positioning
speed.
➂Flow greater than maximum can result in excessive heating,
reduced system performance and short hydraulic system life.
GA0082.eps
Hoist Down
Tilt Forward
Sideshift
Right
Open
Forks
Hoist Up
Tilt Back Close
Forks
5.1-2 Auxiliary Valve Functions
Check for compliance with ANSI (ISO) standards:
Sideshift
Left