S ERVICE MANUAL

55H Fork Positioner

Manual Number 6804542

cascade
corporation
Cascade is a Registered Trademark of Cascade Corporation
 C ONTENTS

Page
INTRODUCTION, Section 1
Introduction 1
Special Definitions 1
INSTALLATION, Section 2
Truck System Requirements 2
Recommended Hydraulic Supply 3
Installation Procedures 4
PERIODIC MAINTENANCE, Section 3
100 Hour Maintenance 11
500 Hour Maintenance 11
1000 Hour Maintenance 11
2000 Hour Maintenance 12
TROUBLESHOOTING, Section 4
General Procedures 13
Truck System Requirements 13
Tools Required 13
Troubleshooting Chart 13
Plumbing 14
Hosing Diagram 14
Circuit Schematic 14
Fork Position Function 15
Supply Circuit Test 15
Fork Position Circuit Test 15
Sideshift Function 16
Supply Circuit Test 16
Sideshift Circuit Test 16
Electrical Circuit 17
SERVICE, Section 5
Fork Positioner Removal 18
Cylinder/Manifold Assembly 19
Cylinder/Manifold Assembly Removal 19
Cylinder/Manifold Dissassembly 20
Cylinder Inspection 21
Manifold Service 21
Cylinder/Manifold Reassembly 22
Fork Carrier 23
Fork Carrier Bushing Service 23
Sideshifter Removal 24
Sideshift Bearings 25
Lubrications 25
Services 25
Sideshifter Cylinder 26
Removal, Inspect, Replacement 26
Rod Seal Replacement 27
SPECIFICATIONS, Section 6
Specifications 28
Hydraulics 28
Auxiliary Valve Functions 28
Truck Carriage 28
Torque Value 29

i 6804542
 I NTRODUCTION

1.1 Introduction
This manual provides the Installation, Periodic
Maintenance, Troubleshooting, Service and Specifications Fork Positioner
for Cascade 55H Fork Positioners. Nameplate
In any communication about the attachment, refer to the
product model number and serial number.
IMPORTANT: All hoses, tubes and fittings on these
attachments are SAE O-Ring. Supply fittings adapted as
required for application.
NOTE: Specifications are shown in both inch and (Metric)
units. All fasteners adapted as required for application.
All fasteners have a torque value range of ±10% of stated
value.

Stamped Cylinder
Assembly Part Number

FP1484.eps

Stamped model Sticker showing patent

number, serial number, numbers, phone numbers
specifications for service.

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.

6804542 1
 I NSTALLATION

2.1 Truck System Requirements

WARNING: Rated Capacity of the truck/
attachment combination is a responsibility
of the original truck manufacturer and may
be less than that shown on the attachment
nameplate. Consult the truck nameplate.

Truck Relief Setting

2300 psi (160 bar) Recommended
2600 psi (180 bar) Maximum

Truck Flow Volume ➀

Min. ➁ Recommended Max. ➂
3 GPM 4 GPM 5 GPM
Fork Position
(11 L/min.) (15 L/min.) (19 L/min.)

1 GPM 2 GPM 3 GPM

Sideshift
(4 L/min.) (7.5 L/min.) (12 L/min.)
➀ Cascade 55H 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.
➁ Flow less than recommended will result in slow and unequal fork
movement.
➂ Flow greater than maximum can result in excessive heating,
reduced system performance and short hydraulic system life.
GA0095.eps

Carriage Mount Dimension (A) ITA (ISO)

Minimum Maximum Carriage – Clean and inspect carriage
A
Class II 14.94 in. (380.0 mm) 15.00 in. (381.0 mm) bars. Make sure bars are parallel and ends
Class III 18.68 in. (474.5 mm) 18.74 in. (476.0 mm) are flush. Grind smooth any protruding welds
that may affect sideshifter lower bearings.
GA0028.eps Repair any damaged notches.

Auxiliary Valve Functions

Check for compliance with ANSI (ISO) standards:

Tilt Sideshift
Forward Left

Open
Forks
Hoist Down

GA0082.eps

Hoist Up Close
Tilt Sideshift Forks
Backward Right
2 6804542
 I NSTALLATION

2.2 Recommended Hydraulic Supply

The 55H Fork Positioner requires one of the hydraulic
supply arrangements shown below. Refer to Cascade
Hose & Cable Reel Selection Guide (Part No. 212199) to
select the correct hose and reel for the mast and truck.
Hose and fitting requirements are as follows:
• All hoses and fittings for fork position and sideshifting (if
equipped) functions should be at lest No. 4 with 3/16 in.
(5 mm) minimum ID.

Non-Sideshifting
A Mast Single Internal Reeving
OR
C LH THINLINETM 2-Port Hose Reel Group

Sideshifting
B C A Mast Double Internal Reeving
OR
A and C Mast Single Internal Reeving and LH
THINLINETM 2-Port Hose Reel Group
A
OR
B and C RH and LH THINLINETM 2-Port Hose Reel
Group

Solenoid Adaption
A and B Mast Single Internal Reeving and RH
Cable Reel Group
OR
GA0033.eps
B RH 6-N-1 Cable/Hose Reel Group

6804542 3
 I NSTALLATION

2.3 Installation Procedure

Follow the steps shown to install the attachment on the truck.
Read and understand all WARNING statements. If you don't
understand a procedure, ask your supervisor or call the nearest
Cascade Service Department for assistance.

1
Attach overhead hoist, remove WARNING: Check the attachment weight
bolt-on lower hooks (located on the nameplate) to make sure
A Remove banding. the overhead hoist and chains or straps
are at least the rated capacity of the
B Attach hoist and lift into vertical position. attachment.

C Remove bolt-on lower mounting hooks.

FP0601.eps

2 Unlock quick-change lower

mounting hooks (if equipped)
A Remove pin and drop hooks into unlocked
position.
B Reinstall pin in lower hole (unlocked).

NOTE: Guides can be reversed to

A change hook-to-carriage clearance
(see lower hook installation, step 4)
Guide

®
CL0097.eps
d e
s ca
ca

-1
14
55
67
C-

B LH Lower
Hook 5/8 in. (16 mm)
offset on top
Pin provides maximum
clearance
Tighten capscrew to 165 ft.-lbs. (225 Nm)

4 6804542
 I NSTALLATION

3 Mount attachment to truck A

A Lower attachment onto truck carriage.
B Engage upper mounting hook. If sideshifter
equipped, make sure bearings are in place and
centering tab engages center notch on truck
carriage.

ITA Class II – 0.60–0.66 in. (15–17 mm)

ITA Class III – 0.72–0.78 in. (18–20 mm)

Center Notch
B

ITA Class II – 0.32–0.36 in. (8–9 mm)

ITA Class III – 0.39–0.43 in. (10–11 mm)

FP0609.eps

Truck Upper SS0139.eps

Sideshifter Lower
Carriage Bearings
SD0023.eps

Sideshifter Upper
Back (Driver's) View Bearings

4 Install or engage lower hooks

BOLT-ON TYPE QUICK-CHANGE TYPE
Inspect hooks
for excessive
clearance. If
needed, reverse
Lower guides to change
Lower
Carriage clearance. Refer
Tap tight into position. Carriage
Bar to step 2.
If equipped with Bar
sideshifter, back off
1 notch and check
clearance:
ST
3/32 in. (2.4 mm) min.
®

JU e
AD ad
3/16 in. (4.8 mm) max. Slide hook as
c
c
up to engage -1
bar, install C-
67
55
14

pin in locked
position
(upper hole).
3/16 in.
(4.8 mm)
max.

SS0140.eps SS0141.eps

Tighten capscrews to 120 ft.-lbs. (165 Nm)

6804542 5
 I NSTALLATION

5 Install Forks
A Disconnect cylinder rod-end anchors from fork
carriers and retract cylinder rods.
B Rotate fork carriers up to provide clearance for
fork installation.

WARNING: Remove locking pins

from forks. Make sure forks slide
freely on sideshifter carriage bars.

C Install forks using bottom fork slot to engage

forks with sideshifter carriage.
D Line up forks with fork carriers on frame and
rotate fork carriers down into position over
forks. Make sure fork spacer plates are in
place, if required.
E Reconnect cylinder rod anchors using two
hardened washers and self-locking nut, as
shown below. Adjust nut to provide 1/32 in.
(1 mm) clearance in joint. Use flats on cylinder
rod end to prevent turning. E
IMPORTANT: Joint must function with a loose 1/32 in. (1 mm)
operating clearance. Lubricate with chassis
grease. Hardened Washers (2)

Cylinder Rod End Self-Locking Nut

Wrench Flat
Backrest
FP0603.eps

Fork Positioner
Fork Spacer Plate
(if required)
D Frame

Fork Carrier

IMPORTANT: Shim spacer

bar for a tight fit on fork to
prevent rocking.

B
FP0610.eps

FP0608.ill
C
Forks

Sideshifter
Assembly

6 6804542
 I NSTALLATION

6 Prepare hoses
A Determine hose length required for hydraulic
supply configuration.
B Cut hoses to length and install end fittings or
quick-disconnect kits.

INTERNAL HOSE REEVING HOSE REELS

Close Forks Close Forks

Open Forks Open Forks

FP0602.eps FP0604.eps

Sideshift Right Sideshift Left Sideshift Right Sideshift Left

Back (Driver's) View

7 Flush hydraulic supply hoses

A Install hoses to hose terminal on carriage.
Connect together using union fittings.
B Operate auxiliary valves for 30 seconds.
C Remove union fittings.

GA0092.eps

6804542 7
 I NSTALLATION

8 Connect hoses prepared in Step 6

to attachment fittings

FP0605.eps

9 Install solenoid control knob or

pushbutton switch (solenoid-equipped)

NOTE: Shrink tubing

Snap Ring Pushbutton may be removed around
Switch button as desired
Plate

PRESS
BUTTON SIDESHIFT Cable
TO POSITION
Ties
3 in. (60 mm)
Button Typical
Foam Tape
toward
driver

Nut Heat-Shrink
Tubing

Adapter AC0898.eps

FP0624.eps

10 Install wiring
(solenoid-equipped) Control Lever Knob
Diode

Knob Diode
Solenoid Coil
Button
(normally
7.5-Amp Fuse open)
Black Black
White White
7.5-Amp
Fuse

CL0258.eps
CL0257.eps

User-supplied wire Solenoid Coil

8 6804542
 I NSTALLATION

11 Cycle Fork Positioner functions

• Open and close forks several times. Sideshift (if
equipped) left and right. Check for smoothness
and equal movement.
• Check for operation in accordance with ANSI (ISO)
standards.
• Check for leaks at fittings, valve and cylinders.

NON-SIDESHIFTING SIDESHIFTING WITH

SIDESHIFTING
A Open Forks SOLENOID VALVE
B Close Forks A Sideshift Left A Sideshift Left
C (not used) B Sideshift Right A Open Forks
D (not used) C Open Forks (press knob button)
D Close Forks B Sideshift Right
B Close Forks
(press knob button)

B A
B A D C B A
B A
B A
FP0164.eps
D FP0164.eps
C
B A
FP0164.eps

AUXILIARY VALVE FUNCTIONS

Tilt Forward
Hoist Down

A C

B D
GA0005.eps
Hoist Up Tilt Back

6804542 9
 I NSTALLATION

12 Adjust forks for equal movement

(if required)
NOTE: Attachment is factory-adjusted for equal
fork movement when operated at recommended
pressure and flow rate at normal operating
temperature.
A Locate flow restrictor fitting on RH cylinder Flow
(1 flow restrictor only used). A Restrictor
Fitting
B Open and close forks fully and look for unequal
fork movement.
C Loosen jam nut and adjust until RH fork moves
equally with LH fork. Tighten jam nut.

FP0625.eps

13 Inspect fork hooks and carriage bar

clearance
NOTE: Use go/no-go wear gauge, part no. 209560
FORK LOWER HOOKS, CARRIAGE

Wear
(Class II) or 209561 (Class III). Gauge
A Inspect the fork lower hooks and carriage bar.
If the gauge fits between the carriage bar and
lower hook, repair or replacement is needed.

OK

UPPER CARRIAGE BAR

B Inspect the upper carriage bar. If the gauge

arrow touches the carriage bar, repair or OK
replacement is needed.

FORK UPPER HOOKS

C Inspect the fork upper hooks. If the gauge

OK
arrow touches the hook, repair or replacement
is needed.

FP0631.eps

10 6804542
 P ERIODIC MAINTENANCE

WARNING: After completing any service

procedure, always test each function
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.

3.1 100-Hour Maintenance

Every time the lift truck is serviced or every 100 hours
of truck operation, whichever comes first, perform the
following maintenance procedures:
• Check for loose or missing bolts, worn or damaged
hoses and hydraulic leaks.

3.2 500-Hour Maintenance FP0607.eps

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

100-hour maintenance, perform the following maintenance
procedures: Frame and Backrest Mounting Capscrew (4)

• Tighten frame and backrest mounting capscrews to Front View

115-125 ft.-lbs. (155-170 Nm).
• Tighten lower hook capscrews:
Class II, III Bolt-On – 120 ft.-lbs. (165 Nm)
Class II, III Quick-Change – 165 ft.-lbs. (225 Nm) Fork Carrier Cylinder Rod
• Apply graphite dry lube to fork carrier bearings ('Slip Bearings (2) Anchors (2)
Plate', 'GraphoKote' or equivalent)
• Apply chassis grease to fork cylinder rod anchors.
• Apply chassis grease to sideshifter upper bearing
grease fittings and lower flat bearings. Sideshifter
Grease
• Check fork hooks and carriage bars for wear using a Fittings (2)
wear gauge (Cascade part no. 209509 for Class II or
209507 for Class III).

3.3 1000-Hour Maintenance

After each 1000 hours of truck operation, in addition to
the 100 and 500-hour maintenance, perform the following
procedures:
• Inspect fork carrier bearings for wear and replace if
necessary.
• Inspect fork cylinder rod anchor washers for wear and
replace if necessary.
• Inspect thickness of sideshifter (if equipped) upper and FP0606.eps

lower bearing sets. If any bearing in the set is worm to

less than 3/32 in. (2.5 mm ) thickness, replace entire
bearing set. Refer to section 5.5-2. Sideshifter Lower Mounting Hook
Lower Bearings (2) Capscrews (4)

Back (Driver's) View

6804542 11
 P ERIODIC MAINTENANCE

3.4 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).

12 6804542
 T ROUBLESHOOTING

4.1 General Procedures WARNING: Before servicing any

hydraulic component, relieve pressure in
the system. Turn the truck off and move
4.1-1 Truck System Requirements the truck auxiliary control valves several
times in both directions.
• Truck hydraulic pressure should be within the range
shown in Specifications, Section 6.1. PRESSURE TO After completing any service procedure, test the
ATTACHMENT MUST NOT EXCEED 2600 psi (180 bar). attachment through several cycles. First test the
attachment empty to bleed any air trapped in the
• Truck hydraulic flow should be within the range shown system to the truck tank. Then test the attachment
in Specifications, Section 6.1. with a load to be sure it operates correctly before
• Hydraulic fluid supplied to the attachment must meet returning to the job.
the requirements shown in Specifications, Section 6.1. Stay clear of the load while testing. Do not raise the
load more than 4 in. (10 cm) off the floor while testing.

4.1-2 Tools Required Flow Meter Kits

In addition to a normal selection of mechanic's hand tools, 10 GPM (37 L/min.) – Part No. 671212
the following are required: 20 GPM (75 L/min.) – Part No. 671477
• Inline Flow Meter Kit: (2) No. 8-12
10 GPM (37 L/min.) – Cascade Part No. 671476. JIC/O-Ring Flow Meter
OR
20 GPM (75 L/min.) – Cascade Part No 671477.
• Pressure Gauge Kit: GA0013.eps
5000 psi (345 bar) – Cascade Par No. 671212. (2) No. 6-8 JIC Reducer
• Assorted fittings, hoses and quick-disconnect couplers
as required.

Pressure Gauge Kit

Part No. 671212
4.1-3 Troubleshooting Chart Pressure
No. 6 and
No. 8 JIC
Gauge ▲ No. 6-6 Hose ▲ Swivel Tee

Determine All The Facts – It is important that all

the facts regarding the problem are gathered before GA0014.eps

beginning service procedures. The first step is to

talk to the equipment operator. Ask for a complete No. 4-6 Pipe/JIC ▲ No. 6-8 JIC No. 4, No. 6 ▲
description of the malfunction. The following Reducer and No. 6
JIC/O-ring
guidelines can then be used as a starting point to
begin troubleshooting procedures:

Fork Positioning Circuit

• Forks will not open or close. Quick-Disconnect Couplers
• Forks open and close unevenly.
To correct one of these problems, see Section 4.3.
Male Straight Thread
O-Ring Coupler:
Sideshifter Circuit
• Attachment will not sideshift. No. 4 (Part No. 212282) ▲
• Attachment sideshifts too fast or too slow. No. 5 (Part No. 210378)
No. 6 (Part No. 678592)
To correct this problem, see Section 4.4.

Female JIC Thread

Coupler: AC0127.eps
No. 4 (Part No. 210385) ▲
No. 6 (Part No. 678591)

▲ NOTE: Diagnostics Kit 394382

includes items marked.

6804542 13
 T ROUBLESHOOTING

4.2 Plumbing Close Forks

4.2-1 Hosing Diagram Open Forks

Manifold

SIDESHIFT RIGHT,
CLOSE FORKS
PRESSURE
RETURN

NOTE: For SIDESHIFT LEFT, Fork Position

OPEN FORKS, reverse the Cylinders
colors shown.
SSR

FORK POSITION
Truck Auxiliary SSL
Valve
FP1369.eps SIDESHIFT Sideshift Cylinder
Truck Auxiliary
Valve IHR or Hose
Reel Terminals

4.2-2 Hydraulic Schematic

Fork Position Cylinders

CLOSE
OPEN

Manifold Flow
Restrictors

Sideshift Cylinder

SSR SSL

IHR or
Hose Reel
Terminals

SIDESHIFT FORK POSITION

Truck Auxiliary Truck Auxiliary
Valve Valve

Truck Relief
Truck Valve Truck
Pump Tank
FP1370.eps

14 6804542
 T ROUBLESHOOTING

4.3 Fork Position Function

Six potential problems can affect the fork positioning
function: WARNING: Before removing hydraulic
• Forks or fork carriers binding in carriage grooves. lines or components, relieve pressure in the
hydraulic system. Turn truck off and open
• Incorrect hydraulic pressure or flow from truck. the truck auxiliary control valve(s) several
• Flow restrictor fittings plugged or improperly adjusted. times in both directions.
• External leaks.
• If equipped with solenoids, electrical circuit faults,

2
defective solenoid coil or valve.
Flow Meter
• Worn or defective cylinder seals.

4.3-1 Supply Circuit Test

1 Check the truck pressure at the mainfold open
port. Pressure must be within the range shown
in Specifications, Section 6.1. PRESSURE TO
THE FORK POSITIONER MUST NOT EXCEED
3500 psi (245 bar).
2 Check the flow volume at the manifold open
port. Flow must be within the range shown in
Specification, Section 6.1.
3 Fully open the forks and hold the lever in the OPEN
position for several seconds. Release the lever
and check for external leaks at fittings, tubing,
hoses and manifold.

4.3-2 Fork Position Circuit Test FP1379.eps

Rear (Driver's) View

1 If equipped, press the solenoid button. Listen
for a 'click' at the solenoid valve. If no sound is
heard, check the fuse, wiring and coil. Refer to
Section 4.5.
IMPORTANT: Solenoid-operated valve should be

3
plumbed so that the solenoid is energized during Pressure Gauge
the fork-positioning function. on Valve 'Tee'
Fitting
2 Fully open or close the forks. If the forks move at

2
different speeds, adjust flow restrictor for equal fork
speed. Refer to Section 2, Installation Instructions,
Step 12.
3 Turn truck off and connect a 5000 psi (345 bar) Fork speed
pressure gauge to the open fitting on the manifold. adjustment

4
flow
4 Start the truck. Fully open forks. Hold the lever in restrictor
the OPEN position for a few seconds.
5 Release the lever and watch the pressure gauge.
• If the pressure drop is less than 150 psi (10 bar)
initially and an additional drop does not exceed
25 psi (2 bar) per minute, the problem is not
hydraulic. Refer to Section 4.3.
• If the pressure drop is more than above, one
of the cross-over relief cartridge may be faulty.
Replace cartridge.
6 Close forks fully and hold the lever in the CLOSE
FP1380.eps

position for a few seconds. If the pressure still

Rear (Driver's) View
drops as before, the cylinders are at fault and must
be serviced. Refer to Section 5.2.

6804542 15
 T ROUBLESHOOTING

4.4 Sideshift Function WARNING: Before removing hydraulic

lines or components, relieve pressure in the
Six potential problems can affect the fork positioning hydraulic system. Turn truck off and open
function: the truck auxiliary control valve(s) several
• Inadequate sideshifter lubrication or worn bearings. times in both directions.
Refer to Periodic Maintenance, Section 3.
• Incorrect hydraulic pressure or flow from truck.
• External leaks.
• If equipped with solenoids, electrical circuit faults,
defective solenoid coil or valve.
• Lower mounting hooks installed with incorrect
clearance. Refer to Installation Instructions, Section 2.
• Worn or defective cylinder seals.

4.4-1 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 6.1.
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 6.1.
3 Hold the lever in each SIDESHIFT position for several
seconds. Release the lever and check for external
leaks at fittings, tubing, hoses and cylinder.

4.4-2 Sideshift Circuit Test

1 Press the solenoid button (if equipped) and listen for a
Hose
'click' at the solenoid valve. If no sound is heard, check end in
the fuse, wiring and coil. Refer to Section 4.5. drain
IMPORTANT: Solenoid-operated valve should be bucket
plumbed so that the solenoid is not energized during
the sideshifting function (straight-through).
2 Turn the truck off and relieve attachment system
pressure. Disconnect the SIDESHIFT RIGHT supply

3
hose from the internal reeving or hose terminal fitting.
Cap the supply fitting and place the hose end in the
drain bucket.
3 Start the truck and actuate the SIDESHIFT LEFT lever FP1404.eps
for 5 seconds:
• If there is substantial hydraulic flow out of the drain SIDESHIFT Cap Supply
hose, the sideshift cylinder is faulty and requires RIGHT Hose Fitting

2
replacement. Refer to Section 5.6.
• If there is little or no hydraulic flow out of the hose,
the problem is not hydraulic. Refer to Section 4.4
(above).
Back (Driver's) View

16 6804542
 T ROUBLESHOOTING

4.5 Electrical Circuit

(Solenoid-equipped attachments)
Use the electrical schematic and diagram shown and
follow the steps below.

1 Check the control knob circuit fuse. Replace if

necessary.
2 Check for loose electrical connections at the truck
ignition switch, control knob button, solenoid coil
terminals and diode.
3 Remove the diode from the solenoid coil terminal. Test
with an ohmmeter for high resistance in one direction
and no resistance in the other direction. If there is no
resistance in both directions, replace the diode.
NOTE: When replacing the diode, the banded (+) end
must connect to the positive (+) side of the coil and
wiring as shown.
4 Disconnect the electrical leads from the solenoid coil
terminals. Use a voltmeter to determine if voltage
is present at the electrical leads when the button is
depressed.
• If there is no voltage at the solenoid, troubleshoot
the electrical circuit for shorts.
• If there is voltage at the solenoid, test for coil
continuity.
5 Test for coil continuity by placing an ohmmeter test lead
on each solenoid coil terminal (ohmmeter on Rx1 scale).
• If there is an ohmmeter reading the coil is good.
• If the coil is good, but the solenoid does not 'click'
when the control knob button is depressed, the
'
solenoid cartridge may be jammed.
• If there is no ohmmeter reading, the coil is defective
and should be replaced.

Control Lever Knob Diode

Diode Solenoid
Coil
Knob Button
7.5 Amp (Normally
Fuse Open)
White Black
Black
7.5 Amp White
Fuse

CL0258.eps

CL0257.eps

User-Supplied Wire Solenoid Coil

6804542 17
 S ERVICE

5.1 Attachment Removal

WARNING: Before servicing hydraulic WARNING: Verify that the locking pins are
components, relieve pressure in the removed from the forks. Forks must slide
system. Turn the truck off and move the freely on carriage bars.
truck auxiliary control valves several times
in both directions.

1 Disconnect the hoses from the manifold. Tag hoses for

reassembly. 6
Cylinder Hardened
WARNING: Check the attachment weight Rod Washers (2)
(located on the nameplate) to make sure the End
overhead hoist and chains or straps are at
least the rated capacity of the attachment.

2
2 Attach an overhead hoist to the backrest shown.
3 Rotate fork carriers up to provide clearance for fork
removal.
4 Remove forks from attachment.
Self-Locking
5 Disconnect/remove the lower hooks. Nut
Bolt-On Hooks – Remove the lower mounting Wrench Flat
hooks. For reassembly, tighten the capscrews
to 120 ft.-lbs. (165 Nm). Check clearance
Fork Carrier
for sideshifting leaving a minimum of 3/32 in.
(2.4 mm) space.

3
Quick Change Hooks – Pull out the locking
pins, slide the hooks down and reinstall the
pins in the lower holes. For reassembly, slide
the hooks up and install the pins in the top
holes.
6 Remove the attachment and lay down on a
pallet.
7 For reassembly, reverse the above procedures
with the following exceptions:
• Service or replace components as required.
• Slide forks to line up with fork carriers on

4
frame and engage fork carriers with forks
and top carriage bar.

FP1454.eps
Attachment

5 BOLT-ON HOOKS QUICK-CHANGE HOOKS

Carriage Bar Guide

RC0368.eps

RR0548.eps
®

T e
J US ad
AD Lower Hook sc
ca

-1
14
55
67
C-

Lower Hook in
unlocked position
Locking Pin
18 6804542
 S ERVICE

5.1-1 Fork Positioner Removal

NOTE: To remove the fork positioner from the sideshifter
unit or false carriage, follow these steps: 5 For reassembly, reverse the above procedures with the
following exceptions:
WARNING: Check the attachment weight • Service or replace components as required.
(located on the nameplate) to make sure the • Slide forks to line up with fork carriers on frame and
overhead hoist and chains or straps are at engage fork carriers with forks and top carriage bar.
least the rated capacity of the attachment.
• If required, install fork spacer plates.

1 Attach an overhead hoist to the backrest as shown. WARNING: Verify that the locking pins are
removed from the forks. Forks must slide
freely on carriage bars.
WARNING: Before servicing hydraulic
components, relieve pressure in the
system. Turn the truck off and move the
truck auxiliary control valves several times

1
in both directions.

2 Disconnect the hoses from the manifold. Tag hoses for

reassembly.
3 Remove the capscrews fastening the fork
positioner frame to the sideshifter or false carriage.
For reassembly, tighten mounting capscrews to
125 ft.-lbs. (170 Nm). Fork Positioner
Frame
4 Raise the frame clear and lay frame on a pallet.

Fork Positioner

5
Fork Spacer Plate
(if equipped)
3
IMPORTANT: Shim spacer
bar for a tight fit on fork to
prevent rocking.

3
Mounting
Capscrews

FP1423.eps

Sideshifter or
6804542 false carriage 19
 S ERVICE

5.2 Cylinder/Manifold
Assembly
5.2-1 Cylinder/Manifold
Assembly Removal
NOTE: The cylinder/manifold assembly can be removed
with the fork positioner mounted on the truck.

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.

1 Close forks completely.

2 Disconnect the tubes and supply hoses at the cylinders
and manifold. Tag for reassembly
3 Remove capscrews fastening cylinder/manifold
assembly to fork positioner frame. For reassembly,
apply Loctite 242 (blue) to threads and tighten to
30 ft.-lbs. (40 Nm).
4 Remove cylinder/manifold assembly.

3
4
FP1436.eps

20 6804542
 S ERVICE

5.2-2 Cylinder/Manifold
Disassembly
1 Use C-clamp to clamp manifold onto a bench top, as
shown. Use wood blocks to support cylinders.
2

4
Remove fittings from cylinder. Remove fork guides from
cylinder rods.
3 To drain any excess fluid, connect a hose to the OPEN
fork fitting on the manifold. The hose should lead to a
catch bucket. Fully extend both cylinder rods.
FP1437.eps

For each cylinder:

5
4 Remove the snap ring from the retainer, as shown.
5 Tap the retainer into the shell approximately 2 in. FP1438.eps
(50 mm). Remove retaining ring by prying it out of its
groove on the opposite side from the split ends. The
retainer will compress and turn sideways for removal.

7
Remove the retainer.
CAUTION: Do not scratch cylinder bore.
To prevent damage to the components and ease of
retaining ring removal, use Service Tool Kit 674424.
6 Remove rod/piston assembly and spacer (if equipped)
from the cylinders.
7 Clamp the piston/rod assembly in a soft jawed vise.
Remove seals. Piston is a shrink-fit on the rod and not
removable. Pry the seals or O-rings up with a brass
seal removal tool (Cascade part no. 674424) and cut
the seals to remove them.
CAUTION: Do not scratch the seal grooves.
FP1439.eps

6804542 21
 S ERVICE

5.2-3 Cylinder Inspection

• Inspect the rod, piston and retainer for nicks and burrs.
Minor nicks or burrs may be removed with 400-grit
emery cloth. If they cannot be removed, replace the
parts.
• Inspect the cylinder bore and remove any minor nicks or
burrs with a butterfly hone. If they cannot be removed,
replace the part.
• Inspect the outside of the shells for any deformities
that could impair performance or cause leaks under
pressure. If necessary, replace shell/manifold assembly.
• Inspect the rod-end anchor parts for wear and replace
as necessary.

Piston/Rod Shell/Manifold
Assembly Spacer Assembly Retaining Ring
Snap Ring

Retainer

Manifold

FP1440.eps

5.2-4 Manifold Service

1 Remove the relief cartridge from the manifold. Remove
the O-rings and back-up rings from the cartridge.
2
2 Remove the fittings from the manifold.
3 Clean all parts with solvent.
4 For reassembly, reverse the above procedures with the
following exceptions:
• Replace O-rings and back-up rings on relief valve
cartridges, as shown.

Relief Cartridge O-Rings

Manifold

1
FP1470.eps
Back-up Rings Relief FP1443.eps
Cartridge

22 6804542
 S ERVICE

5.2-5 Cylinder/Manifold
Reassembly
1 Using 400-grit emery cloth, polish the piston and
retainer chamfer angles, and the ID threads within the
cylinder shell. Clean all parts thoroughly.
2 Lubricate all new seals and O-rings with petroleum jelly.
3 Install seals on the piston and inside retainer. Note
the direction of the seals. If the seals are installed
backward, the will not work properly. For proper seal FP1480.eps
placement, see illustration below.
NOTE: Use internal seal installation tool (Cascade Part
No. 599512) may be used to ease seal installation. If
installing by hand, form the seal into a 'kidney' shape
and position into the internal groove. Use finger
pressure to smooth the seal into the groove.
4 Install new wiper seal, O-ring and back-up ring on the
retainer, as shown.
5 IMPORTANT: Prior to loading the piston into the shell,
check that no sharp edges exist on the internal threads
within the shell.
6 Apply petroleum jelly inside the cylinder shell and piston
OD. Install the piston/rod assembly into the cylinder
shell. If required, use a piston/seal loader to prevent
damage to the seals.
7 Tap the retainer into the shell far enough to install the
circular retaining ring in its groove.
8 Pull the rod out to the fully extended position. Install the
spiral snap ring on the retainer.

3
Note Seal
Direction

Piston/Rod
Assembly Spacer
Shell/Manifold
Assembly 7 8
Retainer

FP1481.eps

Wiper Seal

O-Ring Back-Up
Ring

4
6804542 23
 S ERVICE

5.3 Fork Carrier

5.3-1 Fork Carrier Bushing
Service
The fork carrier bushings can be replaced with the fork
carriers in place. No disassembly is required.
1 Remove the snap rings from the bushing ends.
2 Place the new split bushings on the cylinder OD. Tap
the new bushings woth a soft mallet to displace the old
bushings.
3 Reinstall the snap rings.

Snap Ring

Split
Bushings

FP1486.eps

24 6804542
 S ERVICE

5.4 Sideshifter Removal

Seal Carriers

4
Sideshift Left
3 Sideshift Right

1 Remove the backrest and fork positioner from the

attachment.
2 Remove the forks from the attachment.

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 sideshift cylinder. Tag SS0175.eps

hoses for reassembly.
Front View Wear
4 If the sideshift cylinder is to be serviced, loosen the Limit
seal carriers before removing the attachment. Mark
A Dim.
For reassembly, tighten seal carriers to:
1-13/16 in.
Class II/III – 120 ft.-lbs. (165 Nm) Class II, III
(46 mm) A

5
Class IV – 235 ft.-lbs. (320 Nm)
2-13/32 in.
5 Remove the lower mounting hooks and inspect for wear. Class IV
(61 mm)
Refer to illustration. Replace if beyond wear limit.
Lower Mounting SS0254.eps
6 Attach an overhead hoist to the sideshifter and lift away Hooks (on rear)
from the truck carriage.
7 For installation, reverse the above procedures with the
following exceptions: WARNING: Check the attachment weight
• Clean and inspect carriage bars for damage and (located on the nameplate) to make sure the
smoothness. Bars should be parallel and ends flush. overhead hoist and chains or straps are at
Repair any protruding welds or damaged notches by least the rated capacity of the attachment.
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 hook clearance must be adjusted
as shown for proper sideshifter operation.
• Lubricate both upper and lower bearings with
general-purpose chassis grease.

SS0176.eps

7
BOLT-ON QUICK-CHANGE
Reverse guides to change
hook-to-carriage clearance.
Sideshifter
Truck Carriage

Clearance: Clearance:
1/32 in. (0.8 mm) Min. 1/32 in. (0.8 mm) Min.
Offset on top
1/16 in. (1.6 mm) Max. 1/16 in. (1.6 mm) Max. provides max.
clearance: SS0153.eps
Tighten bolts to:
Class II/III – Tighten capscrews to:
Class II/III – 120 ft.-lbs. (165 Nm)
5/8 in. (16 mm) Class II/III – 120 ft.-lbs. (165 Nm)
Class IV – 235 ft.-lbs. (320 Nm)
Class IV – Class IV – 190 ft.-lbs. (250 Nm)
53/64 in. (21 mm)

6804542 25
 S ERVICE

5.5 Sideshift Bearings Upper Bearing

Grease Fittings

5.5-1 Bearing Lubrication

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
5.5-2 Bearing Service Grease Areas

1 Remove the attachment from the truck as described in

Section 5.4 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 3/32 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 Bearings
lower hook mounts. If any bearing is worn to less

4
than 3/32 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. 3/32 in.
(2.5 mm)
min.
Upper
Bearings
3 Cylinder
Retainer Pins

2 SS0183.eps

3/32 in.
(2.5 mm)
min. Retainer Pins
(bronze bearings only)

SS0182.eps

2
Cylinder / Anchor
SS0185.eps

Bracket Assembly

1
Sideshifter
Frame

26 6804542
 S ERVICE

5.6 Sideshift Cylinder

5.6-1 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 5.1 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
IMPORTANT: Fittings must bottom
against flow restrictor in cylinder port for
proper hydraulic flow characteristics. 3 Cylinder shell

6804542 27
 S ERVICE

5.6-2 Rod Seal Replacement

3
NOTE: The attachment must be removed from the truck to Cylinder/Anchor
replace the cylinder rod seals. Bracket Assembly Rod Seal
Carriers
1

4
Loosen the rod seal carriers, then remove the
attachment from the truck as described in Section 5.1.
2 Remove the cylinder/anchor bracket assembly from the
attachment as described in Section 5.6-1.
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 rod 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

5
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).
8 Apply a thick film of petroleum jelly to the inside of the
Seal Removal Tool
seal carrier and carefully slide onto the cylinder rod. (Part No. 674424)
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

7
Seal

RC0488.eps

8
Rod
SS0163.eps Seal Carrier

28 6804542
 S PECIFICATIONS

6.1 Specifications
6.1-1 Hydraulics

Truck Relief Setting

2300 psi (160 bar) Recommended
2600 psi (180 bar) Maximum

Truck Flow Volume ➀

Min. ➁ Recommended Max. ➂
3 GPM 4 GPM 5 GPM
Fork Position
(11 L/min.) (15 L/min.) (19 L/min.)

1 GPM 2 GPM 3 GPM

Sideshift
(4 L/min.) (7.5 L/min.) (12 L/min.)
➀ Cascade 55H 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.
➁ Flow less than recommended will result in slow and unequal fork
movement.
➂ Flow greater than maximum can result in excessive heating, GA0090.eps
reduced system performance and short hydraulic system life.

Hoses and Fittings

All supply hoses and fittings should be at least No. 4 with
3/16 in. (5 mm) minimum ID.

6.1-2 Auxiliary Valve Functions

Tilt Sideshift
Forward Left

Open
Forks
Hoist Down

GA0082.eps

Hoist Up Close
Tilt Sideshift Forks
Backward Right

6.1-3 Truck Carriage

GA0091.eps

Carriage Mount Dimension (A) ITA (ISO)

A 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)
GA0028.eps

6804542 29
 S PECIFICATIONS

6.1-4 Torque Values

Fastener torque values for the 55H Fork Positioner are NOTE: All fasteners have a torque value
shown in the table below in both US and Metric units. All range of ±10% of stated value.
torque values are also called out in each specific service
procedure section throughout the manual.

Ref. Fastener Location Size Ft.-lbs. Nm

1 Cylinder Capscrews M10 30 40
2
5
Backrest Capscrews M8 125 170
3 Spacer Capscrew M10 30 40
4 Lower Hook Capscrews M16 120 165
5 Manifold Capscrews M10 30 40

FP1483.eps

1
2 3
FP1482.eps

30 6804542
BLANK
Do you have questions you need
answered right now? Call your
nearest Cascade Parts Department.
Visit us online at www.cascorp.com

AMERICAS
Cascade Corporation Cascade Canada Inc. Cascade do Brasil
Parts Sales 5570 Timberlea Blvd. Rua João Guerra, 134
2501 Sheridan Ave. Mississauga, Ontario Macuco, Santos - SP
Springfield, OH 45505 Canada L4W-4M6 Brasil 11015-130
Tel: 888-CASCADE (227-2233) Tel: 905-629-7777 Tel: 55-13-2105-8800
Fax: 888-329-0234 Fax: 905-629-7785 Fax: 55-13-2105-8899

EUROPE-AFRICA
Cascade Italia S.R.L. Cascade (Africa) Pty. Ltd.
European Headquarters PO Box 625, Isando 1600
Via Dell’Artigianato 1 60A Steel Road
37050 Vago di Lavagno (VR) Sparton, Kempton Park
Italy South Africa
Tel: 39-045-8989111 Tel: 27-11-975-9240
Fax: 39-045-8989160 Fax: 27-11-394-1147

ASIA-PACIFIC
Cascade Japan Ltd. Cascade Korea Cascade-Xiamen Cascade India Material
2-23, 2-Chome, 121B 9L Namdong Ind. No. 668 Yangguang Rd. Handling Private Limited
Kukuchi Nishimachi Complex, 691-8 Gojan-Dong Xinyang Industrial Zone No 34, Global Trade Centre
Amagasaki, Hyogo Namdong-Ku Haicang, Xiamen City 1/1 Rambaugh Colony
Japan, 661-0978 Inchon, Korea Fujian Province Lal Bahadur Shastri Road,
Tel: 81-6-6420-9771 Tel: +82-32-821-2051 P.R. China 361026 Navi Peth, Pune 411 030
Fax: 81-6-6420-9777 Fax: +82-32-821-2055 Tel: 86-592-651-2500 (Maharashtra) India
Fax: 86-592-651-2571 Phone: +91 020 2432 5490
Fax: +91 020 2433 0881
Cascade Australia Pty. Ltd. Cascade New Zealand Sunstream Industries
1445 Ipswich Road 15 Ra Ora Drive Pte. Ltd.
Rocklea, QLD 4107 East Tamaki, Auckland 18 Tuas South Street 5
Australia New Zealand Singapore 637796
Tel: 1-800-227-223 Tel: +64-9-273-9136 Tel: +65-6795-7555
Fax: +61 7 3373-7333 Fax: +64-9-273-9137 Fax: +65-6863-1368

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© Cascade Corporation 2010 10-2010 Part Number 6804542