cascade corporation 45G Series User manual

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corporation
ERVICE MANUAL
S
45G-160G
Rotators
Manual Number 6073955-R3

CONTENTS
i6073955-R3
Page
INTRODUCTION, Section 1
Introduction 1
Special Definitions 1
PERIODIC MAINTENANCE, Section 3
Daily Maintenance 2
1000-Hour Maintenance 2
2000-Hour Maintenance 3
Rotate Function Evaluation 3
TROUBLESHOOTING, Section 4
General Procedures 4
Truck System Requirements 4
Tools Required 4
Troubleshooting Chart 4
Plumbing 5
Hosing Diagram 5
Circuit Schematic 6
Rotation Function 7
Supply Circuit Test 7
Rotation Without Load 7
Rotation With Load 8
Rotation Drift Test 9
SERVICE, Section 5
Attachment Removal 10
Drive Group 12
Drive Group Removal and Installation 12
Drive Group Disassembly and Service 12
Drive Group Reassembly 14
Drive Motor 16
Drive Motor Removal and Installation 16
Drive Motor Disassembly 17
Drive Motor Inspection 19
Drive Motor Reassembly 19
Drive Control Valve 21
Drive Control Valve Service 21
Base Unit 22
Capscrew Torque Inspection 22
Bearing Assembly Removal and Inspection 23
Fork Bar Service 25
Bearing Seal Service 25
SPECIFICATIONS, Section 6
Specifications 26
Hydraulics 26
Auxiliary Valve Functions 26
Truck Carriage 26
45G-65G Torque Values 27
80G, 100G Torque Values 28
130G, 160G Torque Values 29
Determining Load Torque Requirements 30

INTRODUCTION
6073955-R3 1
1. 1 Introduction
This manual provides the Periodic Maintenance,
Troubleshooting, Service and Specifications for Cascade
45G-160G Rotators.
In any communication about the attachment, refer to the
product ID number stamped on the nameplate as shown.
If the nameplate is missing, the numbers can be found
stamped on the left, front side of the faceplate between the
fork bars.
IMPORTANT: All hoses, tubes and fittings on these
attachments are JIC.
NOTE: Specifications are shown in both US 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.
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.
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.
Nameplate
(front side of
faceplate)
WARNING: Fork size affects attachment
capacity. Refer to Installation Instructions
6073002, installation Step 13. Verify
capacity for truck nameplate.
+
7
@
123
+
A2-Z
Cascade Corporation • www.cascorp.com • Icons & Patents: www.cascorp.com/support 6095754
RR1197.eps
45G-RRB-10A
PTL 604920-1R0
45G-RRB-10A
PTL604920-1R0

26073955-R3
PERIODIC MAINTENANCE
RR0825.eps
RR0828.eps
Left Side
Ball Race
Grease
Fitting (A)
2.1 Daily Inspection
Prior to each shift of truck operation, complete the
following procedures:
• Check for loose or missing bolts, worn or damaged
hoses, and hydraulic leaks.
• Check that fork locking pins and end bar keepers are
installed and functional.
• Check decals and nameplate for legibility.
• Tighten rotator drive capscrews to a torque of 66 ft.-lbs.
(90 Nm).
• Check rotator drive gearcase lubricant level. Lubricant
should be up to bottom of fill plug or check plug hole.
If necessary, fill with Cascade Rotator Drive Lubricant,
Part No. 656300, or SAE 90 wt. gear lube (AGMA 'mild'
6 EP Gear Oil). Replace plug.
• Check rotation performance using a typical load.
Refer to Rotate Function Evaluation, Section 2.4 of this
manual.
• Lubricate rotation bearing assembly ball race (A), and
gear (B) with EP-2 grease (Whitmore 'Omnitask' or
equivalent). Rotate in 90° increments and grease in
each position.
• Tighten lower mounting hook capscrews to a torque of:
CL II/III – 120 ft.-lbs. (165 Nm)
CL IV – 235 ft.-lbs. (320 Nm)
• Check sample of bearing assembly to faceplate
capscrews for proper torque value. Refer to Technical
Bulletin TB183 or the Service section 4.5-1 of this
Manual for checking and replacement procedures.
• Check sample of baseplate assembly capscrews for
proper torque value. Refer to Technical Bulletin TB183
or the Service section 4.5-1 of this manual for checking
and replacement procedures.
2.2 1000-Hour Maintenance
Every time the lift truck is serviced or every 1000 hours
of truck operation, complete the following maintenance
procedures:
• If equipped, lubricate plungers on hydraulic or
electronic 180° stop valves.
Back (Driver's) View
Fork Carriage
Bars, Keepers
Gear Grease
Fitting (B)
WARNING: After completing any service
procedure, always test the attachment
through five complete cycles. First test
empty, then test with a load to make sure
the attachment operates correctly before
returning it to the job.
WARNING: A sampling of faceplate and
baseplate bearing assembly capscrews
must be checked for proper torque at 1000
hours (see TB183). A complete inspection
is required every 2000 hours. Failure to
keep the capscrews tightened can result in
attachment damage and serious injury.
Gear
Grease
Fitting (B)
End Cover
Hole (level
and fill hole)
Rotator
Drive
Capscrews
Bearing Capscrews
(Access all through
hole in baseplate)
Lower Mounting
Hook Capscrews
Baseplate
Capscrews
Rotator Drive
Capscrews
End Cover
Hole (level
and fill hole)

36073955-R3
PERIODIC MAINTENANCE
2.3 2000-Hour Maintenance
After each 2000 hours of truck operation, in addition to the
1000-hour maintenance, perform the following procedures:
• Check all rotation bearing capscrews for proper torque
value. Refer to Technical Bulletin TB183 or the Service
section 4.5-1 of this manual for checking and replacement
procedures.
• Fork Inspection – After 2000 hours of truck operation, 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), 209561
(Class III) and 6105257 (Class IV).
2.4 Rotate Function Evaluation
The following procedure should be performed every
1000 hours of truck/attachment operation:
1 Engage the forks with a typical bin load that is within the
capacity of the attachment/truck combination.
2 Raise the load the minimum amount to avoid hitting the floor
during rotation.
3 Rotate the load Clockwise (CW) 45° and stop. No rotational
drift should be observed within 30 seconds.
4 Rotate the load Counterclockwise (CCW) 45° to return to the
initial position.
5 Rotate the load Counterclockwise (CCW) 45° and stop. No
rotational drift should be observed within 30 seconds.
6 Rotate the load Counterclockwise (CCW) 45° to return to the
initial position.
7 Repeat steps 3 thru 6 two times to confirm observed
conditions.
• If no rotational drift is observed during the evaluation, no
action is required.
• CAUTION: If rotational drift is observed during the
evaluation, contact the Cascade Service Department to
assist with troubleshooting and symptom resolution.
RR1453.eps
180°
0°
45°45°
3
456
Driver’s View Forward
CCW
CW
Forward
RC5823.eps

TROUBLESHOOTING
46073955-R3
3.1 General Procedures
3.1-1 Truck System Requirements
3.1-2 Tools Required
In addition to a normal selection of hand tools, you will
need:
• Inline Flow Meter Kit:
20 GPM (75 L/Min.) - Cascade Part No. 671477
• Pressure gauge Kit:
5000 psi (345 bar) - Cascade Part No. 671212. Two kits
required.
• Assorted fittings and hoses to adapt gauge and flow
meter to the components being tested
3.1-3 Troubleshooting Chart
• Truck hydraulic pressure should be with in the range
shown in Specifications, Section 5.1. PRESSURE TO
THE ATTACHMENT MUST NOT EXCEED 2300 psi
(160 bar).
• Hydraulic flow should be within the volume range as
shown in Specifications, Section 5.1.
• Hydraulic fluid supplied to the attachment must
meet the requirements as shown in Specifications,
Section 5.1.
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:
Rotator Circuit
• No rotation.
• No rotation with load at rated capacity.
• Rotation in only one direction.
To correct one of these problems, refer to
Section 3.3
• The attachment drifts from its rotated position.
To correct one of these problems, refer to
Section 3.3-4.
GA0013.eps
GA0014.eps
(2) No. 8-12
JIC/O-Ring Flow Meter
(2) 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
Flow Meter Kit:
671477
Pressure Gauge Kit:
671212
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.

56073955-R3
TROUBLESHOOTING
RR1312.eps
3.2 Plumbing
3.2-1 Hosing Diagram
ROTATE COUNTERCLOCKWISE
PRESSURE
RETURN
NOTE: For ROTATE CLOCKWISE, reverse
the colors shown.
Dual Drive Box
Hose Terminal
Hose Reel
To Hose
Reel
ROTATE
Truck
Auxiliary
Valve
CW
CW
CCW
CCW

TROUBLESHOOTING
66073955-R3
RR1441.eps
3.2-2 Circuit Schematic
Single Drive Group Dual Drive Group
CCW CCW
CW CW
Drive Control Valve
with Counterbalance
Cartridges
(Current Valve)
Drive Control Valve
with Counterbalance
Cartridges
(Current Valve)
Drive Control Valve
with Check Cartridges
or Spring-Type
(Early Valves)
To Hose Reel
Truck
Pump
Truck
Tank
Truck
Relief
Hose Reel
Truck Auxiliary
Valve (ROTATE)

76073955-R3
TROUBLESHOOTING
3.3 Rotation Function
There are four potential problem areas that could affect the
rotation function.
• Operator may be handling the load incorrectly.
Loads may be too heavy or rotated off-center,
exceeding capacity of the attachment. Refer to
Operator’s Guide for suggested handling procedures.
• Low hydraulic pressure and/or flow from lift truck.
• Worn or defective motor.
• Worn or defective drive assembly or frame bearing
assembly.
3.3-1 Supply Circuit Test
1Check the pressure delivered by the truck. Refer to
the truck Service Manual. Pressure to the attachment
must not exceed 2300 psi (160 bar), measured at the
carriage hose terminal.
2Check the flow volume at the carriage hose terminal.
Refer to Section 5.1-1 for recommended flow volumes.
If the truck pressure and flow are correct, proceed with
the Rotation circuit pressure test.
3Check for external leaks.
WARNING: Before removing any hoses,
relieve pressure in the hydraulic system.
Turn the truck off, then open the truck
auxiliary control valve(s) several times in
both directions.
3.3-2 Rotation Without Load
1Install pressure gauges to the motor fittings.
2Start the truck and rotate the attachment without a load.
While rotating, note pressure readings of both gauges.
• If the attachment rotates in one direction faster than
the other, or rotates in one direction only, the drive
control valve may need repair. Refer to Section 4.4.
• If the lower gauge reading exceeds 500 psi (35 bar),
there is excessive back pressure in the supply circuit.
Check for restrictions such as numerous fittings and
hose sizes less than No. 8, etc.
RR0545.eps
Install
Pressure
Gauges
RR0555.eps
Install Flow
Meter
RR1317.eps
Install
Pressure
Gauges

TROUBLESHOOTING
86073955-R3
3.3-3 Rotation With Load
1 Attachments with Single Drive –Rotate a load
requiring approximately 3/4 of attachment maximum
torque capacity. Note gauge readings during rotation:
• If the higher gauge reading is substantially less than
the truck pressure as measured at the carriage hose
terminal, the rotator motor gerotor/geroler set may
need repair. Refer to Section 4.3.
• If the higher gauge reading is close to truck pressure
as measured at the carriage hose terminal and no
rotation occurs, the rotator motor output shaft or drive
box may need repair. Continue troubleshooting.
Attachments with Dual Drive – Remove the left drive
group from the attachments as described in Section
4.2-1. Cap the connector fittings on the right hand drive
group. Rotate a load requiring approximately 1/3 of
attachment maximum torque. Note gauge readings
during rotation:
• If the higher gauge reading is substantially less than
truck pressure measured at the junction block/hose
terminal, the RH motor may need repair.
• If the higher gauge reading is close to truck pressure
measured at the junction block/hose terminal, and
no rotation occurs, the RH motor output shaft or drive
may need repair. Continue troubleshooting.
• If the higher gauge is close to truck pressure,
measured at the junction block/hose terminal, and
rotation occurs, the LH motor output shaft or drive
may need repair. Continue troubleshooting.
2 Remove the motor from the drive box assembly as
described in Section 4.3-1.
3 Reinstall the hoses to the rotator fittings. Actuate the
ROTATE circuit.
• If the rotator motor shows rotational output, the drive
box may require service. See Section 4.2.
• If the rotator motor shows little or no rotational output,
the rotator motor requires service. See Section 4.3.
CL5312.eps
Disconnect the
crossover tubes
Cap fittings
Right hand
drive group
Left hand
drive group
Model Maximum Torque Capacity
45G, 55G 63,000 in.–lbs. @ 2300 psi
(7,118 Nm @ 160 bar)
65G 80,000 in.–lbs. @ 2300 psi
(9,039 Nm @ 160 bar)
80G 73,000 in.–lbs. @ 2,300 psi
(8,248 Nm @ 160 bar)
100G 98,000 in.–lbs. @ 2,300 psi
(11,037 Nm @ 160 bar)
130G ★128,000 in.–lbs. @ 2,300 psi
(14,462 Nm @ 160 bar)
160G ■145,000 in.–lbs. @ 2,300 psi
(16,383 Nm @ 160 bar)
★Rated at 15 GPM (56L/min.) flow.
■Rated at 20 GPM (75L/min.) flow.