cascade corporation 45G Series User manual

Cascade is a Registered Trademark of Cascade Corporation
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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.

96073955-R3
TROUBLESHOOTING
3.3-4 Rotation Drift Test
1 Position forks parallel to the floor.
2 Place a mark at the top center of the baseplate and
bearing. Place rotation limit marks at 20° (12 in., 30.5 cm)
at each side of the top center on the faceplate. All marks
should be viewable by the driver.
NOTE: If the faceplate is raised, mark 12 in. (30.5 cm)
from center.
3 With the forks parallel to the floor, pick up a load.
4 Lift a load 15 in. (38 cm) off the floor to provide clearance
for rotation drift test.
5 Rotate load CW to 20° align marks and wait 30 seconds.
Observe if drift occurs.
• If drift occurs, the rotator drive components require
service. Refer to Section 4.2.
6 Rotate load CCW to 20° align marks and wait 30 seconds.
Observe if drift occurs.
• If drift occurs, the rotator drive components require
service. Refer to Section 4.2.
RR1321.eps
Mark at top center
Marks at 20° (12 in., 30.5 cm)
each side of the center

10 6073955-R3
SERVICE
2
4.1 Attachment Removal
1 Rotate the attachment to position the forks parallel to
the ground.
2 Remove the fork bar keepers at each end of the top
carriage bar. For reassembly, tighten the capscrews to
a torque of:
Capscrew Type:
45G−160G− 200 ft.-lbs. (270 Nm)
Bar Type:
45G−65G− 66 ft.-lbs. (90 Nm)
Clean and dry bar type capscrews and threaded holes.
Apply Loctite 242 (blue) to capscrews.
3 If equipped with fork restraint kit, loosen
capscrews on outer restraint and remove from
fork bar. For reassembly, install outer restraint
against the fork. Tighten capscrews to:
45G, 55G – 166 ft.-lbs. (225 Nm)
65G-160G – 295 ft.-lbs. (400 Nm)
4 Release the spring lock on the top of each fork.
Remove the forks from the fork bar.
RR0509.eps
4
OR
OR
RR0511.eps
4
Bar Type
Fork Keeper
Capscrew Type
Fork Keeper
RR1319.eps
3

SERVICE
116073955-R3
RR0510.eps
ADJUST
RC0368.eps
cascade
®
C-675514-1
RR0548.eps
4.1 Attachment Removal
(continued)
5 Disconnect the lower hooks.
Bolt On Hooks – Remove the lower mounting hooks.
For reassembly, tighten the capscrews to a torque of:
Class II/III – 120 ft.-lbs. (165 Nm)
Class IV – 235 ft.-lbs. (320 Nm)
Clean and dry capscrews and threaded holes. Apply
Loctite 242 (blue) to capscrews.
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.
Carriage Bar
Lower Hook
Locking Pin
Guide
Lower Hook in
unlocked position
BOLT-ON HOOKS
QUICK-CHANGE HOOKS
5
7
6 Disconnect the hydraulic hoses to the drive motor. Tag
the hoses for reassembly.
7 Attach a suitable overhead hoist to the upper fork bar.
Remove the attachment from the truck. Lay the
attachment face down on a pallet with the drive group
upward.
8 For installation, reverse the above procedures.
WARNING: Verify that the overhead
hoist and chains or straps are rated for
the weight of the attachment. Refer to
nameplate for attachment weight.
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.

12 6073955-R3
SERVICE
RR0549.eps
RR0520.eps
4.2 Drive Group
4.2-1 Drive Group Removal
and Installation
1 Remove the attachment from the truck as described in
Section 4.1.
2 Dual Drive – Disconnect the crossover tubes from the
drive control valve.
3 Remove the four capscrews fastening the drive group to
the baseplate. For reassembly, tighten the capscrews
to a torque of 66 ft.-lbs. (90 Nm).
4For reassembly, reverse the above procedures with the
following exceptions:
• After the drive group has been reinstalled, check the
gearcase oil level. Oil must be up to the bottom of
the fill plug hole. If necessary, fill with Cascade Gear
Lube Part No. 656300 or equivalent SAE 90 wt. lube
(AGMA 'mild' 6 EP Gear Lube).
3
4
43
7
5
26
Cover
Plate
Housing
End Cover
Housing
4.2-2 Drive Group Disassembly
and Service
1 Remove the drive group from the baseplate as
described in Section 4.2-1.
2 Lay the drive group, pinion down, on two 4 x 4 in.
(10 x 10 mm) wood blocks placed on both sides of the
pinion.
3 Remove the four capscrews fastening the cover plate to
the housing.
4 Remove the center capscrew plug from the cover plate
and install an M10 capscrew with a minimum thread
length of 2 in. (50 mm). Remove the cover plate by
turning the capscrew clockwise while lightly tapping
around the sides of the cover plate.
5 Drain oil from the housing.
6 Remove the three capscrews fastening the end cover to
the housing.
7 Remove the drive motor as described in Section 4.3-1.

SERVICE
136073955-R3
RR0521.eps
RR0522.eps
RC2111.eps
8Tap the worm and bearing assembly out through
the end-cover side of the housing. Remove the
opposite outer bearing race through the motor
side of the housing. 8
9
10
11
Bearing
outer race
Pinion shaft key
NOTE: Two types of large pinion bearing used: sealed
bearing and bearing with separate seal (shown)
Pinion gear
Worm
Worm
Gear
Seal (if equipped)
Housing
Pinion bearing
8
OR
Washers
NOTE: The drive group being serviced may
or may not be assembled with the washers
shown on the worm.
CAUTION: When replacing a worm or worm gear, the serial
number of the attachment and whether washers are or are
not installed on the worm must be supplied to identify the
correct replacement parts.
9 Press the pinion gear, seal, pinion bearings and worm
ring gear out of the housing as an assembly.
10 Remove the snap ring from the pinion gear shaft. Press
the pinion gear bearing from the worm ring gear and
cover plate pinion bearing. Remove the pinion shaft
key.
11 Press the pinion gear out of the housing pinion bearing.
12 Clean and inspect all components. Remove all dried
sealant residue. Replace all worn items. Remove any
burrs or sharp edges with emery cloth.
4.2-2 Drive Group Disassembly
and Service (continued)

14 6073955-R3
SERVICE
RC2118.eps
RR0550.eps
RC2648.eps
RC2125.eps
RC0178.eps
4.2-3 Drive Group Reassembly
Build up the pinion/worm gear assembly vertically with the
pinion gear down.
1Pinion with seal and non-sealed bearing – Position
the seal against the pinion gear, spring-side facing
housing. Apply Loctite 271 (red) to the bearing seating
area as shown. Press a non–sealed housing bearing
onto the pinion shaft.
NOTE: If installing a sealed bearing with external seal,
pry out bearing seals and then press into pinion shaft.
Remove excess Loctite.
Pinion with sealed bearing – No external seal is used.
Apply Loctite 271 (red) to the bearing seating area as
shown. Press housing bearing onto the pinion shaft.
Remove excess Loctite.
CAUTION: Make sure Loctite does not squeeze into the
seal or bearings.
2 Preheat worm gear to 200° F (93° C). Install the key,
worm gear, cover plate pinion bearing and snap ring on
the pinion.
3 Apply Loctite 271 (red) to the housing seating area
and shoulder for the housing pinion bearing. Install the
complete pinion assembly into the housing. Remove
excess Loctite.
CAUTION: Make sure Loctite does not squeeze into the
seal or bearings.
4 Install the worm's outer bearing race in the drive motor
side of the housing. Make sure the race taper is inward
as shown.
5 Install the drive motor as described in Section 4.3-1.
6 Install the worm, bearings, and washers (if equipped)
in the housing. Fully engage the worm with the drive
motor shaft. Install the remaining outer bearing race.
Make sure the race taper is inward as shown.
6
4
5
1
2
Pinion
gear
Key
3
Housing
Bearing
Seating
Area
External
Seal Housing
Pinion
Bearing
Worm Gear,
Bearing, Snap Ring
PINION WITH SEAL AND NON-SEALED BEARING
Seal
Seating
Area
PINION WITH SEALED BEARING
Housing
Pinion
Bearing
(Sealed)

SERVICE
156073955-R3
RR0551.eps
RR0552.eps
7 Temporarily install the end cover without shims. Tighten
the capscrews sequentially in 10 ft.-lb. (15 Nm)
increments to 20 ft.-lbs. (30 Nm).
8 Measure the gap between the end cover and housing in
three places with a feeler gauge or 'Plastigage' thread
and determine the minimum gap.
9 Drive Group with Worm Washers – The worm washers
and bearings require 0.020–0.025 in. (0.50–0.64 mm)
preload. Subtract the preload numbers from the feeler
gauge measurement to determine the shims required
between the end cover and housing. See sample below.
In this case two 0.020 in. (0.50 mm) yellow shims would
be installed to equal 0.040 in. (1.0 mm). Refer to shims
listed below.
Drive Group without Worm Washers – Choose a
combination of end cover shims equal to the minimum
gap measured plus the next higher 0.005 in. (0.12 mm)
increment. See examples below:
• For 0.025–0.029 in. (0.635–0.736 mm) measured
gap, use 0.030 in. (0.762 mm) total shim thickness.
• For 0.010–0.014 in. (0.254–0.356 mm) measured
gap, use 0.015 in. (0.381 mm) total shim thickness.
• For 0.009 in. (0.228 mm) or less, use one 0.010 in.
(0.254 mm) shim. A minimum of one 0.010 in.
(0.254 mm) shim is required for proper seal.
NOTE: Shim Service kit 670578 contains the shims
listed. A minimum of one 0.010 in. (0.25 mm) shim is
required to seal against leakage:
10 Remove the end cover. Apply Loctite 515 sealant
(Cascade Part No. 668184) to both surfaces of the
shims. Install the shim pack and end cover. Tighten
the capscrews to a torque of 65 ft.-lbs. (88 Nm).
Remove excess sealant.
11 With the gearcase laying flat, fill with 2-1/4 Cups (18
fluid ounces or 540 ml) of Cascade Gear Lube Part
No. 656300, or SAE 90 wt. gear lube (AGMA 'mild' 6EP
Gear Lube).
12 Install the cover plate and gasket. If the gaskets shows
porosity, apply Loctite 515 sealent to cover face. Install
the four cover plate capscrews and tighten to 16 ft.-lbs.
(22 Nm). Install the center hole plug.
13 Reinstall the drive group on the baseplate as described
in Section 4.2-1.
12
Cover plate
11
10
9
7
8
Housing
End cover
RR0553.eps
0.063 in.
- 0.025 in.
0.063 in.
- 0.020 in.
(Feeler gauge measurement)
(Preload)
0.038 in. to 0.043 in. (Shim thickness range)
4.2-3 Drive Group Reassembly (continued)
Qty Part No. Color Thickness
1
1
1
1
674513
670574
671757
671758
Blue
Brown
Pink
Yellow
0.005 in. (0.125 mm)
0.010 in. (0.254 mm)
0.015 in. (0.381 mm)
0.020 in. (0.508 mm)

16 6073955-R3
SERVICE
CCW
CW
RR1202.eps
4.3 Drive Motor
4.3-1 Drive Motor Removal and
Installation
1 Remove the attachment from the lift truck as described
in Section 4.1.
2 Remove the drive group from the attachment as
described in Section 4.2-1.
3 Remove the fill plug and drain the lubricant from the
drive group.
4 Lay the drive group, pinion down, on two 4 x 4 in.
(10 x 10 cm) wood blocks placed on both sides of the
pinion gear.
5 Remove the four capscrews and special lockwashers
fastening the drive control valve to the drive motor.
Keep track of the two O-rings between the drive control
valve and drive motor. For reassembly, tighten the
capscrews to 15 ft.-lbs. (20 Nm).
WARNING: Before removing hydraulic
lines, relieve pressure in the hydraulic
system. Turn the truck off and open the
truck auxiliary control valves several
times in both directions.
5
6
6
8
43
8
7
Drive Motor
(Current)
Drive Motor
O-rings
Fill Plug
(two locations)
Drive Control Valve
6 Remove the three capscrews fastening the motor flange
(or adapter plate) to the gearcase housing. Tap on
the drive motor with a rubber mallet to separate the
drive motor (or drive motor with adapter plate) from the
gearcase housing.
7 Early Drive Motors – Remove the four capscrews
fastening the adapter plate to the drive motor. Separate
the motor from the adapter plate.
8 For reassembly, reverse the above procedures except
as follows:
• Early Drive Motors – Apply Loctite 515 sealant
(Cascade Part No. 668184) to both sides of the drive
motor/adapter plate gasket. Apply sealant to the
threads of the four drive motor capscrews. Install the
gasket and adapter plate to the drive motor. Tighten
capscrews to 40 ft.-lbs. (54 Nm).
• Apply sealant to both sides of the motor/gearcase
(or adapter plate/gearcase) gasket. Apply sealant
to the threads of the three motor flange (or adapter
plate) capscrews. Install the motor (or motor with
adapter plate) and gasket to the gearcase housing.
Tighten the capscrews to 65 ft.-lbs. (88 Nm).
• Fill the drive group with fill with 18 fluid ounces
(540 ml) of Cascade Gear Lube Part No. 656300, or
SAE 90 wt. gear lube (AGMA 'mild' 6EP Gear Lube).
Adapter Plate
(if equipped)
Early Drive Motors

SERVICE
176073955-R3
RR1199.eps
RR0841.eps
RR0863.eps
RR0632.eps
Housing
O-Ring ▲
3
6
7
45
Pressure Seal ▲
Wiper Seal ▲
Flange Seal ▲
Housing
Flange
(609XXXX or greater)
Flange
(608XXXX or less)
Load Bearing Race
Thrust Bearing
Output Shaft
Splined
Drive
Spacer
Plate
Geroler Set
End
Cap
Capscrews
Capscrews
Gerotor
Set
2
8
Spacer Plate
O-Ring ▲
O-Ring ▲
O-Ring ▲
Brass Shim ▲
3 Make a scribe across the drive motor, inline with the
capscrew and drive motor’s port surface.
4 Clamp drive motor in a soft-jawed vise across the
flange with the output shaft downward.
5 Remove all capscrews from the end cap.
6 Remove altogether the end cap, geroler/gerotor set and
spacer plate. The splined drive should remain in place
with this group.
7 Remove the O-rings from the end cap, geroler/gerotor
set and housing.
8 Turn the drive motor over, clamping the housing across
the port area with the flange upward.
4.3-2 Drive Motor Disassembly
Cascade provides service replacement parts for the seals
indicated with a ▲below. Due to cost, if other parts need
replacement, the complete drive motor assembly should
be replaced.
1 Remove the drive motor from the drive group as
described in Section 4.3-1.
IMPORTANT: Clean the outside of the drive motor and
service in a clean, dust-free work area. Use a soft-
jawed vise for all service procedures.
2 Remove O-rings from housing.

18 6073955-R3
SERVICE
RR0860.eps
RR0859.eps
RR0843.eps
RR0858.eps
9 Remove the four Loctited capscrews from the flange
with a X10 Torx Socket. Do not use an impact wrench.
CAUTION: Thread sealant used on the capscrews may
require a small amount of heat to the housing to remove
the capscrews. Use a temperature indicator to prevent
overheating the housing.
10 Turn the flange 45° clockwise.
11 Remove the flange and output shaft by pushing the
output shaft from under the housing and pulling up on
the tapered portion of the output shaft.
12 Remove the flange and thrust bearing from the output
shaft.
13 Remove the load bearing race and flange seal from the
flange.
14 Remove the wiper seal and pressure seal from the
flange using a seal removal tool or modified screwdriver
as shown.
NOTE: Remove the seals by pushing from the back
side, as shown.
15 Remove the brass shim from the flange.
10
11
14
Modified Screwdriver
Flange (early design)
Flange
9
14
15 13
Flange
12
RR1200.eps
45°
4.3-2 Drive Motor Disassembly
(continued)