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Cascade G Series Installation Instructions Manual
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Cascade G Series Installation Instructions Manual

Rotators
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NSTALLATION INSTRUCTIONS
G D E
G & D & E-Series Rotators

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Summary of Contents for Cascade G Series

  • Page 1 NSTALLATION INSTRUCTIONS G D E G & D & E-Series Rotators...

  • Page 2: Table Of Contents

    ONTENTS Introduction Special Definitions Recommended Hydraulic Supply Truck Requirements Installation Prior To Operation - 1 -...

  • Page 3: Introduction

    NTRODUCTION This manual provides installation instrucions and prior to operation requirements for Cascade Rotators.In any communication about the attachment refer to the product catalog and serial numbers stamped on the nameplate, as shown. If the nameplate is missing,the numbers can 备注...

  • Page 4: Special Definitions

    PECIAL DEFINITIONS The statements shown below 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 special information that is useful when servicing the attachment. WARNING - A statement preceded by a WARNING is information that should be acted upon to prevent bodily injury.

  • Page 5: Recommended Hydraulic Supply

    ECOMMENDED HYDRAULIC SUPPLY Rotators provide the best performance with the recommended hydraulic supply arrangements shown. Refer to Cascade Hose and Cable Reel Selection Guide, Part No.212199, to select the correct hose reel for the mast and truck. The hose and fitting requirements are(Recommended);...

  • Page 6: Truck Requirements

    Tilt Forward Hoist Down Rotate CCW Cascade Rotators 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.

  • Page 7: Installation

    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. WARNING: Verify that the overhead...
  • Page 8 NSTALLATION Unlock Quick-Change lower mounting hooks (if equipped) Move hooks into unlocked position. Reinstall pin in lower hole. 备注 Guide Note: Guides can be reversed to change hook to carriage clearance. Refer to Step 7. 16mm LH lower Hook 16mm (5/8 in,) offset on top provides maximum clearance.
  • Page 9 NSTALLATION Prepare Hoses A Position truck carriage behind attachment. B Determine hose lengths required. C Cut hoses to length and install end fittings. IMPORTANT: Flush hoses (Step 4) before operating attachment. Rotate Rotate No.6 Hoses and Fittings INSTALLATION USING INSTALLATION USING INTERNAL REEVING RH 2-PORT HOSE REEL - 8 -...
  • Page 10 NSTALLATION CAUTION: Rotate function supply circuit back pressure 35bar exceeding 35 bar (500 psi) can result in excessive oil heating, reduced attachment performance and shortened hydraulic system life. Check for restrictions such as numerous fittings and fitting/hose sizes less than No.6 (30E) or No. 8.(45G-100G, 100D, X100D, 120D 150D ) 120D, 150D).
  • Page 11 NSTALLATION 100D, X100D Rotate CCW Rotate CCW No.8 Hoses and Fittings Rotate CW Rotate CW Hydraulic 180° Stop Group Equipped INSTALLATION USING RH 2-PORT HOSE REEL 120D, 150D Rotate CW Rotate CCW INSTALLATION USING RH 2-PORT HOSE REEL - 10 -...
  • Page 12 Remove gearbox end cover level hole Check lubricant level 656300 End Cover Hole SAE90 wt (AGMA “ ” (level hole) If necessary, fill gearbox with Cascade Gear Lube 656300 or equivalent SAE 90 wt.gear lube(AGMA ' mild' 6EP Gear Oil). Fill Hole - 11 -...
  • Page 13 NSTALLATION 656300 SAE90 wt (AGMA “ ”6EP If necessary, fill gearbox with Cascade Gear Lube 656300 or equivalent SAE 90 wt.gear lube(AGMA ' mild' 6EP Gear Oil). 45G - 100G, 100D, X100D, 120D 150D End Cover Hole End Cover Hole...
  • Page 14 NSTALLATION Mount attachment on truck carriage A Center truck behind attachment. B Tilt forward and raise carriage into position. C Engage top mounting hooks with carriage. 30E - 30E - Make sure the centering tab engages the center 45G-100G, 100D, X100D, 120D, 150D - notch on top carriage bar.
  • Page 15 NSTALLATION 45G -100G ISO 3A IMPORTANT: For integral carriages, install in mast per OEM specifications and procedures. ISO 3A mounting ISO 2A - 15-17 mm (0.60-0.66 in.) shown ISO 3A - 18-20 mm (0.72-0.78 in,) ISO 4A - 18-20 mm (0.72-0.78 in.) ISO 5A - 24.2-25.8 mm(0.95-1.01 in.) Notch Center Spacer...
  • Page 16 NSTALLATION Install and engage lower hooks BOLT-ON TYPE QUICK-CHANGE TYPE Inspect hooks for excessive clearance. Lower Refer to Step 2 to Carraige Lower reverse guides to Carraige change clearance. Install hooks, tap tight into position. Slide hook up to engage bar, install pin in 5 mm locked...
  • Page 17 NSTALLATION Connect hoses to hose terminal fittings as shown in Step 3 100D, X100D, 120D, 150D Rotate Rotate Rotate CCW Rotate CW - 16 -...
  • Page 18 NSTALLATION INSTALLATION USING RH 2-PORT INSTALLATION USING INTERNAL THINLINE HOSE REEL HOSE REEVING - 17 -...
  • Page 19 NSTALLATION Install stop block kit · · Locate a stop block on the outside of each upper hook. Preheat stop block · · AWS E7018 and carriage bar weld area to 180 325°F · Use AWS E7018 low hydrongen rod and weld a 6 mm(.25 in.)fillet full length on three sides of each stop block.
  • Page 20 NSTALLATION 连续旋转测试 Cycle Rotation Function WARNING: Make sure all personnel are clear of the attachment during testing. · With no load, cycle rotation function several · times. · · Check functions for operation in accordance · with ANSI ISO standards. ·...
  • Page 21 NSTALLATION WARNING: Truck contro; handle and attachment function activation shown here conforms to ASME/ANSI B56.1 ASME/ ANSI B56.1 recommended practices. Failure to follow these practices may lead to serious bodily injurt or property damage. End user, dealer and OMEs should review any deviation from the practices for safe operation.
  • Page 22 C Tack the hook in four places with 6 mm (.25 in.) long welds. Recheck dimensions. WARNING: Each fork must have three hooks. Cascade forks for rotators are equipped with a middle hook. If the attachment is supplied without forks, middle hooks are provided. They must be welded using the following procedures.
  • Page 23 NSTALLATION Fork Middle Hook Welding A Preheat weld area(full fork width and 6 in.) above and below hook) to 260℃ (500°F) 152mm 6 in.） minimum, 315℃(600°F) maximum before -315 welding. Maximum interpass temperature should not exceed 370℃(700°F) . B Finish weld middle hook to fork. Apply welds in the hook weld prep areas using the lower hook as an example of the welds required.
  • Page 24 NSTALLATION WARNING: Applications that hold a load interted with a 50% or more capacity, must use Cascade rotator forks. Applications that dump a load when the attachment is rotated at 45 ° from vertical, can use pallet forks with the installed middle hook.
  • Page 25 Fork size chosen may reduce attachment rating(see page 25.) WARNING: Forks must have three hooks. Cascade forks for rotators are already equipped with a middle hook. If the attachment is supplied without forks, middle hooks are provided. See Step 11 for middle hook installation procedure.
  • Page 26 NSTALLATION C Slide the forks into position on the fork carriage bars. NOTE: If the fork middle hook or lower hook fit up is too tight, sand or grind the tip, but do not excced dimension ‘A’ ‘A’ as shown in chart on page 19. D Lock each fork in place by pushing the spring lock lever down or twisting the button down.
  • Page 27 NSTALLATION F Reverse the above procedures for removal. WARNING: When installing or removing forks, rotate carriage to horizontal position. Use pallets or blocks to raise forks to installation height. Keep feet clear of forks when installing. Fork keepers must be in place at all times during attachment operation.
  • Page 28 NSTALLATION CAUTION: Attachment and fork capacity are dependant on fork size. Shaded area indicates maximum rating fork size. 500mm ROTATOR & FORK CAPACITY at 500 mm Load Center 20 in. 货叉安 货叉尺寸（宽×厚） 装等级 Fork Size W×T Model Fork 100 × 35 mm 100 × 40 mm 125 × 40 mm 125 × 45 mm 125 × 50 mm 150 ×...
  • Page 29 The purpose of installing a fork stop is to fix the forks on carriage and prevent them from swinging during rotation, so as to eliminate the excessive wear caused by the upper hook of fork sliding back and forth along the upper carriage bar of rotator.

  • Page 30: Prior To Operation

    WARNING: Truck control handle and attachment function activation shown ASME/ ANSI B56.1 here conforms to ASME/ANSI B56.1 recommended practices. Failure to follow these practices may lead to serious bodily injury or property damage. End user, dealer and OEMs should review any deviation from the pracices for safe operation.
  • Page 31 3 Pick up a maximum load and rotate in both directions. If the attachment is sluggish or does not rotate smoothly, recheck the plumbing. If the attachment still operates incorrectly, contact the Cascade Xiamen Service Department listed on the back cover. 4 若需要，安装180度旋转角度控制装置 - 4 180°...
  • Page 32 5 Electronic Rotational Control,if equipped - When rotating, attachment travel should stop at the vertical and horizontal handling positions. Wait 3 seconds to rotate after stopping OR press the rotate override button to continue rotating. if rotation stops at vertical and horizontal positions, stop positions are correct.
  • Page 33 Limit Switches Stop Capscrew Ramp - 32 -...
  • Page 34 Cascade Xiamen Forklift Truck Attachment Co., Ltd 361026 No.668 Yangguang Road, Haicang, Xiamen, Fujian ,361026 P.R China /Tel: 0592-6512570 /Fax: 0592-6512571 Cascade Xiamen reserves the rights to make change without notice. 1210946 R6 xm cn 03/2016...

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