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Summary of Contents for cascade corporation 45G Series
- Page 1 ERVICE MANUAL 45G-160G Rotators Manual Number 6073955-R3 cascade corporation Cascade is a Registered Trademark of Cascade Corporation...
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Page 2: Table Of Contents
CONTENTS Page INTRODUCTION, Section 1 Introduction Special Definitions PERIODIC MAINTENANCE, Section 3 Daily Maintenance 1000-Hour Maintenance 2000-Hour Maintenance Rotate Function Evaluation TROUBLESHOOTING, Section 4 General Procedures Truck System Requirements Tools Required Troubleshooting Chart Plumbing Hosing Diagram Circuit Schematic Rotation Function Supply Circuit Test Rotation Without Load Rotation With Load... -
Page 3: Introduction, Section
Nameplate (front side of faceplate) A2-Z 45G-RRB-10A PTL604920-1R0 Cascade Corporation • www.cascorp.com • Icons & Patents: www.cascorp.com/support 6095754 RR1197.eps Special Definitions The statements shown appear throughout this Manual where special emphasis is required. Read all WARNINGS and CAUTIONS before proceeding with any work. -
Page 4: Daily Maintenance
PERIODIC MAINTENANCE Daily Inspection WARNING: After completing any service procedure, always test the attachment Prior to each shift of truck operation, complete the through five complete cycles. First test following procedures: empty, then test with a load to make sure the attachment operates correctly before •... -
Page 5: Periodic Maintenance, Section
PERIODIC MAINTENANCE 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. -
Page 6: Troubleshooting, Section
TROUBLESHOOTING General Procedures WARNING: Before servicing any hydraulic component, relieve pressure Truck System Requirements in the system. Turn the truck off and 3.1-1 move the truck auxiliary control valves several times in both directions. • Truck hydraulic pressure should be with in the range shown in Specifications, Section 5.1. -
Page 7: Plumbing
TROUBLESHOOTING Plumbing Hosing Diagram 3.2-1 ROTATE COUNTERCLOCKWISE PRESSURE Dual Drive Box RETURN NOTE: For ROTATE CLOCKWISE, reverse the colors shown. To Hose Reel Hose Reel ROTATE Truck Auxiliary Valve Hose Terminal RR1312.eps 6073955-R3... -
Page 8: Circuit Schematic
TROUBLESHOOTING Circuit Schematic 3.2-2 Single Drive Group Dual Drive Group Drive Control Valve Drive Control Valve with Counterbalance with Counterbalance To Hose Reel Hose Reel Cartridges Cartridges (Current Valve) (Current Valve) Drive Control Valve with Check Cartridges or Spring-Type (Early Valves) Truck Auxiliary Valve (ROTATE) Truck... -
Page 9: Rotation Function
TROUBLESHOOTING 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, Install Flow exceeding capacity of the attachment. Refer to Meter Operator’s Guide for suggested handling procedures. -
Page 10: Rotation With Load
TROUBLESHOOTING Rotation With Load 3.3-3 Model Maximum Torque Capacity 63,000 in.–lbs. @ 2300 psi Attachments with Single Drive –Rotate a load 45G, 55G (7,118 Nm @ 160 bar) requiring approximately 3/4 of attachment maximum torque capacity. Note gauge readings during rotation: 80,000 in.–lbs. -
Page 11: Rotation Drift Test
TROUBLESHOOTING Rotation Drift Test 3.3-4 Marks at 20° (12 in., 30.5 cm) Position forks parallel to the floor. Mark at top center each side of the center 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. -
Page 12: Attachment Removal
SERVICE Attachment Removal Rotate the attachment to position the forks parallel to the ground. 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: Bar Type 45G−65G−... - Page 13 SERVICE Attachment Removal (continued) Disconnect the lower hooks. Bolt On Hooks – Remove the lower mounting hooks. BOLT-ON HOOKS For reassembly, tighten the capscrews to a torque of: Class II/III – 120 ft.-lbs. (165 Nm) Carriage Bar Class IV – 235 ft.-lbs. (320 Nm) Clean and dry capscrews and threaded holes.
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Page 14: Drive Group
SERVICE Drive Group Drive Group Removal 4.2-1 and Installation Remove the attachment from the truck as described in Section 4.1. Dual Drive – Disconnect the crossover tubes from the drive control valve. Remove the four capscrews fastening the drive group to the baseplate. - Page 15 SERVICE Drive Group Disassembly 4.2-2 Bearing outer race and Service (continued) Tap 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. NOTE: The drive group being serviced may or may not be assembled with the washers Worm shown on the worm.
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Page 16: Drive Group Reassembly
SERVICE Drive Group Reassembly 4.2-3 PINION WITH SEAL AND NON-SEALED BEARING Build up the pinion/worm gear assembly vertically with the pinion gear down. External Pinion with seal and non-sealed bearing – Position Seal Housing the seal against the pinion gear, spring-side facing Pinion housing. - Page 17 SERVICE Drive Group Reassembly (continued) 4.2-3 Temporarily install the end cover without shims. Tighten the capscrews sequentially in 10 ft.-lb. (15 Nm) increments to 20 ft.-lbs. (30 Nm). Measure the gap between the end cover and housing in three places with a feeler gauge or 'Plastigage' thread and determine the minimum gap.
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Page 18: Drive Motor
SERVICE Drive Motor WARNING: Before removing hydraulic Drive Motor Removal and 4.3-1 lines, relieve pressure in the hydraulic Installation system. Turn the truck off and open the truck auxiliary control valves several times in both directions. Remove the attachment from the lift truck as described in Section 4.1. -
Page 19: Drive Motor Disassembly
SERVICE Drive Motor Disassembly Spacer Plate 4.3-2 Cascade provides service replacement parts for the seals Geroler Set indicated with a ▲ below. Due to cost, if other parts need replacement, the complete drive motor assembly should RR0863.eps be replaced. Remove the drive motor from the drive group as described in Section 4.3-1. - Page 20 SERVICE Drive Motor Disassembly 4.3-2 (continued) Remove the four Loctited capscrews from the flange with a X10 Torx Socket. Do not use an impact wrench. Flange CAUTION: Thread sealant used on the capscrews may require a small amount of heat to the housing to remove the capscrews.
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Page 21: Drive Motor Inspection
SERVICE Drive Motor Inspection 4.3-3 • Remove all Loctite residue from the threaded holes. • Clean all parts with solvent and blow dry. Do not use paper or cloth towels. • Inspect all parts for small nicks, burrs or scratches. Remove imperfections with emery cloth. - Page 22 SERVICE Drive Motor Reassembly (continued) 4.3-4 Turn the housing over and clamp across the flange with the output shaft taper facing down. Lubricate the O-rings and install into the housing, geroler/gerotor set and endcap grooves. Align the ouput shaft timing dot with the screw hole that is aligned to the port surface.
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Page 23: Drive Control Valve
SERVICE Drive Control Valve WARNING: Before removing hydraulic lines, relieve pressure in the attachment hydraulic system. Turn the truck off and Drive Control Valve Service 4.4-1 move the auxiliary control valves several times in both directions. Disconnect the hydraulic hoses to the drive control valve. -
Page 24: Base Unit
SERVICE Base Unit Bearing Assembly – 4.5-1 Capscrew Torque Inspection Baseplate-to-Bearing Assembly Capscrews 500-Hour Inspection Baseplate Every 500 hours perform the following inspection: Check the accessible baseplate capscrews above upper mounting hooks for an initial torque of: 45G-100G – 77 ft.-lbs. (105 Nm) 130G –... -
Page 25: Bearing Assembly Removal And Inspection
SERVICE Bearing Assembly Removal 4.5-2 and Installation Remove the attachment from the lift truck as described in Section 4.1. Remove the drive group from the attachment as described in Section 4.2-1. Remove upper mounting hooks and adapter plate (if included). For reassembly tighten the capscrews to the torque values below: 45G–100G CL II/III –... - Page 26 SERVICE Bearing Assembly Removal 4.5-2 and Installation (continued) Remove the capscrews fastening the bearing assembly to the faceplate. For reassembly, tighten the capscrews using the following technique: Bearing Assembly/Faceplate Capscrews – Clean and dry capscrews and threaded holes. 45G-100G – Apply Loctite 242 (blue) to capscrews. Threads must be clean and dry for new Loctite to cure properly.
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Page 27: Fork Bar Service
SERVICE Fork Bar Service 4.5-3 65G sequence shown Tighten the fork bar capscrews using the tightening sequence shown: 45G/55G– 200 ft.-lbs. (270 Nm) 65G– 400 ft.-lbs. (540 Nm) 80G/100G/130G/160G– 395 ft.-lbs. (535 Nm) RR0531.eps Bearing Seal Service 4.5-4 Remove attachment from the lift truck as described in Section 4.1 Remove the drive group from the attachment as described in Section 4.2-1. -
Page 28: Specifications
SPECIFICATIONS Hydraulics Truck Relief Setting 2300 psi (160 bar) Maximum Truck Flow Volume ➀ Min. ➁ Recommended Max. ➂ 5 GPM 10 GPM 15 GPM 45G – 160G (20 L/min.) (38 L/min.) (56 L/min.) ➀ Cascade Revolving Clamps are compatible with SAE 10W petroleum base hydraulic fluid meeting Mil. -
Page 29: Truck Carriage
SPECIFICATIONS Truck Carriage Carriage Mount Dimension (A) ITA (ISO) 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) Class IV 23.44 in. (595.5 mm) 23.50 in. (597.0 mm) GA0389.eps 6073955-R3... -
Page 30: 45G-65G Torque Values
SPECIFICATIONS Torque Values NOTE: All fasteners have a torque value 45G-65G Torque Values range of ±10% of stated value. 5.4-1 Fastener torque values for the 45G-65G Rotators are shown in the table below in both US and Metric units. All torque values are also called out in each specific service procedure throughout this manual. -
Page 31: 130G, 160G Torque Values
SPECIFICATIONS 80G, 100G Torque Values 5.4-2 NOTE: All fasteners have a torque value Fastener torque values for the 80G-100G Rotators are shown range of ±10% of stated value. in the table below in both US and Metric units. All torque values are also called out in each specific service procedure throughout this manual. - Page 32 SPECIFICATIONS 130G, 160G Torque Values 5.4-3 Fastener torque values for the 130G, 160G Rotators are shown in the table below in both US and Metric units. All torque values are also called out in each specific service procedure throughout this manual. Ref.
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Page 33: Determining Load Torque Requirements
SPECIFICATIONS Determining Load Torque Requirements IMPORTANT: Positioning the load as close to center as possible will reduce the torque requirements and increase truck stability. To check that an attachment will handle a specific load, calculate the torque requirements as follows: Weigh the load to be handled. - Page 34 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 © Cascade Corporation 2018 03-2018 Part Number 6073955-R3...
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