cascade corporation D Series Service Manual
High capacity 360' rotators
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- Service manual supplement (32 pages) ,
- Installation instructions manual (14 pages)
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Summary of Contents for cascade corporation D Series
- Page 1 ERVICE MANUAL D-Series High Capacity 360° Rotators Manual Number 6817684 cascade corporation Cascade is a Registered Trademark of Cascade Corporation...
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Page 2: Table Of Contents
ONTENTS Page INTRODUCTION, Section 1 Introduction Special Definitions PERIODIC MAINTENANCE, Section 2 100-Hour Maintenance 500-Hour Maintenance 2000-Hour Maintenance TROUBLESHOOTING, Section 3 General Procedures Truck System Requirements Tools Required Troubleshooting Chart Plumbing Hosing Diagram Hydraulic Schematics Rotate Function Supply Circuit Test Rotation without Load Rotation with Load SERVICE, Section 4... -
Page 3: Introduction, Section
NTRODUCTION Introduction WARNING: Fork size affects rotator capacity. Consult Cascade to verify This manual provides Installation, Periodic Maintenance, capacity for truck nameplate. Troubleshooting, Service and Specifications for Cascade High Capacity D-Series Rotators. In any communication about the attachment, refer to the product catalog and serial numbers stamped on the nameplate. -
Page 4: 100-Hour Maintenance
ERIODIC MAINTENANCE WARNING: After completing any service procedure, always test the Rotator through five complete cycles. First test empty, then test with a load to make sure the Rotator Rotator Rotator Bearing operates correctly before returning it to the Drive Fill Assembly Grease Plug job. -
Page 5: 2000-Hour Maintenance
ERIODIC MAINTENANCE 2000-Hour Maintenance After each 2000 hours of truck operation, in addition to the 100 and 500-hour maintenance, perform the following procedures: • Check all rotation bearing capscrews for proper torque value. See Technical Bulletin TB183 or Section 4.5 for inspection and replacement procedures. -
Page 6: General Procedures
ROUBLESHOOTING General Procedures WARNING: Before servicing any hydraulic component, relieve pressure in the system. Turn the truck off and move the truck Truck System Requirements 3.1-1 auxiliary control valves several times in both directions. • Truck hydraulic pressure should be within the range After completing any service procedure, test the shown in Specifications, Section 5.1. PRESSURE TO attachment through several cycles. First test the THE ATTACHMENT MUST NOT EXCEED 2300 psi attachment empty to bleed any air trapped in the (160 bar). system to the truck tank. Then test the attachment with • Hydraulic flow should be within the volume range as a load to be sure it operates correctly before returning shown in Specification, Section 5.1. to the job. • Hydraulic fluid supplied to the attachment must meet the Stay clear of the load while testing. Do not raise the requirements as shown in Specifications, Section 5.1. load more than 4 in. (10 cm) off the floor while testing. Flow Meter Kit 671477 Tools Required 3.1-2 (2) No. 8-12... -
Page 7: Plumbing
ROUBLESHOOTING Plumbing Hosing Diagram 3.2-1 Drive Box Junction Block/ Hose Terminal CHAR-LYNN MOTOR ROTATE (COUNTERCLOCKWISE SHOWN) PRESSURE RETURN Truck Auxiliary Valve IMPORTANT: See motor end cover for Hose Reel identification. RR0914.eps Drive Motors Hydraulic Schematic 3.2-2 Drive Group Check Valve NOTE: Junction Junction blocks may or may Block/Hose not have check Terminal valves. Hose Reel Truck Rotate Valve Truck Relief Valve... -
Page 8: Rotate Function
ROUBLESHOOTING Rotate 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. Install pressure gauges Supply Circuit Test 3.3-1 WARNING: Before removing any hoses, relieve pressure in the hydraulic system. With the truck off, open the truck auxiliary control valve(s) several times in both directions. Check the pressure delivered by the truck. Refer to the truck service manual. PRESSURE TO THE ATTACHMENT MUST NOT EXCEED 2300 psi RR0191.eps (160 bar), measured at the carriage hose terminal. -
Page 9: Rotation With Load
ROUBLESHOOTING Rotation with Load 3.3-2 Model Maximum Torque Capacity Remove the left drive group from the attachment as 216,000 in.-lbs. @ 2300 psi ★ 220D described in Section 4.2-1. Cap the connector fittings (292,857 Nm @ 160 bar) on the right hand drive group. Rotate a load requiring 334,000 in.-lbs. @ 2300 psi approximately 1/3 of attachment maximum torque. ■ 300D (452,843 Nm @ 160 bar) • If the higher gauge reading is substantially less than 425,000 in.-lbs. @ 2300 psi truck pressure measured at the junction block/hose ■ 400D (576,224 Nm @ 160 bar) terminal, the R.H. motor gerotor set may need repair. Refer to Section 4.3-2 or 4.3-3. ★ Rated at 24 GPM (91 L/min.) flow. ■ Rated at 30 GPM (114 L/min.) flow. • If the higher gauge is close to truck pressure measured at the junction block/hose terminal, and no rotation occurs. The R.H. 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 L.H. motor output shaft or drive box may need repair. Continue troubleshooting. -
Page 10: Attachment Removal
ERVICE Attachment Removal Rotate the attachment to position the forks parallel to the ground. Remove the fork keepers at each end of the top carriage bar. For reassembly, tighten the capscrew to a torque of 110 ft.-lbs. (150 Nm). Release the spring lock on the top of each fork. Remove the forks from the rotator. -
Page 11: Drive Group
ERVICE Drive Group Drive Group Removal 4.2-1 and Installation Remove the attachment from the truck as described in Section 4.1. Disconnect the crossover tubes from the check valve assembly. Remove the four capscrews fastening the drive group to the baseplate. For reassembly, tighten the capscrews to 75 ft.-lbs. - Page 12 ERVICE Bearing Tap the worm, worm bearing and washers out through Outer Race the end cover side of the housing. Remove the worm bearing race from the motor side of the housing. NOTE: The drive group being serviced may or may not be assembled with the washers shown on the worm.
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Page 13: Drive Group Reassembly
ERVICE Drive Group Reassembly 4.2-3 Baseplate Install the baseplate pinion bearing and snap ring on Pinion the pinion. Bearing Housing Pinion Bearing Pinion Gear First Second Bearing Bearing Seating Seating Area Area Additional RC2124.eps Snap Ring Apply sealant (668184) to the pinion shaft seating area and shoulder for the housing/pinion bearing. - Page 14 ERVICE Install the end cover. There must not be any shims between the end cover and housing at this time. Tighten the capscrews in 10 ft.-lbs. (13 Nm) increments to a torque of 25 ft.-lbs. (34 Nm). Measure the gap between the end cover and housing in three places with a feeler gauge or plasti-gage and determine the minimum gap.
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Page 15: Drive Motor
ERVICE Drive Motor Drive Motor Removal and 4.3-1 WARNING: Before removing hydraulic Installation lines or components, relieve pressure in the hydraulic system. Turn truck off and open the truck auxiliary control valve(s) several Remove the attachment from the lift truck as described times in both directions. -
Page 16: Char-Lynn Drive Motor Disassembly
ERVICE Char-Lynn Drive Motor ® 4.3-2 Disassembly RR0881.eps Cascade provides service replacement parts for the seals O-Ring ▲ indicated with a ▲ below. Due to cost, if other parts need replacement, the complete drive motor assembly should be replaced. Capscrews (7) Remove the drive motor from the drive group as described in Section 4.3-1. - Page 17 ERVICE 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.
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Page 18: Char-Lynn Drive Motor Inspection
ERVICE Char-Lynn Drive Motor ® 4.3-3 Inspection • 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 19 ERVICE 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, 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 20: Check Valve Assembly
ERVICE Check Valve Assembly Check Valve Assembly Service 4.4-1 WARNING: Before removing supply hoses, relieve pressure in hydraulic lines. Turn truck off, then open the truck auxiliary control valves several times in both directions. Disconnect the hydraulic hoses to the drive group. Tag the hoses for reassembly. -
Page 21: Base Unit
ERVICE Base Unit Bearing Assembly – 4.5-1 Capscrew Torque Inspection Baseplate 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 269 ft.-lbs. (365 Nm). Tighten capscrews to 10 ft.-lbs. -
Page 22: Bearing Assembly Removal And Installation
ERVICE 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, if equipped. For reassembly, tighten the capscrews to the torque of 240 ft.-lbs. -
Page 23: Fork Service
ERVICE For reassembly, reverse the above procedure except as follows: • Tighten the bearing assembly capscrews to half torque value using the star pattern shown. Then tighten to full torque value. • Apply NLGI No. 0 grease to the teeth of the bearing assembly ring gear. -
Page 24: Specifications
PECIFICATIONS Specifications Hydraulics 5.1-1 Truck Relief Setting 2000 psi (140 bar) Recommended 2300 psi (160 bar) Maximum Truck Flow Volume ➀ Min. ➁ Recommended Max. ➂ 12 GPM 20 GPM 25 GPM 220D (57 L/min) (76 L/min) (95 L/min) 8 GPM 20 GPM 30 GPM 300D, 400D... -
Page 25: Torque Values
PECIFICATIONS Torque Values 5.1-3 Fastener torque values for the D-Series Rotators are NOTE: All fasteners have a torque value shown in the table below in both U.S. and Metric units. All range of ±10% of stated value. torque values are also called out in each specific service procedure throughout this manual. -
Page 26: Determining Load Torque Requirements
PECIFICATIONS Determining Load Torque 5.1-4 Requirements IMPORTANT: Positioning the load as close to center as possible will reduce the torque requirements and increase truck stability. To make sure your Rotator will handle a specific load, calculate the torque requirements as follows: Weigh the load to be handled. - Page 27 BLANK...
- Page 28 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 2011 04-2011 Part Number 6817684...
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