Installation - Cascade Corporation
Contents
1. Bearing Spring Worm Small Large Washers Spacer Spacer Worm Thrust Bearing Thrust Spring Bearing Washers 10 WASHER CUSHION DRIVE 16 WASHER CUSHION DRIVE install Assemble Washers 3 Woodruff Key Spacers and Bearings on Worm and Install in the Housing Note Some Units Do Not Have Spring Washers Press Worm Gear onto Pinion Shaft Press Bearing onto Pinion Shaft Form 5186 Rev 0 4 15 san D Service 5 23 Rotator Drive Group Reassembly Cont amp instali the end cap If the gap on cushion drive units is greater than that shown the spring washers are in correctly stacked Remove the worm and restack the Gap Should washers Install 8 be 200 030 Alternately tighten the endcap capscrews 1 2 of a End Cap turn Lube torque to 7 10 ft Ibs Install the cover Instali the motor Fill the gearcase with 44 fluid ounces of Cascade Rotator Fluid Cascade part number C 656300 NOTE C 656300 32 fluid ounces Install the gearcase onto the attachment baseplate O Alternately Tighten Capscrews 1 2 of a Turn For Reassembly Lube Torque to 900 O 7 10 ft Ibs Fill gear case with lubricant Install the Motor D Lube Torque Retaining Nuts to 15 20 ft lbs D Install Gearcase on Attachment Baseplate Lube Torque Capscrews to 40 ft ibs 4 16 Form 5186 Rev O section Service s3 Motor 5 3 1 Motor Removal and Installation2. R7R 120 125 ft Ib 4 19 san D Service 5 4 3 Frame Assembly Service The ring gear and bearing are matched components and must be replaced as an assembly Whenever the frame assembly is disassembled the felt seals must be replaced with new ones as follows 1 Remove the old felt seals and clean the grooves To install a new seal start one end of the seal strip in the groove Push the seal to the bottom of the groove all the way around the groove If the seal is too short stretch it evenly around the groove to lengthen it Cut the two ends of the seal so they meet squarely Bond the ends of the seal with 3M brand weatherstrip adhesive No 8001 or equivalent After the adhesive dries lubricate the seal with SAE30 motor oil to swell the seal into the groove Dust Seals Ring Gear Bearing Assembly Baseplate R3R Revolving Frame Assembly Felt Seals RYE only R4R RGR and R7R Revolving Frame Assembly NOTE Configuration of baseplate varies with rotator model 4 20 l Form 5186 Rev 0 sean Service T Frame Reassembly Attach the hoist chain to the ring gear eyebolts and lift the ring gear bearing assembly into position CAUTION All ring gear bearing assemblies have a heat treat overlap zone This zone is designated by a stamped letter on the outer ring of the assembly When installing the ring gear bearing assembly the heat treat overlap zone
3. The rotator motor can be removed for service with the attachment on the truck WARNING Before removing supply hoses relieve pressure that might be present in the hydraulic system With the truck off open the truck auxiliary control valves several times in both directions Remove cap and tag the supply hoses to the motor Remove the motor from the rotator drive assembly by removing the six retaining nuts Slide the motor out of engagement and remove the coupling and key from the motor shaft Clean the motor and gear case mating surfaces with solvent Apply LOCTITE 515 sealer to these surfaces Install the motor and tighten the retaining nuts toa torque of 15 20 ft Ibs Lubed CAUTION Because the threaded part in the pump is tapered overtightening the fitting in the port will split the housing Fittings should be snug but not over tightened Install reducers and fittings as follows Thread hose fitting A into bushing B until tight Fit the assembly of the bushing and hose A B into the housing C Tighten the bushing B only Any attempt to tighten the hose fitting after installation in the bushing may result in a cracked housing Form 5186 Rev 0 Remove Nuts For Reassembly Lube Torque to 15 20 ft lbs Fitting Bushing LD LA Housing 0 4 17 wun D Service 5 3 2 Motor Disassembly and Reassembly Cascade only services the adapter and cover the drive
4. cascade cares TM e Service Manual 360 Rotators R Series Serial Numbers 634366 through 666580 Manual Number 667448 cascade Contents Pase INTRODUCTION Section1 4 1 INSTALLATION INSTRUCTIONS Section2 4 2 Truck System Requirements 4 2 Prior to Installation 2 0 0 0 00 00 4 3 Installation 0 ee ec eee eee 4 4 Fork Bar Installation 00055 4 4 Middle Hook Installation on Fork 4 4 How to Install and Position the Forks 4 5 Attachment Stop Blocks 4 5 Prior to Operation 0 0 0 0 e eee eee 4 5 PERIODIC MAINTENANCE Section3 4 6 TROUBLESHOOTING Section4 4 7 SERVICE Section5 4 11 Attachment Removal and Installation 4 11 Rotator Drive Group 2 0 00 eee ee 4 12 Rotator Drive Group Removal and Installation 2 2 0 0 0 ce cee eee 4 12 Rotator Drive Group Disassembly and i SEVICE ees ica aA RER ET 4 14 Rotator Drive Group Reassembly 4 15 MOOR a fhe thee ix teen ea enol A aad 4 17 Motor Removal and Installation 4 17 Motor Disassembly and Reassembly 4 18 Frame Assembly POERI 4 19 Baseplate Removal 4 19 Ring Gear Bearing Assembly Removal 4 19 Frame Assembly Service 4 20 Frame Reassembly 4 21 STANDARD LABORTIMES Section6 4 22 Form
5. e Volume Required volume to obtain rated rotation speed sp ification R3R 10 gpm R4R 15 gpm R6R 18 gpm R7R 20 gpm NOTE If you have questions concerning these ratings call Cascade s Service Department toll free 800 547 5266 e Recommended hose and fitting size No 8 1 2 inch 1D with minimum fitting orifices of 0 375 3 8 inch e Truck carriage must conform to the Industrial Truck Association ITA dimensional standards as shown in the following chart Mounting Class li 14 94 15 00 R3R R4R Class III 18 68 18 74 R4R R6R Class IV 23 44 23 50 R6R R7R e Make sure the truck carriage is clean and the notches are undamaged Form 5186 Rev 0 2 Installation Instructions 2 Prior to Installation ton 1 Install the hydraulic hoses to the truck junction blocks using the correct Cascade Attachment Installa tion Kit C 663584 for R3R R4R and R6R C 663597 Straight Thread Connector for R7R OR use hoses and fittings as shown in Figure 1 or 2 Be 1 careful not to twist pinch or otherwise damage the Td hoses IMPORTANT No 8 Rotate In order to conform to industry standard practice the Hose AA E A hoses should be connected to the truck auxiliary valve as ee _ lee indicated by the following chart Connect To Truck Junction Block Attachment Movement Motion of the operator s hand Function VIEWED FROM THE DRIVER S SEAT J Figure 1
6. 4 Frame Assembly 41 Baseplate Removal Remove the attachment as described in Paragraph 5 1 Remove the rotator drive group Paragraph 5 2 1 Remove the upper mounting hooks Remove the two baseplate retaining capscrews closest to each upper mounting hook bolt pattern Replace the two capscrews with eyebolts Attach a hoist chain to each eyebolt Lift the hoist chains to take out the slack WARNING Make sure your hoist has a rated capacity of at least 1000 pounds OOO 6 Remove the remaining baseplate retaining capscrews Lift off the baseplate O Remove the hub seal from the rotator hub 5 42 Ring Gear Bearing Assembly Removal Q Remove the baseplate assembly as described in Paragraph 5 4 1 2 Replace two ring gear retaining capscrews with eyebolts Attach a hoist chain to each eyebolt Lift the hoist chains to take out the slack WARNING Make sure your hoist has a rated capacity of at least 1000 pounds 3 Remove the remaining capscrews and lift the ring gear bearing assembly from the attachment Form 5186 Rev 0 Remove Mounting Hooks Remove Rotator For Reassembly Hub Seal f Lube Torque to R3R 95 100 ft Ib R4R RGR 130 140 ft lb R7R 200 210 ft ib Remove Remaining Baseplate Capscrews Q Remove Baseplate Install Eyebolts and Attach a Hoist Chain 4 to Each Eyebolt Remove Remaining Capscrews For Reassembly Lube Torque to 65 70 ft lb
7. Plumbing Diagram for R3R R4R and R6R Clockwise Rearward or Up Rotate Counter clockwise Forward or Down o 90 Swivel VIEWED FROM THE DRIVER S SEAT E as lbow 45 Str Thd Elbow Rotate Counter Clockwise i Rotate clocks Connect To Truck Junction Block Figure 2 Plumbing Diagram for R7R CAUTION 2 Flush the hoses as follows to prevent damage to the rotator motor a Connect the hoses from the junction block together b Start the truck and actuate the truck control valve in both directions for about 30 seconds to carry any debris left in the hoses to the truck hydraulic tank and filter Nipple To Junction Block To Junction Attachment Block Hose Fittings Form 5186 Rev 0 4 3 secon 2 Installation Instructions Connect Hoses Position Truck 53 l n st all ati on to Clamp i to ok x Install eyebolts on both sides of the rotator fork bar or frame Attach a hoist chain to the eyebolts and set the Truck Carriage Position Clamp rotator vertically Remove the lower mounting hooks and Remove WARNING Make sure your overhead crane has a rated capacity Lower Mounting of at least 3500 pounds Position the truck close enough so the hoses on the junction block can be connected to the attachment Connect the hoses to the attchment as shown in Figure 1 or 2 on page 4 3 O Raise the truck carriage and engag
8. Position the middle hook using the dimension shown Hook Lh A w Mark the hook position on the fork Fork O Use an E 10016 electrode for welding Preheat the fork 400 500 F 5 Weld a 3 8 inch fillet on all four sides of the hook aan Postheat to 600 F aah 4 4 Form 5186 Rev 0 sein installation Instructions Slide Forks 3 2 How to Install and in Position the Forks IMPORTANT Make sure each fork is equipped with three hooks Cascade rotator forks have three hooks Release Spring Lock Lever O Remove the fork keeper at one end of the carriage Remove 2 Release the spring lock on the top of each fork ees Slide the forks into position on the fork bars Lock each fork in place by pushing the spring lock lever down making sure the pin is engaged in the fork bar notch O Install the fork keeper on the end of the carriage S Removal is a reverse of installation S WARNING When removing the forks handle with care to avoid drop ping them on your fingers or feet Install 5 Keeper Fork Bar Notch 27 Attachment Stop Blocks Cascade recommends that a steel block be permanently welded on each side of the truck carriage upper crossbar adjacent to each attachment upper mounting hook To perform the installation Select square steel stock with a width about equal to the flat of the carriage upper crossbar dimension A Cut two blocks from the stock each about as
9. on Bearing Race Lubricate and Install Hub Seal Lube Torque the Capscrews in the Sequence Shown 200 205 ft Ib Standard Labor Times 6 1 6 2 4 22 Standard Labor Time is the average time required to per form each operation described in Section 5 Service Each Standard Labor Time is identified by the Service Section paragraph number and title that corresponds to that operation The Standard Labor Times are based on the assumption a qualified serviceman is working on a reasonably clean at tachment with adequate tools We realize the actual time required to perform an operation may occasionally be greater than that listed especially if a first time serviceman lacks the needed tools or if a bolt is frozen But considering all factors that can affect the job Cascade can only honor warranty labor claims based on these carefully evaluated averages We strongly urge servicemen to read the applicable Service Sections of the manual before repairs are in itiated If problem diagnosis is difficult call the Cascade Service Department at 1 800 547 5266 toll free or in Oregon call 666 1511 To arrive at the total Standard Labor Time for a job list each operation and add the times As an example to replace bushings your list should look something like this 5 1 Attachment Removal and Installation 0 8 5 2 1 Rotator Drive Group Removal and Installation 0 5 5 2 2 Rotator Drive Group Disassembl
10. 22 Rotator Drive Group 4 14 oo O OGOGO 0000 Disassembly and Service Drain the lubricant from the gearcase Lay the gear 4 case pinion down on 4 x 4 s placed on either side of Lubricant Remove Nuts 4 the pinion For Reassembly Lube Torque to 15 20 ft Ibs Remove the rotator motor as described in Paragraph 5 3 1 Motor service procedures are described in Paragraph 5 3 2 Remove the capscrews retaining the gearcase cover Remove the capscrew from the center of the cover and replace it with a 3 8 inch 16 UNC capscrew 2 inches long Turn the capscrew clockwise while lightly tapping the side of the cover with a plastic head hammer to loosen it Remove the end cap and bearing Remove the worm and spring washers if equipped Remove the snap ring from the pinion shaft Using a gear puller remove the worm gear from the pinion shaft nomava oe ad Pepica pa with a 3 87 16 x2 Capscrew Remove the Woodruff key from the pinion shaft Loosen the Cover by Turning Press the pinion out of the gearcase Capscrew Clockwise while i Lightly Tapping the Press the pinion bearing out of the gearcase Side of the Cover Clean and inspect the components Replace any item that is worn or galled Remove any burrs with an emery cloth or small hand grinder Remove Press Pinion Woodruff Key Out of Gearcase Press Bearing Out of Gearcase Use Gear Puller f to Remove Worm Gear Remove Worm and
11. Spring Washers NOTE Some units do not have Spring Washers Bearing Gearcase Gearcase Boss Remove End Cap i and Bearing Remove Snap Ring 5 CAUTION Some units wili have this style relief fitting in the end cap These units may have damaged ball thrust bearings due to low rotator fluid Cascade has a drive box lube kit available which provides new ball thrust bearings and a new pressure relief fitting See Technical Bulletin 114 for complete ordering instructions Form 5186 Rev 0 sin D Service o 5 23 Rotator Drive Group Reassembly l Press the bearing into the housing from the inside using the special tool Cascade part number C 664620 Make sure the bearing is fully seated and flush with the inside of the gearcase Support the bearing from the inside with the special tool and press the pinion into the bearing from the outside Install the Woodruff key into the pinion shaft Press the worm gear onto the pinion shaft making sure you align it with the Woodruff key Press the bearing onto the pinion shaft Install the snap ring Assemble the spring washers spacers if equipped and ball thrust bearings See Caution below on the worm shaft and install in the housing CAUTION The ball thrust bearing must be assembled on the worm with the thickest portion of the outer race the side stamped with the manufacturer and part number facing away from the washers O00 oO
12. Telex 4 29718 S A Part Number 667448
13. must be located in one of the four locations shown Lube torque the capscrews to 65 70 ft Ib R7R 120 125 ft Ib in the order shown NOTE Some units have fewer than the 24 capscrews shown here On those units lube torque using a similar pattern IMPORTANT Apply a liberal quantity of NLGI con sistency No 0 grease to the teeth of the ring gear before continued assembly Using the hoist chain lift the baseplate into position on the bearing race 4 Lube torque the capscrews in the order shown some units may have a different quantity of capscrews Use torque values as follows R3R R4R 65 70 ft Ib R6R 55 60 ft lb R7R 200 205 ft Ib A Lubricate and install the hub seal Reinstall the rotator drive group See Paragraph 5 2 1 Lubricate the bearing race through the grease fitting on the ring gear bearing assembly baseplate on R3R clamps Install the attachment on the truck as described in Section 2 WARNING The capscrews that secure the baseplate to the bearing race must be grade 5 minimum 9 00 Form 5186 Rev 0 fron ss 00 a0 Use Hoist Chain to Place Ring Gear on Frame CAUTION The Letter Stamped on the Ring Gear Must be Located at one of These Arrows Lubricate Grease Fitting Y Lube Torque the Capscrews in the Sequence Shown Lube Torque to 65 70 ft lb R7R 120 125 ft Ib Use Hoist Chain k to Place Baseplate
14. 5186 Rev 0 sum 1 Introduction 1 1 1 2 This manual provides the installation instructions periodic maintenance requirements troubleshooting procedures and service guides for Cascade 360 Rotator models R3R R4R RGR and R7R Truck System Requirements Pressure 2000 psi maximum Volume Required volume to obtain rated rotation speed specification R3R 10 gpm R4R 15 gpm R6R 18 gpm R7R 20 gpm NOTE If you have questions concerning these ratings call Cascade s Service Department toll free 800 547 5266 Special Instructions Definitions AWARNING A statement preceded by A WARNING is information that should be acted upon to prevent bodily injury A WARNING is always inside a ruled box 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 Form 5186 Rev 0 El he La ol ae sun Installation Instructions WARNING Rated capacity of the truck attachment combination is a responsibility of the original truck manufacturer and may be less than that shown on the attachment nameplate Consult the truck nameplate 2 1 4 2 Truck System Requirements Truck relief valve setting 2000 psi maximum
15. al drive coupling and remove both cover halves Then remove the chain around the coupling sprockets Remove the rotator gear drive case retaining capscrews and remove the gearcase s from the attachment baseplate WARNING With the gearcase s removed the baseplate is free to rotate Keep clear of the baseplate to avoid being pinched R7R Models only Remove the coupling sprockets from the worm shaft of each drive group O Service the rotator drive group as described in Paragraphs 5 2 2 and 5 2 3 O Reinstallation of the rotator drive group is a reverse of removal except the R7R Perform the following Steps 7 through 16 to synchronize the R7R dual drive group Install the circular seal located in the coupling cover over one sprocket hub The lip of the seal should face the sprocket teeth Leave the felt dust seal in place in the coupling cover O Install the coupling sprockets on the worm shaft of each drive group Make sure the keys are in place Don t tighten the setscrews in the sprocket hubs yet Q instali both drive groups onto the baseplate For Reassembly Lube Torque to 40 ft lbs Paragraph 3 Form 5186 Rev 0 A See WARNING in s D Service 5 2 1 Rotator Drive Group Removal and installation Cont To synchronize the worm shafts rotate each sprocket counter clockwise by hand until you feel resistance Using the uppermost allen head capscrew on the s
16. counter with the rotate circuit e Attachment will not rotate e Attachment will not rotate loads up to its rated capacity e Attachment rotates in one direction only Problem Attachment will not rotate or will not rotate loads up to its rated capacity Probable causes e Insufficient truck hydraulic pressure e incorrect load handling e Excessive back pressure in the truck hydraulic system Tests Check the pressure delivered by the truck hydraulic system A pressure drop of no more than 100 psi at the auxiliary valve port is OK If the pressure is not as specified refer to the truck service manual for adjust ment or service PRESSURE MUST NOT EXCEED 2000 PSI C Make sure the operator is not handling loads beyond the capacity of the attachment Heavy and long loads rotated off center require a tremendous amount of torque O Install a pressure gauge into each port of the hydraulic motor O Rotate a load that weighs close to the capacity of the attachment and note the pressure readings on the gauges during rotation If the lower pressure reading EXCEEDS 200 psi you have excessive back pressure in your supply circuit Check for restrictions such as numerous fittings and elbows hose sizes less than No 8 clogged oil filter etc If the lower pressure does NOT EXCEED 200 psi and the truck pressure is within specifications the hydraulic motor needs repair Refer to Section 5 Paragraph 5 3 2 for service p
17. e facts regarding the problem before you begin service procedures The best way is to talk with the operator Ask for a complete description of the malfunction Tools Required In addition to a normal selection of hand tools you will need e Two pressure gauges capable of measuring pressure to 2500 psi e Two No 8 swivel nut run tees 37 JIC suitable for mounting gauges Install the gauges in the tees e Needle shutoff valve rated for 2500 psi service _ minimum Recommended supplier for needie shutoff valve Marsh Instrument Co Skokie IH Form 5186 Rev 0 Pressure Gauge Swivel Nut Run Tee Pressure Gauge Needle Shutoff Swivel Nut Valve Run Tee Drain Hose IMPORTANT Make Sure The Arrow Points in This Direction Male Connector 4 7 win 4 Troubleshooting 42 Plumbing 4 21 Hosing Diagram Rotator Motor Rotator Motor R7R ONLY ROTATE COUNTERCLOCKWISE SHOWN PRESSURE samme RETURN SEE Truck Valve 4 2 2 Circuit Schematic Rotator Junction Block Truck Hydraulic Pump Auxiliary NOT Truck Auxiliary Rotator Motor Junction Note Auxiliary Valve Ports and Hose Ree Ports may be Reversed From Those Shown E Junction block may or may not have check valves Form 5186 Rev 0 san roubleshootin 4 3 4 3 1 Rotate Circuit Troubleshooting The following are the most common problems you may en
18. e rotator drive gear case and fill to capacity with Cascade Rotator Drive Lubricant Cascade part number C 656300 or Keystone WG 1 Replace the plug swim Periodic Maintenance IMPORTANT After completing any service procedure always test each function through 5 complete cycles First t st the rotator empty to bleed excess air trapped in the system Then test each function with a load to make sure the rotator operates correctly before returning it to the job Form 5186 Rev 0 sein IOUbDIeshooting 4 1 4 1 1 4 1 3 General Procedures WARNING Before servicing any hydraulic component relieve pressure in the system Turn the truck off and open the truck auxiliary valve several times in both direc tions After completing any service pro cedure always test the unit First rotate the attachment empty to bleed air trapped in the system to the truck system Then rotate with a load to be sure the attachment operates cor rectly before returning it to the job Stay clear of the load while testing Truck System Requirements Pressure 2000 psi maximum Volume Required volume to obtain rated rotation speed specification R3R 10 gpm R4R 15 gpm R6R 18 gpm R7R 20 gpm NOTE If you have questions concerning these ratings call Cascade s Service Department toll free 800 547 5266 Get All The Facts Before You Begin Working On The Attachment It is important that you gather all th
19. e the attachment upper mounting hooks Make sure the centering block on the attachment aligns with the center notch on the carriage IMPORTANT Some models have a positioning block welded to the upper left hand mounting hook Center Making Sure It Is CB Centered Raise The Carriage To Engage The Clamp the attachment on the carriage making sure the posi Tilt Back and tioning block is engaged in a notch on the carriage Install Lower Tilt the mast back and install the lower mounting es hooks Lube torque the capscrews to R3R Class I 74 76 ft Ib R4R and R6R 85 90 ft Ib R7R 180 200 ft lb Lube Torque to R3R Class Il 74 76 ft lb R4R RGR 85 90 ft lb R7R 180 200 ft lb 24 Fork Bar installation If your rotator was delivered without fork bars install them as follows Locate the fork bars on the attachment faceplate install and lube torque the fork bar capscrews according to the following chart Fork Bar Capscrew Torque Rotator Model Specifications ft lb lubed Upper Fork Bar Lower Fork Bar R3R 95 100 52 57 R4R and R6R 130 140 130 140 R7R 200 210 200 210 2 5 Middle Hook HOB Fork Must Have a Three Hooks Installation on Fork Each fork must have three hooks Cascade forks for A Position Middle Hook rotators are equipped with the third hook If you need t Using Dimension A to install the hook yourself use the following Rotator i
20. haft end cap as a _ reference mark one tooth of the sprocket Then turn the sprocket clockwise counting the teeth as they pass the allen head capscrew Stop turning when you feel resistance Now rotate the sprocket back counterclockwise half the number of teeth counted The sprockets are now positioned halfway between where you felt resistance Install the chain around the sprockets If one sprocket does not align with the chain rotate it no more than 1 2 tooth width until it does Center the sprockets within 1 8 inch between the drive unit end housings Tighten the setscrews on both sprocket hubs Coat the chain with Richfield No 2MP grease or equivalent Position the seal on the sprocket so that it aligns with the grooves in the cover Instali the cover over the sprockets making sure the seals are in place CAUTION The steel pin on one cover half must align with the hole in the other half before you tighten the screws After the attachment is installed on the truck power the rotator to check for clearance be tween the coupling and the baseplate Instali the attachment onto the truck as described in Section 2 Form 5186 Rev 0 Center Sprockets Dust Seal Check for Clearance on Truck Synchronize Sprockets See Step 10 to A Capscrew and Ce Lockwasher For Reassembly Lube Torque To 40 ft lb fe install Drive Groups 4 13 swim D Service 5
21. long as the width of the attachment upper mounting hook dimension B Position the blocks adjacent to the upper mounting hooks The blocks should not extend behind the flat of the carriage upper crossbar dimension A Weld the blocks in place Make sure you protect adjacent hoses and hydraulic components from weld splatter 28 Prior to Operation oO Before picking up a load operate the rotator through 360 in both directions to allow any air in the system to return to the truck hydraulic tank 2 Pick up a maximum load and repeat the rotation in both directions If the attachment is sluggish or does not rotate smoothly recheck the plumbing If the at tachment still operates incorrectly contact Cascade s Service Department telephone 800 547 5266 toll free or in Oregon call 666 1511 Attachment Upper Mounting Hook Steel Stop Block o 8 8 Truck Carriage Upper Crossbar Form 5186 Rev 0 4 5 500 Hour Maintenance After each 500 hours of lift truck operation perform the following procedures O Retorque the mounting capscrews Use the torque specifications shown in Section 2 O Lubricate the ring gear bearing assembly with wheel bearing grease Rotate the attachment one full turn during lubrication O Remove the plug on the back of the baseplate and retorque all the ring gear bearing assembly capscrews to 65 70 ft lb R7R 120 125 ft lb Replace the plug O Remove the plug on the side of th
22. n SP Load Arms Remove Lower Mounting Hooks 2 Lower Attachment WARNING Before removing any onto Pallet hoses relieve pressure that might be present in the hydraulic system With For Reassembly Lube Torque to R3R Class tl 74 76 ft lb the truck off open the truck auxiliary control valve several times in both directions R4R RGR 85 90 ft Ib R7R 180 200 ft Ib ez Disconnect the hoses to the rotator motor For reinstallation reverse the above procedures or consult the Installation Instructions Section 2 Form 5186 Rev 0 4 11 win Service 5 2 5 2 1 4 12 Rotator Drive Group Your attachment may be equipped with either a cush ioned rotator drive group or an uncushioned unit Cushioning is achieved by the installation of cone shaped spring washers on both sides of the worm powered by the rotator motor The worm gear is in mesh with the rotator ring gear Therefore shock loads applied to the at tachment arms are transferred to the worm through the worm gear and are absorbed by the spring washers All revolving clamps have a single drive group except the R7R which has a dual drive unit Special procedures for R7R models are noted in the following Rotator Drive Group Removal and Installation o Remove the attachment from the truck as described in Paragraph 5 1 R7R Models only Remove the four capscrews securing the two halves of the cover over the du
23. rocedures Form 5186 Rev 0 Check Truck System Pressure Here Check For Pressure Differential san 4 roubleshooting 4 3 2 Problem Attachment rotates in one direction only Probable cause The pilot spool in the junction block that supplies the rotator motor is jammed Solution Replace the junction block Call Cascade s Service Department If you have carefully and accurately completed this check list and you still have not solved the problem call us Our Service Department is open from 10 00 AM to 8 00 PM Eastern time Call 800 547 5266 toll free In Oregon 666 1511 4 10 Form 5186 Rev 0 stim SErVICe gt Attachment Removal and Installation Q Rotate the attachment so the arms are positioned side by side 2 Remove the lower mounting hooks For reassembly lube torque the lower mounting hook capscrews to R3R Class Il 74 76 ft Ib R4R and R6R 85 90 ft Ib R7R 180 200 ft ib Position wooden blocks or a shipping pallet under the attachment Lower the mast carriage until the attach ment is resting on the blocks Q Set a 1000 pound weight on the forks to hold the at tachment upright O Making sure the weight is secure continue lowering the mast enough to clear the upper mounting hooks Back the truck away a few inches to gain access to the hoses to the rotator motor Lower Carriage and Back Truck away Slightly Disconnect Hoses Put weight o
24. scade Corporation 1980 Cascade N V European Headquarters PO Box 50086 1305 AB Almere Haven Achterwerf 240 1357 CB Almere Haven The Netherlands Tel 03240 92911 Telex 40838 case nl FAX 011 31 3240 92286 Cascade France S A R L 11 rue Jean Charcot Zone Industrielle Sud B P 22 91421 Morangis Cedex France Tel 1369091139 Telex cascade 690016f Cascade Materials Handling Aust Pty Ltd Incorporated in N S W 121 Long Street Smithfield N S W 2164 Australia Tel 02 604 6222 Te Ac 790 24302 Cable Cascaus FAX 011 61 2 609 2742 Cascade N V Benelux Sales and Service PO Box 170 1110 AD Diemen Weesperstratt 110 1112 AP Diemen The Netherlands Tel 020 906411 Telex 14495 casc nl Cascade Hispania S A Avenida De La Fabregada 7 Hospitalet De Llobregat Barcelona Spain Tel 93 3355158 Telex 54018 casc e Cascade Materials Handling Aust Pty Ltd 44E Winterton Road Clayton Victoria 3168 Australia Tel 083 543 4344 Cable Casmel 2 80 Cascade GmbH Klosterhofweg 52 4050 M nchengladbach 3 B R Deutschland Tel 02166 602091 Telex 852812 casc d Cascade UK Ltd 15 Orgreave Crescent Dore House Industrial Estate Handsworth Sheffield S13 9NQ England Tel 0742 697524 5 6 tel 524 5 6 Sa OGi 12 A Telex 547254 cascsh g N Cascade Africa Pty Ltd PO Box 625 15 Power Street Isando 1600 South Africa Tel 011 974 5611 2 3 4 5
25. shaft and the seal kit which includes the seal seat and seat assembly and the 2 large O rings Due to cost if any other parts need replacement it is cost effective to replace the complete motor assembly The instructions below are for replacing the seal kit drive shaft adapter and cover only IMPORTANT Service the motor in a clean work area Clean the outside of the motor and dry thoroughly Remove any sharp edges or burrs Mark the sections of the motor with a punch or scribe for matching during reassembly Remove the four capscrews from the motor cover With a fibre hammer tap the cover to loosen and remove it Inspect the seal seat Replace only if the sealing face is excessively worn or damaged Remove it by inverting the adapter and driving out the seat with a wooden block Press the new seat into the adapter To replace the drive shaft remove the snap ring and press off the gear in an arbor press To reassemble coat the drive gear bore with white lead Install one snap ring and press the gear on the shaft until the gear covers about 1 4 of the key slot Hold the key in place and press the gear the rest of the way onto the shaft until it contacts the snap ring Install the second snap ring 60 O Remove Capscrews For Reassembly Lube Torque Opposite Capscrews to 55 ft Ibs Scribe Marks See Paragraph 6 ey Before Removing the Drive Shaft Form 5186 Rev 0 san D Service
26. y and Service Total Standard Labor Time ol N Standard Labor Times Paragraph Number Times 5 1 Attachment Remova and Installation 0 8 5 2 1 Rotator Drive Group Removal and Installation 0 5 5 2 2 Rotator Drive Group Disassembly and Service 1 5 5 2 3 Rotator Drive Group Reassembly 1 5 3 1 Motor Removal and Installation 0 5 3 2 Motor Disassembly Service and Reassembly 1 5 4 1 Baseplate Removal 2 e eee 1 5 4 2 Ring Gear Bearing Assembly Removal 1 5 4 3 Frame Assembly Service 1 5 4 4 Frame Reassembly 05 2 Form 5186 Rev 0 Do you have questions you need answered right now Call your nearest Cascade Service Department Cascade Corporation P O Box 20187 2201 N E 201st Ave Troutdale OR 97060 Tel 503 666 1518 800 227 2233 Toll Free Telex 590480 Cable Cascade Pt FAX 1 503 665 0301 Cascade Scandinavia Hydraulik A B Muskotgatan 17 E 8 9 252 55 Helsingborg Sweden Tel 042 151135 Telex 72565 caschb as r EDO USOV iwy amp Cascade Hydraulics Ltd 7615 Kimbel Street Mississauga Ontario Canada L5S 1A8 Tel 416 677 9695 Direct Parts Line 416 677 9686 416 677 9684 Te Ac 06 968715 Cascade Japan Ltd 4 1 1 Chome Shin Senri Higashimachi Toyonaka Osaka 565 Japan Tel 06 835 2900 Tel Ac 781 5287115 Cascade J Cable Cascadecfe Osaka FAX 011 816 835 2905 cascade c 3c TM Ca
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