D-Series Rotators Service Manual
Contents
1. Drive Box 125D 150D amp 200D ONLY Junction Block Hose Terminal ROSS MOTOR ROTATE CLOCKWISE SHOWN PRESSURE ss RETURN E IMPORTANT See motor end cover for identification Truck Auxiliary Valve Hose Reel CHAR LYNN MOTOR ROTATE COUNTERCLOCKWISE SHOWN RR0187 eps IMPORTANT See motor end cover for identification Drive Motor O Ol Drive Group Check Valve NOTE Junction blocks may or may not have check Junction i Block Hose a i Terminal valves 1 Hose Reel Truck Rotate Valve Q Truck XN Relief AN Valve Truck Hydraulic Pump RR0188 eps E I ROUBLESHOOTING 3 3 3 3 1 3 3 2 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 e Worn or defective motor e Worn or defective drive assembly or frame bearing assembly Supply Circuit Test WARNING Before removing any hoses A relieve pressure in the hydraulic system With the truck off open the truck auxiliary control valve s several times in both directions 1 Check the pressure delivered by the truck Refer to the truck service manual PRESSURE TO THE ATTACHMENT MUST NOT EXCE2. End Cap 2 Remove O rings from housing Housing O Ring A Flange 608XXXX or less Housing Output Shaft Thrust Bearing Load Bearing Race Flange Seal A Pressure Seal A Brass Shim A Flange Wiper Seal G08XXXX or greater Make a scribe across the drive motor inline with the capscrew and drive motors port surface flange with the output shaft downward 3 4 Use a soft jawed vise to clamp the motor across the 5 Remove all capscrews from the end cap 6 Remove the end cap gerotor set and spacer plate as an assembly The splined drive should remain in place with this group SJ Remove the O rings from the end cap gerotor set and housing 8 Turn the drive motor over clamping the housing across the port area with the flange upward 16 672946 R5 S ERVICE 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 degrees 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 s
3. 27 Nm Timing Dot on Output Shaft Screw hole that is aligned with port surface Q Port Surface RR0627 eps 1 3 Short Spline NC Z O Ring Splined Drive Spacer Plate Timing Dot 672946 R5 S ERVICE 44 Check Valve Assembly 4 4 1 Check Valve Assembly Service 20 Models 40D 55D 65D 100D 120D 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 h Disconnect the hydraulic hoses to the drive group valve Tag hoses for reassembly 2 Remove the four capscrews fastening the check valve to the drive group Keep track of the two O rings between the check valve and drive motor For reassembly tighten the capscrews to 24 ft lbs 30 Nm 3 Remove the plug fittings check valve internal parts early models or cartridges later models 4 Clean all parts with clean solvent Remove any burrs or sharp edges with emery cloth 5 Inspect the internal ball seats for imperfections that would keep the balls from seating fully 6 For reassembly reverse the above procedures except as follows Note the correct direction of the internal conical springs early model Install new O rings and back up rings on the check valve cartridges as shown later model EARLY CHECK VALVE Rotator Drive Check Valve LLLA b cue C
4. A Double Torque tighten loosen 1 2 turn retighten 672946 R5 27 S PECIFICATIONS 5 1 5 Determining Load Torque 28 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 1 Weigh the load to be handled Example 1500 Ibs 2 Determine the center of the rotator faceplate Draw a line between a set of faceplate holes that are 180 apart Repeat for a second set of holes Where they cross is the center point of the rotator 3 Determine the vertical off center distance of the load Measure from the load vertical centerline to the rotator vertical centerline 4 Determine the horizontal off center distance of the load Measure from the load horizontal centerline to the rotator horizontal centerline 5 Off center distance calculation Model Maximum Torque Capacity e Square the vertical measurement A 40D 55D 65D Example 3 in 9 in 75 000 in Ibs 2000 psi 8 475 N m 140 bar e Square the horizontal measurement 100D aoe aon Example 4 in 16 in N 115 000 in Ibs 2000 psi Add these two figures together 1208 12 995 N m 140 bar Example 9 in 16 in 25 in 100D 129 000 in Ibs 2000 psi Determine the square root and you have the tot
5. 3 e f capscrews do not rotate inspection is complete RR0891 eps Bearing Bearin Capscrews ng Baseplate Removed 672946 R5 S ERVICE 45 2 Bearing Assembly Removal 2 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 upper mounting hooks For reassembly tighten the capscrews to the torque values below 40D 55D 65D 100D 115 ft Ibs 155 Nm 120D 150D 200 ft Ibs 270 Nm RRO180 eps 4 Remove the capscrews fastening the baseplate to the bearing assembly For reassembly tighten the capscrews to the torque values shown If necessary remove the lower mounting spacers to gain access to all of the capscrews For reassembly tighten the capscrews to a double torque values below 40D 120D 80 ft Ibs 108 Nm 150D 200D 280 ft lbs 380 Nm WARNING Check the attachment weight located on the nameplate to make sure the overhead hoist and chains or straps are at least the rated capacity of the attachment 5 Attach two eyebolts to the baseplate Attach an overhead hoist and lift away the baseplate RR0179 eps 6 Remove the capscrews fastening the baseplate to the faceplate New capscrews are supplied with each new bearing assembly tighten the new capscrews to a double torque values below 40D 55D 65D 100D 120D 80 ft Ibs 10
6. 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 672946 R5 1 P 2 1 2 2 ERIODIC MAINTENANCE 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 A 100 Hour Maintenance Every time the lift truck is serviced or every 100 hours of truck operation whichever comes first complete the following maintenance procedures e Check for loose or missing bolts worn or damaged hoses and hydraulic leaks e Check that fork locking pins and end bar keepers are installed and functional e f equipped lubricate plungers on hydraulic or electric 180 stop valves e Check decals and nameplate for legibility 500 Hour Maintenance After each 500 hours of truck operation in addition to the 100 hour maintenance perform the following procedures e Check a sample of baseplate bearing assembly capscrews for proper torque value See Technical Bulletin TB183 or Service Section 4 5 1 for inspection and replacement procedures Check a sample of faceplate b
7. of 25 ft lbs 35 Nm Remove the commutator set manifold rotor set spacer and drive link Remove coupling shaft thrust bearing thrust washer seal and spacer Set S cu Manifold e Thrust Seal Washer QS NI Thrust Spacer Commutator Bearing RR0183 eps 5 672946 R5 S ERVICE 4 3 2 Ross Drive Motor Disassembly and Service Continued 7 Inspect the rotor set for pits and wear marks If either part is pitted or worn the set should be replaced 8 Measure the tip clearance between the rotor sets rotor and stator Replace the rotor set if the clearance exceeds 0 006 in 0 15mm 9 For reassembly reverse the above procedures except as follows e Lubricate the bearings with wheel bearing grease prior to reassembly e Before installing the end cover apply wheel bearing grease to the small washer and place the washer over the pin in the end cover 672946 R5 RR0184 eps 15 S ERVICE 4 3 3 Char Lynn 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 RR0881 eps Capscrews 7 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
8. 8 Nm 150D 280 ft Ibs 380 Nm 200D 394 ft Ibs 534 Nm 7 Attach two eyebolts to the baseplate Attach an overhead hoist and lift away the baseplate RR0182 eps 672946 R5 23 S ERVICE 8 For reassembly reverse the above procedure except as follows Bearing Assembly e Align and position the bearing assembly ring gear heat treat overlap zone R and outer race grease fitting as shown prior to assembly with the faceplate and baseplate Faceplate 5 RR d S NO 9 O O SEY 1 I 40D 55D 65D 34 2 100D 37 120D 38 125D 28 RRO176 eps 150D 28 200D 30 e 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 e After mounting the attachment on the lift truck apply chassis grease to the bearing assembly grease fitting Rotate the attachment slowly while applying grease RRO177 eps 45 3 Fork Service 1 Tighten the fork bar capscrews using the tightening sequence shown 40D 110 ft Ibs 150 Nm 55D 65D 100D 140 ft Ibs 190 Nm 120D 125D 150D 200 ft lbs 270 Nm RRO0178 eps 24 672946 R5 S ERVICE as 180 Stop Group 461 Stop Valve Service WARNING Before removing
9. 905 629 7777 Fax 905 629 7785 Cascade Africa Pty Ltd PO Box 625 Isando 1600 60A Steel Road Sparton Kempton Park South Africa Tel 27 11 975 9240 Fax 27 11 394 1147 Cascade Korea 121B 9L Namdong Ind Complex 691 8 Gojan Dong Namdong Ku Inchon Korea Tel 82 32 821 2051 Fax 82 32 821 2055 Cascade New Zealand 15 Ra Ora Drive East Tamaki Auckland New Zealand Tel 64 9 273 9136 Fax 464 9 273 9137 02 2015 Cascade do Brasil Praga Salvador Rosa 131 141 Jordan polis S o Bernardo do Campo SP CEP 09891 430 Tel 55 13 2105 8800 Fax 55 13 2105 8899 Cascade India Material Handling Private Limited No 34 Global Trade Centre 1 1 Rambaugh Colony Lal Bahadur Shastri Road Navi Peth Pune 411 030 Maharashtra India Phone 91 020 2432 5490 Fax 491 020 2433 0881 Cascade Xiamen No 668 Yangguang Rd Xinyang Industrial Zone Haicang Xiamen City Fujian Province P R China 361026 Tel 86 592 651 2500 Fax 86 592 651 2571 Sunstream Industries Pte Ltd 18 Tuas South Street 5 Singapore 637796 Tel 465 6795 7555 Fax 65 6863 1368 Part Number 672946 R5
10. B S ERVICE MANUAL D Series 360 Rotators Manual Number 672946 R4 Cascade Corporation Cascade is a Registered Trademark of Cascade Corporation C ONTENTS Page INTRODUCTION Section 1 Introduction 1 Special Definitions 1 PERIODIC MAINTENANCE Section 2 100 Hour Maintenance 2 500 Hour Maintenance 2 2000 Hour Maintenance 3 TROUBLESHOOTING Section 3 General Procedures 4 Truck System Requirements 4 Tools Required 4 Troubleshooting Chart 4 Plumbing 5 Hosing Diagram 5 Hydraulic Schematics 5 Rotate Function 6 Supply Circuit Test 6 Rotation without Load 6 Rotation with Load 7 SERVICE Section 4 Attachment Removal 8 Drive Group 9 Drive Group Removal and Installation 9 Drive Group Disassembly and Service 9 Drive Group Reassembly 11 Drive Motor 13 Drive Motor Removal and Installation 13 Ross Drive Motor Disassembly and Service 14 Char Lynn Drive Motor Disassembly 16 Char Lynn Drive Motor Inspection 18 Char Lynn Drive Motor Reassembly 18 Check Valve Assembly 20 Check Valve Assembly Service Models 40D 55D 65D 100D 120D 20 Check Valve Assembly Service Models 150D 200D 21 Base Unit 22 Bearing Assembly Capscrews Torque Inspection 22 Bearing Assembly Removal and Installation 23 Fork Service 24 180 Stop Group 25 Stop Valve Service 25 Stop Group Adjustment 25 SPECIFICATIONS Section 5 Specifications 26 Hydraulics 26 Auxiliary Valve Functions 26 Truck Carriage 26 Torque Values 27 Determining Load Torque
11. ED 2300 psi 160 bar measured at the carriage hose terminal 2 Check the flow volume at the carriage hose terminal Refer to Specifications section for recommended flow volumes 3 Check for external leaks Rotation without Load 1 install pressure gauges to the motor fittings 2 Start the truck and rotate the attachment without a load While rotating note pressure readings of both gauges e Ifthe attachment rotates in one direction faster than the other or rotates in one direction only the check valve assembly may need repair Refer to Section 4 4 e 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 Install pressure gauges RR0190 eps 40D 55D 65D 100D 120D Drive Group Install pressure gauges RRO191 eps 125D 150D 200D Drive Group 672946 R5 _ T ROUBLESHOOTING 3 3 2 Rotation with Load 1 Rotate a load requiring approximately 3 4 of attachment maximum torque capacity shown in the chart Refer to Section 5 1 4 to determine load required Note gauge readings during rotation e Ifthe higher gauge reading is substantially less than truck pressure measured at the junction block hose terminal the motor gerotor set may need repair Refer to Section 4 3 2 or 4 3 3 e Ifthe higher gauge is close to truck pressure measured at the junction blo
12. Ibs 2000 psi 40D 55D 65D 100D 10 170 N m Q 140 bar 115 000 in Ibs 2000 psi 120D 12 995 N m 140 bar 100D 129 000 in Ibs 2000 psi 14 580 N m 140 bar 150D 126 000 in Ibs 2000 psi 14 238 N m 140 bar 200D 190 000 in Ibs 2000 psi 21 470 N m 140 bar Rated at 15 GPM 56L min flow E Rated at 20 GPM 75L min flow Disconnect the Crossover tubes Cap fittings Right Hand Drive Group Drive Group RR0193 eps S ERVICE 41 Attachment Removal 1 2 3 4 7 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 60 ft Ibs 80 Nm Release the spring lock on the top of each fork Remove the forks from the rotator Disconnect the lower hooks Bolt On Hooks Remove the lower mounting hooks For reassembly tighten the capscrews to a torque of Class II III 110 ft Ibs 150 Nm Class IV 80D 100D 195 ft Ibs 265 Nm Class IV 120D amp larger 260 ft lbs 360 Nm 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 WARNING Before removing any hoses relieve pressure in the hydraulic system Turn the truck off then op
13. 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 Ibs 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 e 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 GEP Gear Lube 672946 R5 13 S ERVICE 4 3 2 Ross Drive Motor Disassembly and Service IMPORTANT See motor end cover for identification Cascade provides service replacement parts for only the unshaded parts below Due to cost if other parts need 14 replacement the complete drive motor should be replaced 1 Remove the drive motor from the drive group as described in Section 4 3 1 IMPORTANT Service the drive motor in a clean work area Drain oil from the drive motor by rotating the coupling shaft Wash the outside of the drive motor with solvent and blow dry Clamp the drive motor in a vise with the coupling shaft downward Remove the end cover bolts end cover washer seal and sleeve For reassembly tighten the cover bolts to a torque
14. Requirements 28 672946 R5 NTRODUCTION 11 Introduction This manual provides Periodic Maintenance I Troubleshooting Service and Specifications for Cascade 0 WARNING Fork size affects attachment D Series Rotators capacity Refer to Installation Instructions 672327 Fork Middle Hook Installation In any communication about the attachment refer to section Verify capacity for truck nameplate the product catalog and serial numbers stamped on the nameplate If the nameplate is missing the numbers can be found stamped on the right front web of the baseplate IMPORTANT All hoses tubes and fittings on these attachments are JIC NOTE Specifications are shown in both inch and Metric units All fasteners have a torque value range of 10 of stated value UR cee oc 10427 80D RRB 14H wal e RJ A A 8 PTL123456 1R0 E N my N zl C 3 Cascade Corporation e www cascONY com Icons amp Patents www cascorp com support 6095754 RR1208 eps Nameplate 12 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 WARNING A statement preceded by A WARNING is information that should be acted upon to prevent bodily injury A WARNING is always
15. S O Rings RR0524 eps LATE CHECK VALVE Body Check Valve Cartridges Up Rings 672946 R5 S ERVICE 4 4 2 Check Valve Assembly Service Models 150D 200D WARNING Before removing supply A 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 Remove the check valve cartridges Remove the O rings and backup rings from the check valve cartridges Clean the parts with solvent g C N For reassembly reverse the above procedures except as follows e Lubricate all O rings and seals prior to reassembly with petroleum jelly e The check valve cartridge backup rings and O rings must be installed Refer to previous page 672946 R5 RRO181 eps 21 S ERVICE 4 5 Base Unit 4 5 1 Bearing Assembly 22 Capscrew Torque Inspection 4 77 500 Hour Inspection Every 500 hours perform the following inspection Baseplate 1 Check the accessible baseplate capscrews above upper mounting hooks for an initial torque 40D 120D 80 ft Ibs 110 Nm 150D 200D 280 ft lbs 380 Nm Tighten capscrews to 10 ft Ibs 14 Nm above initial torque Mark each capscrew after checking e If any baseplate capscrews are lo
16. al 14 580 im e Ta off center distance 150D 126 000 in Ibs 2000 psi Example 25 in 5 in off center distance w e Multiply the total off center distance by the load 200D e a Randle the load Compare this furs D z Rated at 15 GPM 56L min ow specifications in the chart Example 5 in x 1500 7500 in Ibs 2 Load Rotator Vertical Centerline a 4 ire gt E 4 Load Vertical Centerline 3 in Load Horizontal Centerline Rotator Horizontal Centerline RR0173 eps 672946 R5 BLANK Do you have questions you need answered right now Call your nearest Cascade Service Department Visit us online at www cascorp com AMERICAS Cascade Corporation U S Headquarters 2201 NE 201st Fairview OR 97024 9718 Tel 800 CASCADE 227 2233 Fax 888 329 8207 EUROPE AFRICA Cascade Italia S R L European Headquarters Via Dell Artigianato 1 37030 Vago di Lavagno VR Italy Tel 39 045 89891 11 Fax 39 045 8989160 ASIA PACIFIC Cascade Japan Ltd 2 23 2 Chome Kukuchi Nishimachi Amagasaki Hyogo Japan 661 0978 Tel 81 6 6420 9771 Fax 81 6 6420 9777 Cascade Australia Pty Ltd 1445 Ipswich Road Rocklea QLD 4107 Australia Tel 1 800 227 223 Fax 61 7 3373 7333 ot oI c TM Cascade Corporation 2015 Cascade Canada Inc 5570 Timberlea Blvd Mississauga Ontario Canada L4W 4M6 Tel
17. any hoses A relieve system pressure in the hydraulic system Turn the truck off the open the auxiliary control valves several times in both directions 1 Disconnect the hydraulic hoses and tube from the stop valve fitting 2 Remove the elbow fitting that comes out through the baseplate RR0175 eps 3 Remove the capscrews fastening the stop valve to the baseplate For reassembly tighten the capscrews to a torque of 40 ft Ibs 55 Nm 4 Remove the end glands Remove the plungers and Wiper Ring spring Remove the exterior Backup Ring 5 Replace the O rings backup rings and wiper rings O Ring 6 For reassembly reverse the above procedures Gland O Ring Wiper Ring RR0195 eps Backup Ring 46 2 Stop Group Adjustment Rotate the attachment in each direction to the stop positions If the stop positions need to be changed loosen the stop bolt locknuts and adjust the stop bolts as required Retighten the lock nuts after adjusting Adjust the stop bolts as required 672946 R5 25 S PECIFICATIONS s1 Specifications 5 1 1 Hydraulics Truck Relief Setting 2000 psi 140 bar Recommended 2300 psi 160 bar Maximum II EE al Truck Flow Volume Min Recommended Max 9 5 GPM 10 GPM 15 GPM oe jt A j 49D 1090 19 L min 88 L min 57 L min 120D 7 GPM 12 GPM 15 GPM 26 L
18. ck hose terminal and no rotation occurs The motor output shaft or drive box may need repair Continue troubleshooting with Step 2 below 125D 150D 200D Models Remove the left drive group from the attachment 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 e Ifthe higher gauge reading is substantially less than truck pressure measured at the junction block hose terminal the R H motor gerotor set may need repair Refer to Section 4 3 2 or 4 3 3 e fthe 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 e Ifthe 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 2 Remove the motor from the malfunctioning drive assembly as described in Section 4 2 2 3 Reinstall the hoses to the motor fittings Actuate the rotate circuit e f the motor shows rotational output the drive box may require service Refer to Section 4 2 2 e If the motor shows little or no rotational output service the motor as described in Section 4 3 2 or 4 3 3 672946 R5 Model Maximum Torque Capacity 75 000 in Ibs 2000 psi 8 475 N m Q 140 bar 90 000 in
19. eal 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 Flange 1 4 RR0860 eps Modified Screwdriver RR0843 eps Flange Original Design RR0858 eps 672946 R5 RR0859 eps 17 S ERVICE 4 3 4 Char Lynn Drive Motor Inspection e Remove all Loctite residue from the threaded holes e Clean all parts with solvent and blow dry Do not use paper or cloth towels e Inspect all parts for small nicks burrs or scratches Remove imperfections with emery cloth Replace parts where imperfections could not be removed e Inspect the flange seal seats for scratches Check for cracks in the flange area that could cause leakage 4 3 5 Char Lynn Drive Motor Reassembly 1 Install the brass shim into the pressure seal side of the flange Install wiper seal and pressure seal into the flange The pressure seal must be seated evenly Place the bearing race in the flange seated evenly with pressure seal and flange Lubricate the flange seal with petroleum jelly and seat in lip of flange on the pressure seal side as shown Install thrust bearing onto the output shaft Install the flange onto the output shaft with the pressure seal side against the output shaft Clamp housing into the vise with the flange s
20. earing assembly capscrews for proper torque value See Technical Bulletin TB183 or Service Section 4 5 1 for inspection and replacement procedures e Tighten lower mounting hook capscrews to a torque of Class II III 125 ft Ibs 165 Nm 80D 100D 165 ft lbs 225 Nm 120D 150D 200D 195 ft lbs 265 Nm e Tighten rotator drive capscrews to 75 ft lbs 105 Nm e Lubricate rotation bearing assembly with EP 2 grease Whitmore Omnitask or equivalent Rotate in 90 increments and apply grease Check rotator drive gearcase lubricant level Lubricant should be up to bottom of fill 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 Rotator Rotator Bearing Drive Fill Assembly Grease plug Fitting Y Fork Carriage i Bars and Keepers p y RR0460 eps WARNING A sampling of faceplate and baseplate bearing assembly capscrews must be checked for proper torque at 500 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 A Rotator Drive Capscrews Bearing Capscrews Access through hole in baseplate Baseplate Capscrews Q 3 Rotator PD 9 a Drive 1 O O Fill Plug ee RR0461 eps Mounting Hook Capscrews 672946 R5
21. ed as a starting point to begin troubleshooting procedures Rotate Circuit e Attachment will not rotate e Attachment will not rotate with load at rated capacity e Attachment rotates in one direction only To correct one of these problems see Section 3 3 WARNING Before servicing any A 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 Flow Meter Kit 671477 2 No 8 12 JIC O Ring Flow Meter d IE EI E GA0013 eps 2 No 6 8 JIC Reducer Pressure Gauge Kit 671212 Pressure Gauge No 6 6 Hose eS oq GA0014 eps 2 No 6 8 JIC No 4 No 6 Reducer and No 8 JIC O Ring No 6 and No 8 JIC Swivel Tee No 4 6 Pipe JIC 672946 R5 _ T ROUBLESHOOTING 32 Plumbing 3231 Hosing Diagram 32 2 Hydraulic Schematic 672946 R5 Drive Box Drive Box
22. en the truck auxiliary control valve s several times in both directions Disconnect the hydraulic hoses to the drive motor Tag the hoses for reassembly WARNING Verify that the overhead A hoist and chains or straps are rated for the weight of the attachment Refer to nameplate for attachment weight Attach a suitable overhead hoist to the upper fork bar Remove the rotator from the truck Lay the rotator face down on a pallet with the drive group upward For installation reverse the above procedures Upper fork bar RR0196 eps RR0192 eps Quick Change Hooks Hook Locking Pin 672946 R5 S ERVICE 4 2 4 2 1 4 2 2 Drive Group Drive Group Removal and Installation 1 Remove the attachment from the truck as described in Section 4 1 2 125D 150D 200D Rotators Disconnect the crossover tubes from the check valve assembly 3 Remove the four capscrews fastening the drive group to the baseplate For reassembly tighten the capscrews to 75 ft Ibs 100 Nm 4 For reassembly reverse the above procedures except as follows e After the drive group has been reinstalled check the oil level The oil level must be visible in the fill hole Fill if necessary with Cascade Gear Lube 656300 or equivalent SAE 90 wt lube AGMA mild 6EP Gear Oil Drive Group Disassembly and Service 1 Remove the drive group from the attachment as descr
23. ibed in Section 4 2 1 2 Lay the drive group pinion down on wooden blocks approximately 4 x 4 in 10 x 10 mm placed on both sides of the pinion 3 Remove the four capscrews fastening the cover plate to the housing 4 Remove the cover plate center capscrew Install a 3 8 NC capscrew with a minimum of 2 in 50 mm thread length in the cover plate center hole Remove the cover by turning the capscrew clockwise and tapping on the side of the cover plate 5 Drain oil from 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 672946 R5 HR0520 eps Housing RR0205 eps S ERVICE 8 Tap the worm worm bearing and washers out through Bearing the end cover side of the housing Remove the worm Outer Race bearing race from the motor side of the housing d 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 Washers 9 Press the pinion pinion bearings and worm gear out of the housing as an assembly Housing Pinion bearing 10 Remove the snap ring from the pinion Press the pinion and housing pinion bearing from the worm gear and cover plate pinion bearing Re
24. ide facing upward Install the output shaft flange assembly into the housing oN o 0 N Apply Loctite sealant 242 blue or equivalent to the four holes of the housing and the four capscrews Wipe away any excess sealant Install the four capscrews and tighten in a alternating cross pattern to 250 in Ibs 28 Nm IMPORTANT Capscrews must be clean and dry 18 Wiper Seal Brass Shim I Pressure Seal 1 Flange e RRO0633 eps Bearing Race Flange Seal Output Shaft RR0861 eps 672946 R5 S ERVICE 9 Turn the housing over and clamp across the flange with the output shaft taper facing down 10 Lubricate the O rings and install into the housing gerotor set and endcap grooves 11 Align the ouput shaft timing dot with the screw hole that is aligned to the port surface Use the scribe mark to help with the alignment 12 Use the drive splines to align the gerotor star point with the capscrew hole as shown 13 Assemble together the endcap with O ring gerotor set with O ring drive short spline end into gerotor set and spacer Se IMPORTANT Make sure O Rings are properly seated gt 14 Install endcap assembly onto housing while aligning the scribe marks and capscrew holes Make sure the drive RR0674 eps engages with output shaft 15 Install the capscrews into the end cap Tighten the capscrews using a alternating cross pattern to 240 in Ibs
25. ifference 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 amp carriage wear gauge 209560 Class Il 209561 Class III and 6105257 Class IV 672946 R5 T ROUBLESHOOTING General Procedures 3 1 1 Truck System Requirements e Truck hydraulic pressure should be within the range shown in Specifications Section 5 1 PRESSURE TO THE ATTACHMENT MUST NOT EXCEED 2300 psi 160 bar e Hydraulic flow should be within the volume range as shown in Specification Section 5 1 e Hydraulic fluid supplied to the attachment must meet the requirements as shown in Specifications Section 5 1 3 1 2 Tools Required In addition to a normal selection of hand tools you will need e Inline Flow Meter Kit 20 GPM 75 L min Cascade Part No 671477 e Pressure Gauge Kit 5000 psi 345 bar Cascade Part No 671212 two kits required e Assorted fittings and hoses to adapt gauges and flow meter to the components being tested 3 1 3 Troubleshooting Chart 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 us
26. min 45 L min 57 L min 150D 10 GPM 20 GPM 24 GPM 37 L min 76 L min 95 L min 200D 12 GPM 20 GPM 24 GPM 57 L min 76 L min 95 L min Cascade D Series Rotators are compatible with SAE 10W petroleum base hydraulic fluid meeting Mil Spec MIL 0 5606 or GA0139 eps 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 Contact Cascade Flow less than recommended will result in a rotate speed less than 2 RPM Flow greater than maximum can result in excessive heating reduced system performance and short hydraulic system life 5 1 2 Auxiliary Valve Functions Tilt Forward Hoist Down Rotate CCW sr tte alaks t 3 1 1 7 Hoist Up Rotate CW Tilt Back 5 1 3 Truck Carriage GA0175 eps Carriage Mount Dimension A ITA ISO Minimum Maximum Class Ill 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 GA0028 eps A Class II 14 94 in 380 0 mm 15 00 in 381 0 mm 26 672946 R5 _ S PECIFICATIONS 5 1 4 Torque Values Fastener torque values for the D Series Rotators are NOTE All fasteners have a torque value shown in the table below in both US and Metric units All range of 10 of stated value torque values are also called out in each specific service
27. move the pinion key 11 Press the pinion out of the housing pinion bearing Cascade 125D 150D and 200D Drive Groups have an additional baseplate pinion bearing and snap ring to remove 12 Clean and inspect all components Remove all dried sealant residue Replace all worn items Remove burrs or sharp edges with emery cloth RC0175 eps 10 672946 R5 S ERVICE 4 2 3 Drive Group Reassembly NOTE The 125D 150D and 200D Drive Groups have an additional bearing and snap ring on the pinion All other procedures are similar for all drive groups 1 o Install the worm bearing race The race taper must be inward Cascade 125D 150D and 200D Drive groups Install the baseplate pinion bearing and snap ring on the pinion Apply sealant 668184 to the pinion shaft seating area and shoulder for the housing pinion bearing Install the housing pinion bearing Remove excess sealant Preheat worm gear to 200 F 93 C Install the key worm gear cover plate pinion bearing and snap ring on the pinion Apply sealant 668184 to the housing seating area and shoulder for the housing pinion bearing Install the pinion assembly in the housing Remove excess sealant Install worm bearing race in the drive motor side of the housing Make sure the bearing race is facing in the correct direction Install drive motor as described in Section 4 3 1 Install the worm worm bearings and washers if equipped in the housing F
28. ose rotate or broken replace all baseplate fasteners as described RC2142 eps in Section 4 5 2 e f capscrews do not rotate continue with faceplate capscrew inspection in Step 2 2 Remove the access plug from the back of the baseplate Baseplate and rotate the attachment forks are positioned parallel to the ground Check three capscrews closest to the access hole for an initial torque 40D 120D 80 ft Ibs 110 Nm 150D 280 ft Ibs 380 Nm 200D 394 ft Ibs 534 Nm Tighten capscrews 10 ft lbs 14 Nm above initial torque Mark each capscrew after checking Bearing Assembly Capscrews e f any faceplate capscrew are loose rotate or broken replace all faceplate fasteners as described in Section 4 5 2 e f capscrews do not rotate inspection if complete RC2143 eps Access Plug 2000 Hour Inspection Every 2000 hours perform the following inspection NOTE The attachment must be removed from truck to provide access to all bearing assembly capscrews For Faceplate faceplate capscrews remove the baseplate shown or use access hole to provide access to all faceplate capscrews Refer to section 4 5 3 1 Checkall basepate and faceplate capscrews fastened to the bearing assembly Tighten until torque is 10 ft Ibs 14 Nm above torque values listed above Mark each capscrew after checking e f any capscrews are loose rotate or broken replace all capscrews as described in Section 4 5
29. procedure throughout this manual Ref Fastener Location Size Ft Ibs Nm 1 Fork Keeper Capscrews 1 2 M12 60 80 40D 65D 100D III 5 8 M16 115 155 9 UpperHook 400D IV 3 4 M20 130 176 Capscrews 120D M20 265 360 125D 150D 3 4 M20 200 210 40D 120D 1 2 M12 80 108 A Bearing 7 3 Capscrews 125D 150D 3 4 M20 280 380A 200D M20 394 534 A 4 Baseplate 40D 120D 1 2 M12 80 108A Capscrews 125D 200D 3 4 M20 280 380A Drive Group Housing a 9 Capscrews 12 M12 75 100 6 Check Valve Capscrews 5 16 M8 24 32 T Adapter Plate Motor Capscrews 3 8 M10 40 54 Adapter Plate Housing 8 Capscrews 7 6 M12 65 88 40D M16 110 150 Fork Bar 9 Capscrew 55D 100D 3 4 M20 140 190 120D 150D 3 4 M20 200 270 10 Housing Cover Plate Capscrews 5 16 M8 16 22 E 11 Housing End Cover Capscrews 7 16 M12 65 88 40D 55D 5 8 M16 15 100 12 Center Spacer 65D 5 8 M16 115 155 Capscrews 100D 125D 1 2 M12 45 60 120D 150D 1 2 M10 45 60 40D 5 8 M16 110 150 1 QUUD d 58 m20 110 150 s 13 Lower Hook Capscrew 100D IV 3 4 M20 195 265 120D M20 260 360 9 125D 150D 3 4 M20 200 270 44 Hook Spacer 1000 5 8 M16 115 155 Capscrew 4200 3 4 M20 200 270 RR0174 eps H Use Loctite 242 Blue
30. r Removal and WARNING Before removing hydraulic H lines or components relieve pressure in the Installation A hydraulic system Turn truck off and open the truck auxiliary control valve s several times in both directions 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 oil fill plug and drain oil from the Early Drive Motors drive group Drive Motor 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 Adapter Plate if equipped 5 Remove the four capscrews fastening the check valve assembly to drive motor Keep track of the two O rings between the check valve assembly and drive motor For reassembly tighten the capscrews to a torque of 15 ft Ibs 20 Nm Drive Motor Current 8 6 Remove the three capscrews fastening the motor flange or adapter plate to the gear box housing Tap 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 1 RR1202 eps the motor from the adapter plate Fill Plug two locations 8 For reassembly reverse the above procedures except as follows Early Drive Motors Apply Loctite 515 sealant Cascade
31. t higher 0 005 in 0 12 mm feeler gauge measurement increment See examples below e For 0 020 0 024 in 0 508 0 610 mm measured gap use 0 025 in 0 635 mm total shim thickness e For 0 025 0 029 in 0 635 0 736 mm measured gap use 0 030 in 0 762 mm total shim thickness The shim pack must contain only one blue 005 in shim See shims listed below Shim Service kit 670578 contains the following shims Qty Part No Color Thickness 1 674513 Blue 0 005 in 0 125 mm il 670574 Brown 0 010 in 0 254 mm 1 671757 Pink 0 015 in 0 381 mm 1 671758 Yellow 0 020 in 0 508 mm 11 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 12 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 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 Ibs 22 Nm Install the center hole plug 13 14 Reinstall the drive group on the rotator baseplate as described in Section 4 2 1 End cover 12 End cover 9 RRO209 eps 672946 R5 S ERVICE 43 Drive Motor 4 3 1 Drive Moto
32. u p ERIODIC MAINTENANCE 22 500 Hour Maintenance continued e Inspect forks carriage bars and frame for cracks and wear Replace components as required Bolt On Fork Weldment If equipped tighten capscrews to 100D 150D 200D 285 ft lbs 385 Nm 220D 300D 400D 395 ft lbs 535 Nm Fork Bar If equipped tighten capscrews to CL II 150 ft Ibs 145 Nm CL Ill 135 ft lbs 185 Nm CL IV 190 ft Ibs 255 Nm CL V 390 ft Ibs 530 Nm Weldment Capscrews RR1040 eps RR1041 eps 23 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 Service Section 4 5 1 for inspection 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 D
33. ully engage the worm with the drive motor shaft Install the remaining worm bearing race NOTE Some production drive groups are not equipped with the washers shown on the worm Install the worm bearing race The race taper must be inward THU n N Eb 9 o 6 672946 R5 RR0829 eps RC0178 eps Install housing pinion bearing RR0215 eps Apply sealant 11 ERVICE S 8 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 Ibs 13 Nm increments to a torque of 25 ft Ibs 34 Nm 9 Measure the gap between the end cover and housing in three places with a feeler gauge or plasti gage and determine the minimum gap 10 Drive Group with Worm Washers The washers and bearings require 0 020 0 025 in 0 050 0 064 mm preload Subtract the preload numbers from the feeler gauge measurement to determine the shims required between the end cover and housing Example 0 063 in 0 063 in Feeler gauge measurement 0 025 in 0 020 in Preload 0 038 in to 0 043 in Shim thickness range 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 the end cover shims equal to the nex
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