cascade corporation D Series User manual

Cascade is a Registered Trademark of Cascade Corporation
cascade
corporation
ERVICE MANUAL
S
D-Series
High Capacity
360° Rotators
Manual Number 6817684

ONTENTS
C
i6817684
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
Char-Lynn Drive Motor Disassembly 14
Char-Lynn Drive Motor Inspection 16
Char-Lynn Drive Motor Reassembly 16
Check Valve Assembly 18
Check Valve Assembly Service 18
Base Unit 19
Bearing Assembly – Capscrews Torque
Inspection 19
Bearing Assembly Removal and Installation 20
Fork Service 21
SPECIFICATIONS, Section 5
Specifications 22
Hydraulics 22
Auxiliary Valve Functions 22
Torque Values 23
Determining Load Torque Requirements 24

NTRODUCTION
I
6817684 1
1.1 Introduction
This manual provides Installation, Periodic Maintenance,
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. 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.
1.2 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
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.
Nameplate
WARNING: Fork size affects rotator
capacity. Consult Cascade to verify
capacity for truck nameplate.
LIFT TRUCK ATTACHMENT
ATTACHMENT CAPACITY
SERIAL
NUMBER
CATALOG
NUMBER
ADDITIONAL
EQUIPMENT
ADDITIONAL
EQUIPMENT
ADDITIONAL
EQUIPMENT
WEIGHT
LBS.
POUNDS
AT
INCH LOAD
CENTER
CAPACITY OF TRUCK AND ATTACHMENT COMBINATION
MAY BE LESS THAN ATTACHMENT CAPACITY SHOWN
ABOVE. CONSULT TRUCK NAMEPLATE.
RECOMMENDED SYSTEM PRESSURE – 2000 PSI
MAXIMUM SYSTEM PRESSURE – 2300 PSI


c
FOR TECHNICAL
ASSISTANCE, CONTACT
800-227–2233
PORTLAND, OREGON USA
FOR PARTS AND SERVICE
MANUALS, CONTACT
800-227–2233
SPRINGFIELD, OHIO USA
215033-P-1
220D-RRB-14H 2220
S/N 215033-P-1
RR0917.eps

6817684
ERIODIC MAINTENANCE
P
2
2.1 100-Hour Maintenance
Every time the lift truck is serviced or every 100 hours
of truck operation, whichever comes first, complete the
following maintenance procedures:
• Check for loose or missing bolts, worn or damaged
hoses, and hydraulic leaks.
• Lubricate plungers on 180° stop valve (if fitted).
• Check decals and nameplate for legibility.
2.2 500-Hour Maintenance
After each 500 hours of truck operation, in addition to the
100-hour maintenance, perform the following procedures:
• Check a sample of baseplate-to-bearing assembly
capscrews for proper torque value. See Technical
Bulletin TB183 or Section 4.5 for inspection and
replacement procedures.
• Check a sample of faceplate-to-bearing assembly
capscrews for proper torque value. See Technical
Bulletin TB183 or Section 4.5 for inspection and
replacement procedures.
• Tighten rotator drive capscrews to 75 ft.-lbs. (105 Nm).
• 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.
• Inspect forks, carriage bars and frame for cracks and
wear. Replace components as required.
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
operates correctly before returning it to the
job.
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.
RR0460.eps
Rotator Bearing
Assembly Grease
Fitting
Rotator
Drive Fill
Plug
Fork Carriage
Bars and Keepers
Bearing Capscrews
(Access through
hole in baseplate)
Rotator Drive
Capscrews
Baseplate
Capscrews
Rotator
Drive
Fill Plug
RR0913.eps

6817684
ERIODIC MAINTENANCE
P
3
2.3 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.
• 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
– Difference 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 & carriage wear gauge 209560 (Class II),
209561 (Class III) and 6105257 (Class IV).

ROUBLESHOOTING
6817684
T
4
3.1 General Procedures
3.1-1 Truck System Requirements
• Truckhydraulicpressureshouldbewithintherange
showninSpecications,Section5.1.PRESSURE TO
THE ATTACHMENT MUST NOT EXCEED 2300 psi
(160 bar).
• Hydraulicowshouldbewithinthevolumerangeas
showninSpecication,Section5.1.
• Hydraulicuidsuppliedtotheattachmentmustmeetthe
requirementsasshowninSpecications,Section5.1.
3.1-2 Tools Required
Inadditiontoanormalselectionofhandtools,youwillneed:
• InlineFlowMeterKit:
20GPM(75L/min.)–CascadePartNo.671477
• PressureGaugeKit:
5000psi(345bar)–CascadePartNo.671212,twokits
required.
• Assortedttingsandhosestoadaptgaugesandow
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rst
stepistotalktotheequipmentoperator.Askfor
acompletedescriptionofthemalfunction.The
followingguidelinescanthenbeusedasastarting
pointtobegintroubleshootingprocedures:
Rotate Circuit
• Attachmentwillnotrotate.
• Attachmentwillnotrotatewithloadatrated
capacity.
• Attachmentrotatesinonedirectiononly.
Tocorrectoneoftheseproblems,seeSection3.3.
WARNING:Beforeservicingany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oorwhiletesting.
GA0013.eps
GA0014.eps
Flow Meter Kit 671477
Pressure Gauge Kit 671212
(2)No.8-12
JIC/O-Ring FlowMeter
(2)No.6-8JICReducer
Pressure
Gauge No.6-6Hose
No.6andNo.8
JICSwivelTee
No.4-6Pipe/JIC No.6-8JIC
Reducer
No.4,No.6
andNo.8
JIC/O-Ring

6817684
ROUBLESHOOTING
T
5
RR0914.eps
3.2 Plumbing
3.2-1 Hosing Diagram
3.2-2 Hydraulic Schematic
DriveBox
JunctionBlock/
HoseTerminal
HoseReel
Truck
Auxiliary
Valve
CHAR-LYNN MOTOR ROTATE
(COUNTERCLOCKWISE SHOWN)
PRESSURE
RETURN
IMPORTANT:Seemotorendcoverfor
identication.
DriveMotors
DriveGroup
CheckValve
Junction
Block/Hose
Terminal
HoseReel
Truck
Rotate
Valve
Truck
Relief
Valve
TruckHydraulicPump
NOTE:Junction
blocks mayormay
nothavecheck
valves.
RR0919.eps

ROUBLESHOOTING
6817684
T
6
3.3 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owfromlifttruck.
• Wornordefectivemotor.
• Wornordefectivedriveassemblyorframebearing
assembly.
3.3-1 Supply Circuit Test
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.
1 Checkthepressuredeliveredbythetruck.Refer
tothetruckservicemanual.PRESSURE TO THE
ATTACHMENT MUST NOT EXCEED 2300 psi
(160 bar),measuredatthecarriagehoseterminal.
2 Checktheowvolumeatthecarriagehoseterminal.
RefertoSpecicationssectionforrecommendedow
volumes.
3 Checkforexternalleaks.
3.3-2 Rotation without Load
1 Installpressuregaugestothemotorttings.
2 Startthetruckandrotatetheattachmentwithoutaload.
Whilerotating,notepressurereadingsofbothgauges.
• Ifthe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.
• 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
ttingsandhosesizeslessthanNo.8,etc.
RR0191.eps
Install
pressure
gauges

6817684
ROUBLESHOOTING
T
7
3.3-2 Rotation with Load
1 Removetheleftdrivegroupfromtheattachmentas
describedinSection4.2-1.Captheconnectorttings
ontherighthanddrivegroup.Rotatealoadrequiring
approximately1/3ofattachmentmaximumtorque.
• Ifthe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.
• 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.
2 Removethemotorfromthemalfunctioningdrive
assemblyasdescribedinSection4.2-2.
3 Reinstallthehosestothemotorttings.Actuatethe
rotatecircuit.
• Ifthemotorshowsrotationaloutput,thedrivebox
mayrequireservice.RefertoSection4.2-2.
• Ifthemotorshowslittleornorotationaloutput,
servicethemotorasdescribedinSection4.3-2or
4.3-3.
Model Maximum Torque Capacity
220D★216,000in.-lbs.@2300psi
(292,857Nm@160bar)
300D■334,000in.-lbs.@2300psi
(452,843Nm@160bar)
400D■425,000in.-lbs.@2300psi
(576,224Nm@160bar)
★Ratedat24GPM(91L/min.)ow.
■Ratedat30GPM(114L/min.)ow.
RR0193.eps
Disconnectthe
Crossovertubes.
Capttings
RightHand
DriveGroup
RemoveLeftHand
DriveGroup.

6817684
ERVICE
S
8
5 Disconnect the hydraulic hoses to the drive motor.
Tag the hoses for reassembly.
6 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.
7 For installation, reverse the above procedures.
WARNING: Before removing any hoses,
relieve pressure in the hydraulic system.
Turn the truck off, then open the truck
auxiliary control valve(s) several times in
both directions.
4 Remove the lower mounting hooks, if equipped.
For reassembly, tighten the capscrews to a torque of
240 ft.-lbs. (325 Nm).
4.1 Attachment Removal
1 Rotate the attachment to position the forks parallel to the
ground.
2 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).
3 Release the spring lock on the top of each fork.
Remove the forks from the rotator.
RR0196.eps
3
2Upper
fork bar
3
2
ADJUST
RC0368.eps
Carriage Bar
Lower Hook
BOLT-ON HOOKS
6
RR0510.eps

6817684
ERVICE
S
9
RR0915.eps
4.2 Drive Group
4.2-1 Drive Group Removal
and Installation
1 Remove the attachment from the truck as described in
Section 4.1.
2 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.-lbs. (100 Nm).
4 For reassembly, reverse the above procedures except
as follows:
• 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).
RR0205.eps
26
7
4
3
5
Cover
Plate
Housing
4.2-2 Drive Group Disassembly
and Service
1 Remove the drive group from the attachment as
described 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.
4
5
6
7
3
2
4
32

6817684
ERVICE
S
10
RR0920.eps
RR0522.eps
RR0521.eps
8 Tap the worm, worm bearing and washers out through
the end cover side of the housing. Remove the worm
bearing race from the motor side of the housing.
9 Press the pinion, pinion bearings and worm gear out of
the housing as an assembly.
10 Remove the snap ring from the pinion. Press the pinion
and housing pinion bearing from the worm gear and
cover plate pinion bearing. Remove the pinion key.
11 Press the pinion out of the housing pinion bearing.
Remove baseplate pinion bearing and snap ring.
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.
12 Clean and inspect all components. Remove all dried
sealant residue. Replace all worn items. Remove burrs
or sharp edges with emery cloth.
Bearing
Outer Race
Key
Worm
Pinion
Housing/Pinion
Bearing
Snap Ring
Baseplate/Pinion
Bearing
Housing
Pinion bearing
Washers
Worm
Gear
8
9
8
10
11
OR

6817684
ERVICE
S
11
RR0829.eps RC0178.eps
RC2125.eps
4.2-3 Drive Group Reassembly
1 Install the baseplate pinion bearing and snap ring on
the pinion.
Key
Housing
2 Apply sealant (668184) to the pinion shaft seating area
and shoulder for the housing/pinion bearing. Install the
housing/pinion bearing. Remove excess sealant.
3 Preheat worm gear to 200° F (93° C). Install the key,
worm gear, cover plate/pinion bearing and snap ring on
the pinion.
4 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.
5 Install worm bearing race in the drive motor side of the
housing. Make sure the bearing race is facing in the
correct direction.
6 Install drive motor as described in Section 4.3-1.
7 Install the worm, worm bearings and washers (if equipped)
in the housing. Fully 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.
Install the worm bearing
race. The race taper
must be inward.
1
1
2
2
3
4
5
6
7
7
RC2124.eps
Pinion
Gear
First
Bearing
Seating
Area
Baseplate
Pinion
Bearing
Additional
Snap Ring
Second
Bearing
Seating
Area
Housing
Pinion
Bearing

6817684
ERVICE
S
12
RC0180.eps
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.-lbs. (13 Nm) increments to a
torque of 25 ft.-lbs. (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 .020-.025 in.
(.050-.064 mm) preload. Subtract the preload numbers
from the feeler gauge measurement to determine the
shims required between the end cover and housing.
Example:
.063 in. .063 in. (Feeler gauge measurement)
– .025 in. – .020 in. (Preload)
.038 in. to .043 in. (Shim thickness range)
In this case two .020 in. (.50 mm) yellow shims would
be installed to equal 0.40 in. (1.0 mm). See shims listed
below.
Drive Group without Worm Washers –
Choose a combination of the end cover shims equal
to the next higher .005 in. feeler gauge measurement
increment. See sample below.
.020–.024 in. measured clearance, use .025 in. total
shim thickness.
.025–.029 in. measured clearance, use .030 in. 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
2 671758 Yellow .020 in. (.50 mm)
2 671757 Pink .015 in. (.39 mm)
1 670574 Brown .010 in. (.25 mm)
1 674537 Blue .005 in. (.12 mm)
11 Remove the end cover. Apply sealant 668184 to both
surfaces of the shims. Install the shims and end cover.
Tighten the capscrews to a torque of 65 ft.-lbs. (88 Nm).
Remove excess sealant.
12 With the gear case laying flat, fill with 2.5 cups (600ML)
Cascade Gear Lube 656300 or equivalent SAE 90 wt.
lube (AGMA 'mild' 6EP Gear Oil).
13 Install the cover plate. Install the center capscrew.
Install the four outer capscrews. Tighten the outer
capscrews to a torque of 16 ft.-lbs. (22 Nm).
14 Reinstall the drive group on the rotator baseplate as
described in Section 4.2-1.
RC0181.eps
RR0209.eps
#
9
End cover
Housing
End cover
8
9
9
12
11
13

6817684
ERVICE
S
13
4.3 Drive Motor
4.3-1 Drive Motor Removal 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 the oil fill plug and drain oil from the
drive group.
4 Lay the drive group (pinion down) on wooden blocks
approximately 4 x 4 in. (100 x 100 mm) placed on both
sides of the pinion.
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
22 ft.-lbs. (30 Nm).
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 break the motor
assembly loose from the gear box housing.
7 If equipped with adapter plate, remove the four
capscrews fastening the adapter plate to the drive
motor. Separate the motor from the adapter plate.
8 For reassembly, reverse the above procedures except
as follows:
• Apply sealant (668184) to both sides of the drive
motor/adapter plate gasket (if equipped). Apply
sealant to the threads of the four drive motor
capscrews. Install the gasket and adapter plate to
the drive motor. Tighten the capscrews to a torque of
40 ft.-lbs. (54 Nm).
• Apply sealant to both sides of the adapter plate/
gearcase (or motor/gearcase) gasket. Apply sealant
to the threads of the three adapter plate capscrews.
Install the adapter plate/drive motor and gasket to
the gear box housing. Tighten the capscrews to a
torque of 65 ft.-lbs. (88 Nm).
• Fill the drive group with 2.5 cups (600 ml) Cascade
Gear Lube part no. 656300 or equivalent SAE 90 wt.
lube (AGMA 'mild' 6EP Gear Oil).
RC0183.eps
O-Rings
Adapter
Plate ▲
3
4
56
7
8
8
Drive Motor
WARNING: Before removing hydraulic
lines or components, relieve pressure in the
hydraulic system. Turn truck off and open
the truck auxiliary control valve(s) several
times in both directions.
Fill Plug
(two locations)
▲If equipped. Adapter plate is
on motors with Cascade part
no. less then 608XXXX.

6817684
ERVICE
S
14
RR0881.eps
RR0632.eps
RR0623.eps
4.3-2 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.
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.
2 Remove O-rings from housing.
3 Make a scribe across the drive motor, inline with the
capscrew and drive motor’s port surface.
4 Use a soft jawed vise to clamp the motor across the
flange with the output shaft downward.
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.
7 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.
Housing
O-Ring ▲
3
6
45
Pressure Seal ▲
Wiper Seal ▲
Flange Seal ▲
Housing
Flange
(608XXXX or less)
Flange
(608XXXX or greater)
Load Bearing Race
Thrust Bearing
Output Shaft
Splined
Drive Spacer
Plate
End Cap
Capscrews (7)
Capscrews (4)
Gerotor Set
2
O-Ring ▲
O-Ring ▲
O-Ring ▲
Brass Shim ▲
RR0841.eps
8

6817684
ERVICE
S
15
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 seal 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.
45°
RR0842.eps
Flange
Flange
10
9
RR0860.eps
RR0859.eps
RR0843.eps
RR0858.eps
Flange
Original Design
Modified Screwdriver
14
14
13
12
15
11

6817684
ERVICE
S
16
4.3-4 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.
2 Place the bearing race in the flange, seated evenly with
pressure seal and flange.
3 Lubricate the flange seal with petroleum jelly and seat in
lip of flange on the pressure seal side, as shown.
4 Install thrust bearing onto the output shaft.
5 Install the flange onto the output shaft with the pressure
seal side against the output shaft.
6 Clamp housing into the vise with the flange side facing
upward.
7 Install the output shaft/flange assembly into the housing.
8 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 criss-cross pattern to 250 in.-lbs.
(28 Nm).
IMPORTANT: Capscrews must be clean and dry.
RR0633.eps
Brass Shim
Wiper Seal
Pressure Seal
Bearing Race
Flange
Flange Seal
4.3-3 Char-Lynn®Drive Motor
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. Replace parts
where imperfections could not be removed.
• Inspect the flange seal seats for scratches. Check for
cracks in the flange area that could cause leakage.
RR0861.eps
RR0862.eps
8
7
45
Output Shaft

6817684
ERVICE
S
17
7
5
3
1
6
4
2
RR0731.eps
Spacer Plate
O-Ring
Gerotor
O-Ring
End Cap
14
Star
Point
Scribe
Mark
12
Short Spline O-Ring
15
RR0647.eps
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.
IMPORTANT: Make sure O-Rings are properly seated.
14 Install endcap assembly onto housing while aligning the
scribe marks and capscrew holes. Make sure the drive
engages with output shaft.
15 Install the capscrews into the end cap. Tighten the
capscrews using a criss-cross pattern to 240 in.-lbs.
(27 Nm).
Splined Drive
Timing Dot
RR0627.eps
Timing Dot on Output Shaft
Screw hole that is
aligned with port
surface.
Port
Surface
11
RR0674.eps
10
Splined Drive

6817684
ERVICE
S
18
4.4 Check Valve Assembly
4.4-1 Check Valve Assembly Service
6038929
CKCB-XCN
Sun
RC2519.eps
O-RIngs
Back-Up Rings
PO Check Cartridge
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.
1 Disconnect the hydraulic hoses to the drive group. Tag
the hoses for reassembly.
2 Remove the check valve cartridges.
3 Remove the O-rings and backup rings from the check
valve cartridges.
4 Clean the parts with solvent.
5 For reassembly, reverse the above procedures except
as follows:
• Lubricate all O-rings and seals prior to reassembly
with petroleum jelly.
• The check valve cartridge backup rings and O-rings
must be installed. Refer to previous page. RR0181.eps
1
2
12