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