Rotator Drive Assembly Service Kits 6839416 and 6839420
Contents
1. BE des more palitos ol Rosso i i Clamp si o Ei WG RC0441 eps oo Open Single Drive Dual Drive Back Driver s View Back Driver s View cascade Corpora tion For Technical Support To Order Parts Call 1 800 227 2233 Fax 1 888 329 8207 Call 1 888 227 2233 Fax 1 888 329 0234 Internet www cascorp com Internet www cascorp com Write Cascade Corporation PO Box 20187 Portland OR 97294 Write Cascade Corporation 2501 Sheridan Ave Springfield OH 45505 Attachment and Drive Group Removal and Installation Continued 3 Disconnect the lower hooks Bolt On Hooks Remove the lower mounting hooks For reassembly tap hooks tight against lower carriage bar and tighten the capscrews to a torque of Single Drive CL IV 90F 100F 260 ft lbs 850 Nm Dual Drive 120F 150F 200 ft lbs 270 Nm 160F CL IV 235 ft los 320 Nm 160F CL V 250 ft los 340 Nm Quick Change Hooks Pull out the locking pins and drop the lower hooks to the unlocked position Reinstall the pins in the lower holes For reassembly slide the hooks up to the locked position and install the locking pins in the top holes 4 Set the attachment on a pallet Tilt the mast forward and lower the carriage to remove the attachment from the truck RC4738 eps Lower Hooks 3 32. 11 Apply Loctite 515 sealant Cascade Part No 668184 to 1 1 both surfaces of the new end cover gasket Cascade Part No 6805513 and the capscrews Install the assembled end cover with components gasket spring stack and capscrews as shown Tighten the capscrews to a torque of 65 ft lbs 90 Nm Remove excess sealant RC4744 eps End Cover P Capscrew Gasket End Cover with assembled components 12 install brake tube 13 With the gearcase laying flat fill with 56 fluid ounces 540 ml of Cascade Gear Lube Part No 656300 or SAE 90 wt gear lube AGMA mild 6EP Gear Lube 14 install the cover plate and O ring Install the four cover plate capscrews and tighten to a torque of 15 ft lbs 20 Nm Install the center hole plug 15 Reinstall drive group to baseplate and attachment to truck by reversing the steps in section Attachment and Drive Group Removal and Installation Perform Adjustment amp Troubleshooting Section 12 Brake Tube WARNING After completing any service A procedure always test the attachment through five complete cycles First test the attachment empty then test with a load to make sure the attachment operates correctly before returning it to the job RC4745 eps Disabling Brake Circuit The following steps are for temporarily disabling the brake circuit for a short term 1 Perform section Attachment and Drive Group Removal and Install
3. 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 Cascade Corporation 2013 Cascade Canada Inc 5570 Timberlea Blvd Mississauga Ontario Canada L4W 4M6 Tel 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 64 9 273 9137 Cascade do Brasil Rua Jo o Guerra 134 Macuco Santos SP Brasil 11015 130 Tel 55 13 2105 8800 Fax 55 13 2105 8899 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 65 6795 7555 Fax 65 6863 1368 09 2013 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 91 020 2433 0881 Part Number 6840889 R1
4. 5000 psi 345 bar Cascade Part No 671212 cou 8 e Assorted fittings and hoses as required Pressure Gauge Kit 671212 Troubleshooting Procedure Perform the following troubleshooting steps 1 Install the three pressure gauges and tee fittings to the rotator motor fittings and brake drive fitting Replace brake drive tube with a hose Gauge 1 2 With gauges installed rotate the attachment CCW During Rotate CCW rotation the gauges should read Gauge 1 High up to 2300 psi 160 bar Gauge 2 Low approximately 200 psi 14 bar Gauge 3 Between 700 1000 psi 48 70 bar must not exceed 1000 psi 70 bar e lf rotation is jerky and Gauge 3 is less than 700 psi 48 bar while rotating turn in the relief cartridge on the drive motor valve to bring the pressure within the range of 700 1000 psi 48 70 bar e f Gauge 3 is greater than 1000 psi 70 bar while rotating turn out the relief cartridge on the valve to bring pressure within the range of 700 1000 psi 48 70 bar Gauge 2 Rotate CW Gauge 3 Replace tube with Brake Pilot Line hose and tee fitting RC4746 eps Adjustment and Troubleshooting continued 3 Stop rotating the attachment Gauges should read NOTE If further troubleshooting is required before contacting Gauge 1 Less than 300 psi 21 bar Cascade record all gauge readings Gauge 2 Less than 300 psi 21 bar Gauge 3 Less than 300 psi 21 bar e f Gaug
5. BOLT ON HOOKS 5 Dual Drives Disconnect the crossover tubes from the check valve and brake valve assemblies 6 Remove the capscrews fastening the drive assembly with the brake valve to the baseplate For reassembly tighten the capscrews to a torque of 75 ft Ibs 100 Nm 7 Continue to Installing Service Kits 6839416 and 6839420 section 8 For reassembly reverse the above procedures with the following exceptions e After the drive group has been reinstalled check the gearcase lubricant level Lubricant must be up to the bottom of the fill plug hole If necessary fill with Cascade Gear Lube Part No 656300 or SAE 90 wt gear lube AGMA mild 6 EP Gear Lube e Refer to F Series Roll Clamp Installation Instructions 674510 Fixed Frame or 674511 Swing Frame QUICK CHANGE HOOKS RC0367 eps LH Lower Hook Locked Position with Brake Valve LH shown 6 Drive Assembly Dual Drive Roll Clamp shown Installing Service Kits 6839416 and 6839420 NOTE Service Kit 6839420 can only be installed in end covers stamped with 6830562 1 Perform section Attachment and Drive Group Removal and Installation 2 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 Remove brake tube Do not discard Remove the three capscrews fastening the end cover to the housing Remove end cover Remove the four capscrews fastening the c
6. Brake Valve Brake crossover tube fitting Brake crossover tube fitting Single Drive Brake Valve Rotation Drift Test Place a mark at the top center of the baseplate and rotate bearing Place rotation limit marks at 10 approximately 6 in 15 cm each side of top center on the faceplate All marks Mark at should be viewable by the driver Marks at 10 top center 6 in 15 cm e Clamp roll with pads at bottom of roll each side of center WARNING Make sure all personnel are clear of the attachment during testing e Lift roll 15 in 38 cm off floor to provide clearance for rotation drift test a e Rotate roll 10 CW and wait 30 sec No drift is allowed e Rotate roll 10 CCW and wait 30 sec No drift is allowed e If roll drift occurs troubleshoot brake as described in the section below ay RC4704 eps NOTE If the brake circuit is disabled contact Cascade Adjustment and Troubleshooting NOTE Refer to the schematic on the following page Pressure No 6 and No 8 Gauge No 6 6 Hose JIC Swivel Tee Truck Requirements Review attachment hydraulic specifications in F Series Service Manual 674512 di i as D ip E r of Tools required In addition to a normal selection of Ea GA0014 eps mechanic s hand tools the following are required e Pressure Gauge Kit 3 kits required No 4 6 Pipe JIC NO 6 8 JIG Nee Ne
7. ation 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 Remove brake tube Do not discard the end cover to the housing Remove end cover Remove the piston with seal friction disks pressure plates brake rotor assembly guide rod disc springs and spring seat NOTE The seal collar in the end cover does not need to be removed if equipped Piston with Seal Apply Loctite 515 sealant Cascade Part No 668184 to both surfaces to a new end cover gasket Cascade Part No 6805513 and the capscrews Install the gasket and end cover Tighten the capscrews to a torque of 65 ft lbs 90 Nm Remove excess sealant metal caps the steps in Attachment and Drive Group Removal and Installation 5 Friction Discs amp Pressure Plates Cap brake fittings on brake valve and end cover with No Reinstall drive group and attachment to truck by reversing Spring Seat Disc Springs Guide Rod Brake Rotator Assembly a 4 4 6 LH Drivebox Brake Valve shown WARNING After completing any service procedure always test the attachment through five complete cycles First test the attachment empty then test with a load to make sure the attachment operates correctly before returning it to the job A RC4347 eps 7 Brake crossover tube fitting RH Drivebox Brake Valve Solenoid
8. cascade CI CITM Nn Sta l atl O Nn Rotator Drive Assembly Service Kits 6839416 and Instructions 5853942 This sheet provides installation instructions for service kits 6839416 and 6839420 Service kit 6839416 includes a preassembled spring stack and a preassembled cover with dowel pins seal collar with seals pressure plates friction discs piston and brake rotor Service kit 6839420 includes a NOTE Service Kit seal collar with seals After servicing the brake components 6839420 can only perform the Rotation Drift Test Also included is a disabling be installed in end brake procedure for temporary circumstances only and covers stamped a troubleshooting section Perform troubleshooting prior with 6830562 contacting Cascade Service Attachment and Drive Group Removal and Installation RC4737 eps 1 If possible rotate the attachment to the vertical roll handling position Extend the arms outside the width of the frame 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 2 Disconnect and plug the hydraulic supply hoses to the attachment Tag hoses for reassembly Rotate CCW Rotate CCW Rotate CW SEER Rotate CW a cama bye 8 OO Ki o o
9. e 1 and or Gauge 2 is greater than 300 psi 21 bar the hydraulic system requires an independent tank line Install Cascade Pressure Relief Kit 6043749 and hose 207299 e lf drifting occurs and all gauges read less than 300 psi 21 bar Disc Spring Stack Diagram while drifting occurs verify that Spring Seat Guide Rod Shines washer N tecachDisg the disc springs are stacked in Spring s orientation the correct orientation as shown Check the overall length and shim as required Verify that the disc springs are in good condition RARA ANN NN Kh TY AN NN ANN NA Wh Ny E e 150 8 0 08 mm nl RC4741 eps Hydraulic Schematic Dual Drive Brake Valve with Counterbalance Cartridges Rotator Dual Drives and C Motors To Clamp Components Andan lo Valve Truck Relief Truck Pump Truck Tank RC4942 eps 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 ltalia S R L European Headquarters Via Dell Artigianato 1 37030 Vago di Lavagno VR Italy Tel 39 045 8989 111 Fax 39 045 8989160 ASIA PACIFIC Cascade Japan Ltd 2 23 2 Chome Kukuchi Nishimachi Amagasaki Hyogo
10. over plate to the housing o ua Bo Remove the center capscrew plug from the cover plate and install a early 3 8 in NC or later M10 capscrew with a minimum thread length of 2 in 50 mm Remove the cover plate by turning the capscrew clockwise while lightly tapping around the sides of the cover plate 7 Turn drive group over and drain the lubricant from the housing 8 Remove brake components IMPORTANT If installing Kit 6839420 keep components 9 Kit 6839416 Verify kit spring stack Spring Seat disc springs are oriented as shown and the overall length is 5 937 0 003 in 150 8 0 08 mm Kit 6839420 Inspect drive group disc springs for damage and verify the overall length is 5 937 0 003 in Cover Plate Remove brake components Guide Rod Note each Disc Spring s orientation Shims Washer 150 8 0 08 mm Replace disc springs as needed m RC4741 eps 5 937 0 003 in 150 8 0 08 mm Disc Spring Stack Diagram 10 Kit 6839420 Use tool 6839417 to remove the seal collar Brake Rotor from the end cover Install new seal collar using the Assembly tool to seat and tighten into the end cover to a torque of 120 ft lbs 160 Nm Seat the piston in the seal collar Stack pressure plates friction discs and brake rotor assembly into the cover Pressure Plates and Friction Tool 6839417 Discs Piston Seal Collar RC4742 eps RC4743 eps
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