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669223_45C Quad Mast Service

1. 45C Viewmast l Quad Free lift Roller Masts Serial Numbers 668175 through 692606 Manual Number 669223 cascade Cascade is a Registered Trademark of Cascade Corporation View s a Registere ai a Contents l Page Number INTRODUCTION Section 1 naesssoesrensreesserecsasroresones 1 INSTALLATION INSTRUCTIONS Section 2 2 Truck System Requirements 0 c cece eect e eee n eee ene nee 2 Mounting Bracket Installation ccc cece s ect e cence crete cere 2 Masts Installations s ctcns isha os dra tod desea s eaters as 4 Operational Inspection and Adjustments cece eevee eee 4 PERIODIC MAINTENANCE Section 3 00 0 cee eee eens 5 Daily Inspection rs ne aneen erona vikarer dere 5 100 Hour Inspection ara ureranererenarerneevevevernenenreer 5 500 Hour INSPECHION 0 cece te cece rece eE a a e aiea 5 TROUBLESHOOTING Section 4 cc cee cee cence cen eee ees 6 SERVICE Section S suussistenr des tease adver casters 8 Hoist Cylinder sess cceccaiheseseasevceevs vevas eve dctecdes deste wees 8 Descnpiomsirusas ors iN Er AAE EN ESEESE E pEi 8 Bi Element Seal Assemblies 0 eee cece cence ee eneee 8 Lowering Control Valve Removal and Adjustment 8 Cylinder Operation 0 ccc cece eee cece eee ee ene eteanensees 10 Cylinder Removal cece cee e cee e eee e ee ae enter eeneteeerees 12 Cylinder Disassembly Service a
2. Cable Cascade Pil Cascade Scandinavia Hydraulik A B Musk tgatan 17 E 8 9 25255 Helsingborg Sweden Tel 042 151135 Telex 72565 caschbg s Cascade Hydraulics Ltd 7615 Kimbel Street Mississauga Ontario Canada L5S 1A8 Tel 416 677 9695 Direct Parts Line 416 677 9686 f 416 677 9684 Te Ac 06 968715 Cascade Japan Ltd Cascade N V European Headquarters P O Box 50086 1305 AB Almere Haven Achterwerf 240 1357 CB Almere Haven The Netherlands Tel 03240 92911 Telex 40838 case nl Cascade France S A R L 11 rue Jean Charcot Zone Industrielle Sud B P 22 91421 Morangis Cedex France Tel 06 9091139 Telex cascade 690016f Cascade Materials Handling Aust Pty Ltd Incorporated in N S W P O Box 67 Ermington 2115 N S W Australia Tel 02 648 2571 Te Ac 790 24302 Cable Cascaus 4 1 1 Chome Shin Senri Higashamachi Toyonaka Osaka 565 Japan Tel 06 835 2900 Te Ac 781 5287115 Cascade J Cable Cascadecfe Osaka re cascade oo TM Cascade 1984 1 84 Cascade N V Benelux Sales and Service P O Box 170 1110 AD Diemen Weesperstraat 110 1112 AP Diemen The Netherlands Tel 020 906411 Telex 14495 casc nl Cascade Iberia S A Nave Industrial Calle Cromo 99 Nave G Hospitalet de Llobregat Barcelona Spain Tel 93 3350567 Telex 54018 casc e Cascade Materials Handling Aust Pty Ltd 44E Winterton Road Clayton Victoria 3168 Austra
3. shim adjustable load rollers The two upper load rollers are secured to their stub shafts by keepers the four lower load rollers are held in place by the inner channel when the carriage is assembled onto the mast All six load rollers are interchange able pair of adjustable chain anchors are used to connect the carriage chains to the carriage 5 2 2 Carriage Removal The carriage may be removed with the mast installed on the truck according to the following procedures 1 Lift the carriage to gain access to the carriage stop screws on the inner upright See Figure 23 Screw in the stop screws to clear the stop bar on the carriage 2 Block the carriage off the ground and lower the mast to slacken the carriage chains Connect a sling to the carriage and secure it with some suitable lifting device HOIST CHAIN a le REQUIRED CHAIN ANCHOR I K in FR NUT 2 REQUIRED COTTER PIN 2 REQUIRED CARRIAGE SHIM 2 REQUIRED PIN 2 REQUIRED Deg KE PIN 4 REQUIRED NOTE Stud shafts are replaceable per Technical Bulletin 126 SHIM AS REQUIRED ROLLER 6 REQUIRED SHIM 030 INCH 6 REQUIRED RETAINER 6 REQUIRED Q CAPSCREW 4 REQUIRED a ZY en DA RET gt TORQUE TO 6 7 FT LB y ROLLER Figure 22 The Carriage Assembly 669223 Rev 1 17 sin D Service 5 2 2 Carriage Removal Cont 3 Remove the cotter pins and pin retaining the chains to the or
4. External leaks at retainers a Relief valve defective b Master piston check valve leaking a Air in cylinder a Air in cylinder b Sticky or defective truck relief vaive A WARNING Extreme care should be used when working on a unit when the carriage with or without load is in a raised position c Bent or damaged cylinder plunger s h Clean or replace as necessary i Replace reliefvalve Do not adjust or repair j Replace seals a Replace relief valve do not adjustor repair a Tighten or replace as necessary b Repair or replace truck valve c Replace slave piston check valve assembly d Replace all cylinder seals a Replace relief valve do not adjust or repair b Replace check valve a Bleed air from cylinder a Bleed air from cylinder b Remove and check truck relief valve If contaminated oil caused the malfunction drain and flush the system change the filter and refill with fresh oil c Disassemble check and repair cylinder assembly A WARNING Extreme care should be used when working on a unit when the carriage with or without load is in a raised position d Load rollers improperly adjusted or defective A WARNING Extreme care should be used when working on a unit when the carriage with or without load is in a raised position e Mast channels improperly lubricated e Lubricate mast A WARNING Extreme care should be used when working on a unit when the carriage
5. Hoist Chains os erekce netrane itant iaoe aa eiar ska gee els 28 Inspection and Tension cece cece eee e cence teen teens 28 Measuring Chain Stretch Hdg tints erecta set pans Fyret hes 28 Mast Chain Adjustment cccccccrecseecetneuceteencs 29 Carriage Chain Adjustment cccecseceeceseeereecs 29 Outer Upright Chain Removal and Replacement 30 STANDARD LABOR TIMES Section 6 cece eee e cues 31 Determining Labor Times 0c ce cca e cee etecereeseune 31 Standard Labor TiM S cece sce e cece eee reseeeeseeees 31 669223 Rev 1 sum I Introduction This manual provides the installation instruction maintenance troubleshooting and service procedures for the Cascade Quad Viewmast II a four stage full free lift roller mast The Quad Viewmast II provides exceptional visibility for the lift truck driver The mast carriage and upright channels are all roller mounted which results in smooth operation and long service life A unique three stage hoist cylinder provides fast CATALOG AND SERIAL NUMBERS LEFT HAND SIDE OF OUTER UPRIGHT CHANNEL operation and uniform lifting and lowering speeds of the carriage In any communication about your Cascade Quad Viewmast II always refer to the mast catalog and serial numbers stamped on the mast nameplate If the nameplate is missing these numbers are also stamped on the left hand side plate o
6. LOWERING CONTROL VALVE TORQUE TO 10 15 FT LBS SETSCREW TORQUE TO 12 17 IN LBS STAKE ONE PLACE THREADED WASHER TORQUE TO 65 70 FT LBS STAKE ONE PLACE RELIEF VALVE TORQUE TO 12 17 FT LBS SEQUENCE ROD NUT TORQUE TO 75 9 FT LBS Figure 9 Hoist Cylinder Components BACK UP RING NYLON RING SEAL O RING BACK UP RING amp O RING O RING SEAL NYLON RING INCLUDED IN SEAL KIT BEARING TORQUE TO 50 55 FT LBS as follows 10 Using a lifting strap and hoist remove the cylinder from the 8 Remove the hose at the cylinder Be prepared to collect oil mast 9 Cap the opening on the cylinder with a steel cap Plugthe 11 Lay the completely collapsed cylinder on 4 X 4 s NOTE hose Cut 2 two 2 deep V cuts in each 4 X 4 12 669223 Rev 1 sem D Service 5 1 6 Cylinder Disassembly Service and Reassembly 1 Use a claw type spanner wrench to remove the cylinder shell retainer item 1 Figure 9 Slide the master primary and slave plungers out of the cylinder shell as an assembly Before removing the master plunger piston first remove the O ring plug at the bottom of the piston Use a socket wrench to remove the sequence valve rod nut shown in Figure 10 MASTER PLUNGER MASTER PLUNGER PISTON SEQUENCE VALVE PLUNGER SPRING SEQUENCE VALVE PLUNGER SEQUENCE VALVE ROD NUT O RING D Figure 10 Sequence Valve Pl
7. SHELL 030 TYP 669223 Rev 1 5 1 7 Bleeding the Cylinder Before the mast is put in service air must be bled from the hoist cylinder according to the following procedures Do not use bleed screw on side of cylinder shell to bleed air 1 Assemble the forks or attachment onto the mast carriage 2 Without a load on the forks extend and retract the mast through one complete cycle 3 With the mast fully lowered check the truck hydraulic tank and top off if necessary 4 Extend and retract the mast completely at least four more times This action will force air in the system to the center cavity under the bleed fitting Leave the mast in the extended position 20 30 minutes prior to lowering and bleeding 5 Extend the carriage to about 10 inches off the ground 6 The Customer User Kit 668677 includes a metal hex tube wrench 661507 and a length of clear plastic hose 661922 Slide the plastic hose through the hex tube wrench and onto the bleed fitting located at the top of the cylinder crosshead Put the other end of the tube in a container to collect oil See Figure 18 CLEAR PLASTIC HOSE 661922 HEX TUBE WRENCH Figure 18 Hoist Cylinder Bleed Kit CAUTION Stay clear of the carriage and the forks or attachment 7 Open the bleed fitting no more than 1 4 turn with the hex tube wrench The weight of the carriage will force air and hydraulic oil out of the cylinder through the bleed fitting 8 If the carri
8. plunger wiper A piston assembly is threaded onto the base of the master and stave plungers Both cylinder pistons have a Bi Element seal assembly to provide a high pressure hydraulic seal between the piston and the plunger or shell IMPORTANT During cylinder operation the pressure pro duced in the cavity between the cylinder shell and the master plunger is greater than that produced at the cylinder base truck pressure Thus the seal assembly on the master plunger piston item 37 Figure 7 must be installed with the lip toward the plunger end of the cylinder The pistons also have static O ring seals to seal between the piston and the plunger or shell A synthetic bearing is installed on the master plunger piston and cast iron half rings are installed at the base of the primary plunger The master plunger piston also serves as a housing for a poppet operated check valve a relief valve and a sequence valve assembly The sequence valve assembly ensures the proper sequencing of the cylinder plungers during extension and retraction It is comprised of a spring loaded ball and seat assembly actuated by a spring cushioned plunger The sequence valve plunger is actuated by a rod The valve plunger is attached to the rod at the rod s lower end The rod extends through a square hole in the base of the primary plunger and into the central cavity of the slave plunger and terminates near the top of the slave plunger A spacer i
9. with or without load is in a raised position f Low battery charge g Low pump volume h Low oil level i Insufficient hydraulic tank capacity or d Adjust or repair as necessary f Charge battery g Install accumulator h Fill oil reservoir and bleed cylinder i Install larger tanks or baffles baffles Improperly sequencing mast cylinder Adjust sequence rod k Other k Contact Cascade Corporation 669223 Rev 1 sin D Service 5 1 Hoist Cylinder 5 1 1 Description The hoist cylinder shown in Figure 7 is a three stage displace ment cylinder It consists of a shell with three hollow telescop ing plunger assemblies The slave plunger smallest diameter telescopes into the primary plunger and the primary plunger telescopes into the master plunger largest diameter The shell master plunger and primary plunger are threaded at one end to receive retainers A retainer is threaded into the shell to limit the stroke of the master plunger A retainer is threaded onto the master plunger which secures an aluminum bearing to limit the stroke of the prirnary plunger A retainer is threaded onto the primary plunger which secures an aluminum bearing to limit the stroke of the slave plunger Each retainer has a Bi Element seal assembly to provide a high pressure hydraulic seal between the retainer and its adjacent plunger In addition each retainer has a static non moving O ring assembly and a
10. 7 966 058 007 3020 997 1027 90 7 Chain length is measured from hole center to hole center of end links CHAIN LENGTH amp 0300 9710 ole ole ol ole 4 669223 Rev 1 sin D Service 5 4 3 Mast Chain Adjustment The mast chain should be adjusted so that when the unloaded mast is fully lowered all upright channels are even with each other at the bottom within 1 8 inch See Figure 42 1 To adjust raise the mast until the mast chain adjusting nut is just above the outer upright See Figures 42 and 43 Tighten or loosen the adjusting nut to adjust one chain to achieve the equal dimension Adjust the other mast chain until equal tension is achieved HOIST CHAIN ADJUSTING NUTS OUTER INTERMEDIATE UPRIGHT INNER INTERMEDIATE UPRIGHT EQUAL 1 8 inch HOIST CHAIN ADJUSTING NUTS EQUAL 1 8 inch OUTER UPRIGHT EQUAL 1 8 inch Figure 42 Mast Chain Adjustment 2 Lower the mast and check your adjustment Al channels should be even with each other at the bottom within 1 8 inch 5 4 4 Carriage Chain Adjustment The carriage chains should be adjusted so that when the unloaded mast is fully lowered the carriage is positioned as shown in Figure 44 669223 Rev 1 CHAIN ADJUSTING NUT COTTER PIN CHAIN ANCHOR Figure 43 Mast Chain Anchor To adjust the carriage chains 1 Locate the adjusting nuts on the carriage sideplates 2 Adjust one carriag
11. ARNING Failure to install the correct brackets and crossmembers can result in mast structural failure bodily injury and loss of warranty TILT CYLINDERS TRUCK COWL FRONT VIEW SIDE VIEW Figure 1 Determining Mounting Bracket and Crossmember Location 2 669223 Rev 1 mm 2 Installation Instructions 2 2 Mounting Bracket Installation Cont 1 Mounting bracket and crossmember welding must be performed by a qualified welder only using the following procedures a b Disassemble the outer channel from the mast prior to welding See Section 5 3 6 for disassembly procedures Clean all surfaces to be welded Remove paint oil grease and other contaminants Locate the mounting brackets and crossmembers on the mast channels Clamp in place with a C clamp Protect the mast channel inner surfaces from weld splatter Use only 7018 low hydrogen electrodes AWS E7018 5 32 diameter Electrodes must be in good condition Bake as required to remove all moisture per electrode manufacturers procedures Use DC reverse polarity or an AC welding machine Set the amperage at 175 amps Preheat the upright and mounting bracets to 100 F Montior with a Tempstick crayon Do not weld in a drafty area WARNING Weld areas that will be vertical seams when the mastis standing upright only DO NOT WELD ANY HORIZONTAL SEAMS Weld areas that will be vertical seams when the mast is standing upright onl
12. MARY PLUNGER SLAVE PLUNGER CHECK VALVE CHECK VALVE MASTER SEATED PLUNGER SEQUENCE VALVE BALL UNSEATED ADJUSTING NUT SPACER SEQUENCE VALVE ACTUATING ROD SEQUENCE VALVE BALL UNSEATED SEQUENCE OIL MASTER PLUNGER SEQUENCE VALVE PLUNGER SHIFTED a CHECK UPWARD VALVE SEATED CHECK VALVE MASTER PLUNGER PISTON SEQUENCE VALVE BALL MASTER PLUNGER UNSEATED RELIEF VALVE 669223 Rev 1 11 sim D Service 5 1 5 Cylinder Removal 1 c Make sure the hoist cylinder is fully lowered AUTION Always lubricate new seals O rings and wipers with petroleum jelly or hydraulic oil prior to installation WARNING Never work on the mast with a load on the forks or attachment nor while BLEED FITTING TORQUE TO 25 27 FT LBS PRIMARY PLUNGER RETAINER TORQUE bol EAR roe WIPER NYLON RINGe SEAL O RING i TO 100 150 FT LBS an anyone is near the lift truck S IS S WIPER Ja ALS control handles PRIMARY PLUNGER Sj N S NYLON RING R N SEAL 2 Loosen the bleed screw no more MASTER PLUNGER R WES than required to bleed off any hy RETAINER TORQUE is INN BACK UP RING draulic pressure that may remain in TO 150 200 FT LBS S O RING i i N N the cylinder The bleed screw is AR located on the side of the cylinder MASTER PLUNGER f WIPER shell just below the larg
13. TE UPRIGHT Figure 48 Chain Replacement 4 Pull the plate and old chain out of the channel As you pull the plate out feed the new chain through keeping it taut 5 Remove the old chain from the plate and install the new chain using new cotter pins The roller can be replaced at this time if necessary 6 Install the roller plate and torque the capscrews to 55 60 ft Ibs 7 Install the chain end to the chain anchor using new cotter pins Adjust for tension after installing both new chains WARNING When working on the other side UPRIGHT make sure the C clamp is in position on the side you have just completed 669223 Rev 1 a sam Standard Labor Times 6 1 Determining Labor Times Standard Labor Time is the average time required to perform each operation described in Section 5 Service Each Standard Labor Time is identified by the Service Section paragraph number and title that corresponds to that operation The Standard Labor Times are based on the assumption a qualified serviceman is working on a reasonably clean mast with adequate tools We realize the actual time required to perform an operation may occasionally be greater than that listed especially if a first time serviceman tacks the needed tools or if a bolt is frozen But considering all factors that can affect the job Cascade can only honor warranty labor claims based on these carefully evaluated averages We strongly urge servicemen
14. UNGER Nylon ring Wiper Wiper Nylon ring Seal Slave plunger retainer O ring Lowering control valve Primary plunger half ring Seal Nylon ring Setscrew Check valve O ring Plug Spring Slave plunger piston Back up ring O ring Bleed fitting SLAVE PLUNGER sam D Service 10 5 1 4 Cylinder Operation Figure 8 View A The entire cylinder assembly is filled with oil at the beginning of its lifting sequence Since the cylinder is fully lowered the check valve is unseated by its actuating poppet in contact with the base of the cylinder shell Since the sequence valve ball is seated oil in the cavity between the cylinder shell and the master plunger referred to as sequencing oil is trapped The master plunger is thus prevented from moving As a result when oil from the truck enters the cylinder through the intet port it flows through the angled port in the master plunger piston and through the unseated check valve to the primary and slave plunger cavity View B Since the area of the primary plunger piston is greater than that of the slave plunger the primary plunger begins to extend As the primary plunger reaches the end of its stroke its base contacts the spacer at the top of the sequence valve actuating rod The actuating rod thus shifts upward pulling the sequence valve plunger upward with it The sequence valve plunger unseats the sequence valve ball The point at which this event occurs ma
15. acity of the mast the truck relief valve should be set to relieve at the pressures indicated in the chart This chart also indicates the hose and fitting size to use between the truck control valve and the mast cylinder hose Cascade Minimum Maximum Hose Fitting Viewmast Relief Relief Sizes Thread il Pressure Pressure Sizes scana moser more wa ae WARNING For proper truck stability or to prevent interference tilt restriction may be required Contact the truck manufacturer or one of the Cascade Service Departments listed on the back cover for the specific tilt modification required Note To achieve the proper tilt restriction contact the lift truck manufacturer or your truck service manual IMPORTANT Standard Viewmast li masts are com patible with SAE 10W petroleum base oil per Mil Spec MIL 0 5606 or MIL 02104 B only Use of synthetic or aqueous base hydraulic oil is not recommended If fire resistant hydraulic oil must be used contact one of the Cascade Service Departments listed on the back cover 2 2 Mounting Bracket Installation If itis necessary to install mounting brackets and crossmembers to fit your truck consult with the nearest Cascade Service Department listed on the back cover You must supply dimensions A through F shown below in Figure 1 Failure to install the correct brackets and crossmembers can result in mast structural failure bodily injury and loss of warranty W
16. age reaches the bottom of its travel before all the air is bled close the bleed fitting and repeat Steps 5 through 7 9 When the oil stream no longer contains air bubbles close the bleed fitting and torque to 25 27 ft Ib 10 Top off the truck hydraulic tank with clean fresh oil 11 Extend and retract the mast completely NOTE Normal mast bounce is approximately 2 between the uprights or a total of 6 at the carriage If mast bounce exceeds this repeat steps 2 through 10 15 sn D Service 16 5 1 8 Cylinder Sequencing WARNING Never work on the hoist cylinder with a load on the forks or attachment or while anyone is near the lift truck control handles Before putting the mast in service operate the mast through a few complete cycles and check for proper sequencing The hoist cylinder is comprised of three plungers primary master and slave See Figure 19 When the mast is actuated from the fully lowered position the primary plunger should extend from within the master plunger to the end of its stroke Then the master and slave plungers should extend simultaneously to the end of their strokes THE PRIMARY PLUNGER SHOULD EXTEND FIRST THEN THE MASTER AND SLAVE PLUNGERS SHOULD EXTEND SIMULTANEOUSLY SLAVE PLUNGER PRIMARY PLUNGER PRIMARY PLUNGER MASTER PLUNGER CYLINDER SHELL Figure 19 Sequence of Hoist Cylinder Plunger Extension When the cylinder is lowered from the fully ext
17. aining the check valves in the pistons See Figure 12 The washer and setscrew are staked in one place Unstake them and remove the valves WASHER STAKE ONE tS Eni EE CHECK VALVE PLUNGER PISTON POPPET SLAVE PLUNGER PISTON SETSCREW Figure 12 Check Valve Assembly 9 10 11 Remove the relief valve located on the bottom of the master plunger piston See Figure 13 It is recommended that the relief valve be replaced Thoroughly clean the piston retainers and all loose parts Check the plunger inside diameter retainers and pistons for any nicks or burrs Remove burrs and minor nicks with an emery cloth or butterfly NOTE Minor nicks are those that will not bypass oil when under pressure BACE MASTER PLUNGER PISTON BALL SPACER SPRING PLUG oS RELIEF VALVE Figure 13 Sequence Valve Ball Assembly and Relief Valve 13 sin D Service 14 5 1 6 Cylinder Disassembly Service and Reassembly Cont 12 Lubricate the new seal kit with STP and install the seals 17 Place the 4 50 O D retainer loader over the end of the according to Figure 9 13 Install the new O rings on the check valves and reinstall the check valve components on the pistons See Figure 12 IMPORTANT Make sure you reinstall the check valve with the arrows stamped on the valve body pointing as Shown in Figure 12 14 Install the sequence valve rod spring spacer and adjusting nut on the rod if
18. connecting the tilt cylinders to the mast make sure the cylinders bottom evenly Adjust the tilt cylinders as required to prevent the mast from racking during tilting Refer to your truck service manual for procedures LIFT TRUCK HOSE FROM TRUCK CONTROL VALVE 3 Connect the tilt cylinders to the cylinder anchor brackets 4 Before connecting the truck hose to the mast cylinder hose connect the truck hose to the truck return fitting and actuate the control valve to flush the system with hydraulic oil 5 Connect the lift truck hose to the cylinder hose on the mast See Figure 4 The lift truck hose can be SAE 100 R2 or R9 NOTE Use as few fittings as possible and always use 45 elbows instead of 90 elbows Keep the hose lengths to a minimum Avoid sharp bends or pinch points when rauting the hose Figure 4 Cylinder and Truck Hose Connection 2 4 Operational Inspection and Adjustments CAUTION The factory set adjustments may not be correct for your truck Check each of the following before using the mast for the first time O Bleed air from the mast cylinder as described in Section 5 1 7 Do not use bleed screw on side of cylinder shell O The hoist cylinder must sequence as described in Section 5 1 8 O Inspect the chains and check chain tension as described in Section 5 4 1 O Check crosshead rollers for proper adjustment as described in Section 5 1 9 o Inspect the cylinder hose
19. corrosion loosen them with SAE 30 oil or penetrating chain anchor on the carriage weldment See Figure 22 oil If they cannot be loosened or if tight joints are caused by bent pins or plates or by peened plate edges 4 Power the hoist cylinder to extend until the inner upright replace both strands of chains channel clears the carriage load rollers Back the truck away from the carriage If the hoist cylinder is inoperative e Check for protruding or turned pins Replace both raise the inner upright channel with a hoist crane or some strands of chains other suitable lifting device Check for chain side wear If pins and outside plates show signs of wear check for misalignment of sheaves anchors or other components Correct the misalignment If wear is excessive replace both strands of chains Check for worn broken or misaligned chain anchors CARRIAGE Replace or adjust as required UPRIGHT 5 2 4 Carriage Installation with the mast installed on the truck 1 Make sure the inner upright channel members are lubricated with chassis lube or Kendall SR 12X Cascade part number 599474 See Figure 24 CARRIAGE STOP BAR CHANNEL SECTION W UPPER CARRIAGE STOP SCREW FOR REASSEMBLY TIGHTEN TO A TORQUE OF 100 110 FT LBS CARRIAGE FORK BARS LOAD ROLLER LUBRICATE ONLY WHERE INDICATED BY THE HEAVY LINE FOR THE FULL LENGTH OF EACH Figure 23 Carriage Stop Screw Assembly UPRIGHT i i Figur
20. crews located on each side of the upright at the bottom limit the outer inter mediate upright assembly wheh the mast is extended and titted back These blocks are movable to provide the tightest fit A cushion is attached to the outer inter mediate upright lower crossmember to cushion the inner intermediate upright when the mast is fully lowered 669223 Rev 1 The inner intermediate upright assembly telescopes within the outer intermediate upright assembly A pair of shim adjustable load rollers is attached to canted stub shafts at the top of the upright and a pair is attached at the bottom of the upright In addition a pair of chain sheaves is located on the back side of the upright to provide a rolling surface for the hoist chain A pair of adjustable chain anchors is located near the bottom of the upright The hoist cylinder rests on a cradle which is integral with the lower crossmember of the inner intermediate upright assembly Inner Upright Assembly The inner upright assembly telescopes within the inner intermediate upright assembly A pair of shim adjustable load rollers is attached to canted stub shafts near the bottom of the assembly A pair of adjustable chain anchors is located on the middle crossmember of the inner upright assembly to which the hoist chains are attached In addition a pair of non adjustable chain anchors is located on the middle crossmember to which the carriage hoist chains are attached 5 Mast Operat
21. crosshead sheaves Remove the snap ring that retains the crosshead assembly to the hoist cylinder rod and remove the crosshead With the lifting device secured to the sling lift the cylinder from the mast For cylinder service refer to Section 5 1 5 3 6 Upright Disassembly with mast removed from the truck Refer to Figure 32 A WARNING Disassembly of the mast up rights with the mast mounted on the truck is NOT recommended 10 Remove the carraige and hoist cylinder Refer to Sections 5 34 and 5 3 5 Manually extend the mast until the mast chain anchors on the inner upright are exposed Remove the pins that secure the mast chains to the chain anchors and remove the chain anchors from the inner upright Back out the stop screws also located on the inner upright Roll the inner upright toward the top of the mast until the inner upright load rollers are exposed by the cutouts at the top of the inner intermediate upright Use sling and hoist or some other appropriate lifting device to lift the inner upright out of the inner intermediate upright and set it on a work surface Manually extend the inner intermediate upright unti the hoist chain anchor blocks are exposed Remove the pins that secure the hoist chains and remove the hoist chain anchors Roll the inner intermediate towards the top of the mast until the load rollers are exposed at the cutouts at the top of the o
22. d at the top of the outer upright They are looped around the sheaves on the outer inter mediate upright and attach to the inner intermediate upright The hoist cylinder rests on a cradle which is integral with the lower cross member of the inner intermediate upright Figure 28 Mast operation 669223 Rev 1 CARRIAGE CHAIN B FREE LIFT When the hoist cylinder is extended from the fully lowered position the carriage is drawn upward within the inner upright at a speed twice that of the hoist cylinder The free lift ends when the crosshead lifting pad contacts the upper crossmember of the inner upright T MAST CHAIN CARRIAGE CHAIN MAST CHAIN INTERMEDIATE OUTER INTERMEDIATE UPRIGHT C FULLY EXTENDED _ Continued hoist cylinder extension causes the inner upright and carriage to be drawn upward The extending inner upright causes the mast chains to draw the inner intermediate and outer inter mediate uprights upward The speed of the extending inner intermediate upright is two thirds that of the inner upright The speed of the extending outer inter mediate upright is one third that of the inner upright This phase of mast extension continues until the mast is fully extended The lowering of the mast is a reversal of extension 21 min D Service 22 5 3 2 Crosshead Description The crosshead shown in Figure 29 is attached to the top of the hoist cylinder Rollers attached to the cr
23. e Install a pair of load rollers and use an equal number of shims on each side of the assembly within one shim A standard shim 631881 is 0 030 inch thick To check the clearance pry between the upright and load roller as shown below so the opposite load roller is tight against the upright Measure the clearance for the pair of load rollers at the XXX shown Repeat for each pair of rollers PRY HERE MEASURE CLEARANCE HERE 030 MAXIMUM LOAD ROLLERS Measurements typical for each pair of rollers Figure 39 Roller Clearance 669223 Rev 1 5 3 13 Hose Tracking Adjustment Loosen the connector fitting at the cylinder port shown in Figure 40 Position the cylinder hose to track in the center of the rollers then tighten fittings Extend the mast above freelift Loosen the hose clamp atthe top of the mast Adjust the tension on the hose The hose must form a smooth continuous curve over the rollers without contacting the bracket TOO TIGHT TOO LOOSE HOSE TENSION ADJUSTED PROPERLY FORA CONTINUOUS SMOOTH CURVE OVER ROLLERS AND NO CONTACT WITH BRACKET HOSE CLAMP CYLINDER CYLINDER HOSE ADJUST L TENSION BRACKET Figure 40 Quad Lift Cylinder Hose 27 sein D Service 5 4 Hoist Chains 28 5 4 1 Inspection and Tension Each pair of hoist chains have been factory lubricated using heat and pressure to force the lubricant thoroughly into the chain links Avoid removal or contamination of th
24. e 24 Mast Lubrication typical 5 2 3 Cleaning and Inspection Mo Me L bricatian typical 1 Remove the load rollers and thoroughly clean the carriage 2 Assemble the load rollers onto their stub shafts using an assembly with cleaning solvent Note the number of shims appropriate number of shims See Figure 22 The shims on the rollers so that an appropriate number of shims can should be installed to provide a total clearance no looser be installed during reassembly than 0 030 inch at the tightest point throughout the travel 2 Inspect the rollers for excessive wear or damage Roller of the carriage Refer to Section 5 3 12 for load roller assemblies with visible flat spots or cracks should be shimming replaced 3 With a sling position the carriage assembly in place on 3 Inspect the roller bearings by turning the rollers on their blocks in front of the mast shafts Roller assemblies with roughness or noticeable restrictions to turning should be replaced 4 Raise the inner upright sufficiently for the carriage load rollers to be fitted within the inner upright channels Lower 4 Inspect all welds between the carriage side plates and the the inner upright over the carriage carriage fork bars If any weld seams are cracked replace the carriage 4 k 5 Lift the carriage the full length of the inner upright channel and check side play and freedom of movement Adjust load 5 Inspect the stub shafts If they are damaged or if
25. e chain see Figure 45 to achieve the correct carriage position when fully lowered 3 IN 5 IN UNDERCLEARANCE A 2 IN UNDERCLEARANCE OR 6 IN UNDERCLEARANCE A 3 IN Figure 44 Correct Carriage positions when Mast is fully lowered 3 Adjust the other carriage chain to achieve equal chain tension CARRIAGE CARRIAGE CHAIN ADJUSTING NUT Figure 45 Carriage Chain Anchor 29 sim D Service 5 4 5 Outer Upright Chain Removal and Replacement A WARNING Replace one chain at a time 1 Raise the mast until the chain anchors on the inner inter mediate are exposed See Figure 46 Attach a C clamp to 2 Remove the chain from the chain anchor and connect the end of the new chain to the end of the old chain with mechanics wire See Figure 48 the side of the mast you are not workjng with See Figure 3 Remove the 5 capscrews retaining the roller plate to the 46 below INNER INTERMEDIATE UPRIGHT CHAIN ANCHOR Figure 46 Exposing the Chain Anchors WARNING Attach a C clamp to the side of the mast you are not working with See Figure 47 OUTER INTERMEDIATE UPRIGHT Figure 47 Secure the Mast with a C clamp 30 outer upright See Figure 48 INNER INTERMEDIA OUTER IE INTERMEDIATE UPRIGHT CHAIN ANCHOR CONNECT CHAIN ROLLER PLATE TOGETHER WITH i CAPSCREW MECHANICS WIRE FOR REASSEMBLY TORQUE TO 55 60 FT LBS OUTER UPRIGHT OUTER UPRIGHT OUTER INTERMEDIA
26. e mast is equipped with a hose reel block under the mast sufficiently to clear the reel or remove the reel TRUCK AUXILIARY HOIST CYLINDER HOSE Figure 30 Rear View of Mast Assembly 5 3 4 Carriage Removal with mast removed from the truck Connect a sling to the carriage and secure it with a suitable lifting device Remove the pins that secure the carriage hoist chains to the chain anchors located on the carriage weldment See Figure 31 l NVIV I CARRIAGE HOIST CHAIN Figure 31 Carriage Chain Anchor 3 Move the carriage towards the top of the mast to gain access to the carriage stop screw See Figure 23 Use an allen wrench to back the screw out enough to clear the stop bar on the carriage With the lifting device secured to the carriage remove the carriage out the bottom of the mast assembly Remove the carriage hoist chains from the inner upright middle crossmember For carriage cleaning and inspection refer to paragraph 2 3 669223 Rev 1 sam D Service 5 3 5 Crosshead and Cylinder Removal with mast removed from the truck Remove the cylinder hose connected near the middle of the hoist cylinder Be prepared to collect oil Connect a sling around the hoist cylinder and secure it with a suitable lifting device Remove the pad at the top of the cylinder crosshead See Figure 29 Pull the carriage hoist chains through the
27. e piston re el ul NYLON RING tainer Tighten the screw securely a SHELL RETAINER SI i EG SEAL 0 3 Remove the carriage according to TORQUE TO IS NI BACK UP RING the removal procedures specified in 250 300 FT LBS R the carriage section 5 2 N Aj O RING d at the top of the er FLG st N peo y 7 rede EN LEN TORQUE TO 5 Remove the snap ring that retains 95 100 FT LBS VY 20 22 IN LBS the crosshead assembly to the hoist DO NOT USE cylinder rod TO BLEED 6 Remove the crosshead CYLINDER 7 Wash the cylinder assembly with O RING solvent to remove any foreign mate rial on the shell Especially clean around the plunger retainers Blow dry with compressed air If you are going to replace the seals O rings and or wipers in the plunger retainers only you can doso with the cylinder in place on the mast according to the following procedures refer to Figure 9 a Unthread and remove all three retainers Do not remove any of the cylinder plungers b Replace the seals O rings and or wipers in the retainers as required Carefully note their positions see Figure 9 Avoid excessive stretching of the O ring on the large diameter retainer c Install the retainers as described in section 5 1 6 steps 17 18 and 21 Torque all retainers as shown in Figure 9 If you are going to replace com ponents in addition to those de scribed above the cylinder must be removed from the mast Continue
28. e upright near the top of the outer upright as shown in Figure 34 Loop chains around the chain roller located near the bottom of the outer intermediate upright Keep the chain taut as you slide the uprights together using new cotter pins Install the plates to the outer upright Tighten the capscrews to a torque of 55 60 ft lbs Connect chains to the outer intermediate upper cross member using new cotter pins See Figure 32 OUTER UPRIGHT R INTERMEDIATE OLLER PLATE UPRIGHT ROLLER PLATE INNER INTERMEDIATE UPRIGHT CHAIN CHAIN ANCHORS SHEAVES CHAIN ANCHORS Figure 34 Upright Reassembly 8 Use a sling and hoist to position the inner intermediate upright at the top of the two assembled uprights See Figure 34 Loop chains around the chain sheaves on the inner intermediate upright Keep the chains taut as you lower the upright into the outer intermediate and slide them together Adjust load roller clearance no greater than 030 inch at the tightest point of member travel Refer to Section 5 3 12 10 Connect the loose end of chains to the inner intermedi ate upright chain ON anchors See Figure 34 669223 Rev 1 Use a sling and hoist or some other appropriate lifting 11 Use a sling and hoist to position the inner upright over the three assembled uprights 12 Lower the inner upright into the inner intermediate and slide the uprights together Adjust load r
29. ended position the slave and master plungers should completely lower simultaneously then the primary plunger should lower Depending upon mast lifting height the plungers may not completely retract into the cylinder shell The sequencing of the hoist cylinder is controlled by an internal sequence valve If the plungers do not sequence properly then adjust the sequence valve as follows CAUTION Before proceeding make sure the cylinder is fully lowered 1 Remove the bleed fitting at the top of the slave plunger 2 Insert a 3 16 inch long handle hex socket wrench 662611 into the bleed hole and engage the adjusting nut 3 Turn the adjusting nut counterclockwise until it bottoms The nut is crimped slightly to prevent free turning so it may be a little stiff Don t force the nut after it bottoms See Figure 20 MAST I BEAM FLANGE CROSSHEAD ASSEMBLY gt HEX SOCKET WRENCH C 662611 lg DON T FORCE THE NUT AFTER IT BOTTOMS Figure 20 Turning the Adjusting Nut Counterclockwise Turn the adjusting nut clockwise two full turns to provide an initial adjustment Remove the wrench and install the bleed fitting Operate the cylinder with about a half capacity load to check for proper sequencing f the slave plunger extends fast and the master plunger does not extend at all the 5 sequence valve is not opening Turn the adjusting nut clockwise one turn only Reinstall the bleed fitting and ret
30. est Continue this process until the cylinder sequences properly See Figure 19 NOTE The adjusting screw has a capacity of approximate ly 13 turns 6 As soon as the cylinder sequences properly turn the adjust ing nut clockwise one more turn only to assure positive adjustment 7 Extend and retract the cylinder completely If it does not operate smoothly or if it appears to be spongy bleed air from the cylinder as specified in paragraph 5 1 7 5 1 9 Crosshead Adjustment The sum total clearance between the tire shoulders and the Mast Beam must be 060 as shown in Figure 21 If one tire is touching the l Beam which is acceptable the other tire should have 060 clearance Adjust the Crosshead to attain the clearance as follows 1 Loosen the hex locking nut See Figure 21 2 Use a hex socket wrench to turn the shaft to attain the clearance shown in Figure 21 3 Tighten the hex locking nut to a torque of 30 35 ft lbs CAUTION Insufficient tightening can result in the tire loosening and the crosshead jamming between the Beams MAST I BEAM FLANGE CAUTION The tire should never touch the guide at these points Figure 21 Crosshead Adjustment 669223 Rev 1 sem D Service 5 2 Carriage 5 2 1 Description The carriage shown in Figure 22 is the structure to which hook type forks or the attachment is attached The carriage travels within the channels of the mast inner upright on six
31. estore the mast to normal operating condition NOTE Any time oil is added to the truck reservoir check the hoist cylinder for possible entrapment of air Refer to Section 5 1 7 Q PROBLEM Hoist cylinder doesn t lift load or won t move PROBLEM CAUSE SOLUTION Empty a Plugged inlet hose a Unplug hose or replace b insufficient oil b Check truck hydraulic system for correct oil level in tank defective pump or pump drive leaks in the lines or disconnected control valve linkage Repair or replace as necessary c Bent or jammed plungers c Replace defective plungers WARNING Extreme care should be used when working on a unit when the carriage with or without load is in a raised position Loaded a Plugged piston check valve master may a Unplug check valve or replace Mis sequencing Empty or light load Primary up 1st Slave up 2nd Master up 3rd if at all Loaded Primary up ist Master Slave 2nd Slave stops short of full lift move b Reversed piston check valve master may move c Truck relief setting low d Over capacity b reverse direction of check valve arrow up c Raise truck relief setting to specified level Do not exceed 2200 PSI d Reduce load to specified capacity e Mechanical bind due to bent plunger s bad rollers and or bad cross head rollers e Remove mechanical bind by replacing freeing plungers and rollers A WARNING Ext
32. f the speed that the primary plunger extended However since the master and slave plungers extend simultaneously at the same speed the combined speed of the master and slave plungers equals the speed of the primary plunger As a result the cylinder assembly extends and lowers at a constant speed throughout its complete sequence of operation A relief valve shown in View C is included in the master plunger piston if the pressure of the sequencing oil should exceed a value preset by the relief valve the valve will unseat to allow pressure to be relieved to the base of the cylinder This could occur each time the cylinder is extended or when excessive pressure build up of the sequencing oil such as would occure when the cylinder is at rest is heated by ambient air A check valve is located in the base of the slave plunger piston The check valve allows release of trapped oi which could occur is oil leaks past the seal and gets caught between the piston and retainer The lowering of the cylinder assembly is a reversal of exten sion SLAVE PLUNGER PRIMARY PLUNGER MASTER CHECK VALVE UNSEATED SEQUENCE VALVE BALL SEATED CHECK VALVE POPPET Figure 8 Hoist Cylinder Sequence of Operation 669223 Rev 1 sin D Service SLAVE PLUNGER VIEWC SLAVE PLUNGER PRIMARY PLUNGER MASTER PLUNGER PRIMARY PLUNGER VIEW B FULLY EXTENDED SLAVE PLUNGER PRI
33. f the upper crossbar SEE TRUCK NAMEPLATE e FOR TRUCK CAPACITY NOTE OS H A PROVIDES MODIFICA TIONS AND ADDITIONS WHICH AFFECT CAPACITY AND SAFE OPERATION SHALL NOT BE PERFORMED BY THE CUSTOMER OR USER WITHOUT MANUFACTURER S PRIOR WRITTEN APPROVAL CAPACITY OPERATION AND MAINTENANCE IN STRUCTION PLATES TAGS OR DECALS SHALL BE CHANGED ACCORDINGLY cascade VIEWMAST SERIAL NUMBER er Soe te WEIGHT i CATALOG fe Sie Sas O E M Pen NUMBER NUMBER ADDITIONAL EQUIPMENT ARRANGEMENT MAXIMUM HYDRAULIC PRESSURE S IN Ps THE RATED CAPACITY OF THIS MAST IS LOAD POUNDS LOAD CENTER INCHES LIFT iNCHES RATED CAPACITY OF TRUCK AND MAST COMBINATION IS A RESPONSIBILITY OF THE ORIGINAL TAUCK MANUFAC TURER amp MAY BE LESS THAN SHOWN CONSULT TRUCK NAMEPLATE BACKREST CONTROL VALVE AT mr FOR SERVICE AND PARTS LITERATURE CONTACT cascade corporation 503 666 1511 PORTLAND OREGON U S A WARNING Do not install a Quad Viewmast II on a truck with a rated capacity greater than the capacity shown below CASCADE QUAD VIEWMAST II TRUCK CAPACITY AT 24 INCH LOAD CENTER 6000 Pounds Rated capacity of the truck mast combination is a responsibility of the original truck manufacturer and may be less than shown on the mast nameplate Consult the truck nameplate 669223 Rev 1 sm 2 Installation Instructions 2 1 Truck System Requirements To achieve the maximum lifting cap
34. for correct tension and tracking over the rollers Refer to Section 5 3 13 4 669223 Rev 1 swim I Periodic Maintenance 3 1 3 2 For proper operation and an extended service life your Viewmast II should be inspected and serviced regularly as part of your normal lifttruck maintenance schedule according to the following outlines The recommended inspection intervals are for masts operating under normal conditions If the mast is operating in severe Daily Inspection Perform the following at the beginning of each work shift O Extend the carriage a few inches off the ground and make sure the carriage chains are under equal tension Refer to Section 5 4 1 O Extend the masttoits full height to make sure the hoistcylinder sequences properly The primary plunger should extend fully then the master and slave plungers should extend together Make sure the mast channels and carriage extend freely without binding Refer to Section 5 1 8 C1 While the mast is extended inspect the upright channels for proper lubrication Refer to Section 5 3 8 step 1 With the mast extended make sure the hoist chains are under equal tension Refer to Section 5 4 1 conditions or very corrosive atmospheres these operations should be performed more frequently WARNING Never work on the mast with a load on RANE n A the forks or attachment or while anyone is near the lift AA truck control handles O Lower the mast and make s
35. haft Roller and sheave assemblies with rough ness or noticeable restrictions to turning should be replaced If they do not turn freely or are damaged or excessively worn replace the roller assemblies Torque the roller nut to 30 35 ft Ibs Inspect the stub shafts An assembly with a damaged stub shaft or a cracked stub shaft base should be repaired or replaced Refer to Technical Bulletin 126 for stub shaft replacement Inspect the cushions on the lower crossmember of the upright channels If the cushions are damaged crushed or missing replace them Inspect the crosshead lifting pad If it is damaged or crushed replace it Inspect the hoist chains If inspection reveals that one strand of a pair of chains requires replacement both strands of the pair should be replaced e Check for rust and corrosion e Check for cracked side plates If you find cracked side plates replace both strands of chains e Check for tight joints If tight joints are caused by rust or corrosion loosen them with SAE 30 oil or penetrating oil If they cannot be loosened or if tight joints are caused by bent pins or plates or by peened plate edges replace both strands of chains e Check for protruding or turned pins Replace both strands of chains e Check for chain side wear If pins and outside plates show signs of wear check for misalignment of sheaves anchors or other components Correct the misalign ment If wear is e
36. heck for worn broken or misaligned chain anchors Replace or adjust as required 5 4 2 Measuring Chain Stretch Regular inspection and lubrication of the hoist chains will increase their service life and reduce downtime If the hoist chains stretch beyond the recommended amount they should be replaced in pairs Chain stretch can be measured with chain wear scale 661923 included with the Customer User Kit Measure the chains as shown in Figure 41 according to the instructions printed on the chain wear scale without a load on the carriage 1 To check the carriage hoist chains raise the carriage a few inches off the ground to put tension on the chains 2 Tocheck the mast hoist chains the mast must be extended sufficiently to expose the chains CHAIN WEAR SCALE 661923 NEW CHAIN STRETCHED CHAIN Figure 41 Check Chain Stretch If the chains are removed from the mast you can check chain stretch without using the chain wear scale If the overall length of a hoist chain exceeds 103 of its original length the chains should be replaced in pairs The following table provides the HOIST CHAIN TABLE Overall Retracted Channel Hoist inches Length of Chain When New Length of Carriage Chain Length of Hoist Chain When New inches 103 Limit length of the hoist chains when new and their limits of stretch inches When New 103 Limit inches 64 9 842 896 f 877 904 7
37. ion Figure 28 illustrates diagrammatically the operation of the Quad Viewmast 19 min D Service NOTE Upright stub shafts are replaceable per Technical Bulletin 126 INNER INTERMEDIATE UPRIGHT INNER UPRIGHT Figure 27 Exploded View of Mast Upright Assembly 20 OUTER UPRIGHT OUTER INTERMEDIATE UPRIGHT p gt gt gt ARON Eana CWOMNAMAWN Shim Roller Pin Cotter Pin Stub Shaft Shoulder Bolt Capscrew Outer Upright Capscrew Lockwasher Cushion Adjustable Chain Anchor Sheave Snap Ring Bearing Block Shoulder Bolt Outer Intermediate Upright Nut Chain Anchor Block Plate Inner Intermediate Upright Inner Upright Sheave Pin Cotter Pin Capscrew Lockwasher Capscrew Lockwasher Snap Ring Non Adjustable Chain Anchors 669223 Rev 1 sim D Service 5 3 1 Upright Description Cont OUTER INNER INTERMEDIATE UPRIGHT UPRIGHT INNER INTERMEDIATE UPRIGHT OUTER UPRIGHT CARRIAGE MAST CHAIN A FULLY LOWERED The carriage chains are anchored to the inner upright They are looped over the crosshead sheaves and attach to the carriage Mast chains are anchored at the top of the outer intermediate upright They are looped around the sheaves on the inner intermediate and attach to the inner upright Mast chains are anchore
38. is factory applied lubricant Do not wash sand blast etch steam clean or paint the chains on initial mast installation Hoist chains must be adjusted with equal tension to ensure proper load distribution and mast operation To determine equal tension extend the unloaded mast to put the chains under tension Press the center of a strand of chain with your thumb Then press at the same place on the other chain of the pair Each chain in a pair should have equal give Do this with all hoist chains If they do not have equal tension perform the Mast or Carriage chain adjustment in paragraphs 5 4 3 and 5 4 4 Inspect the hoist chains If inspection reveals that one strand ofa pair of chains requires replacement both strands of the pair should be replaced Check for rust and corrosion e Check for cracked side plates If you find cracked side plates replace both strands of chains Check for tight joints If tight joints are caused by rust or corrosion loosen them with SAE 40 oil or penetrating oil If they cannot be loosened or if tight joints are caused by bent pins or plates or by peened plate edges replace both strands of chains e Check for protruding or turned pins Replace both strands of chains Check for chain side wear If pins and outside plates show signs of wear check for misalignment of sheaves anchors or other components Correct the misalignment If wear is excessive replace both strands of chains C
39. lia Tel 03 543 4344 Cable Casmel Cascade GmbH Klosterhofweg 52 4050 M nchengladbach 3 B R Deutchland Tel 02166 602091 Telex 852812 casc d Cascade UK Ltd 15 Orgreave Crescent Dore House Industrial Estate Handsworth Sheffield 513 9NQ England Tel 0742 697524 5 6 7 Telex 547254 cascsh g Cascade Africa Pty Ltd P O Box 625 15 Power Street Isando 1600 South Africa Tel 011 36 5611 2 3 4 5 Te Ac 960 8 8869 P N 669223 R 1
40. lying horizontally 1 Assemble the carriage load rollers onto their stub shafts 4 Roll the carriage the full length of the inner upright channel using an appropriate number of shims See Figure 36 The and check side play and freedom of movement Adjust the shims should be installed to provide a clearance no looser load roller clearances as specified in Step 1 above than 0 030 inch at the tightest spot throughout its travel h Bata to Section 5 412 for load roller shimming 5 Thread in the carriage stop screw assemblies See Figure 37 2 Make sure the carriage stop screw assemblies are retracted CAUTION Failure to thread in the stop screw assemblies See Figure 37 can cause the mast uprights to sequence incorrectly 3 Connect a sling to the carriage With a suitable lifting 6 Roll the carriage chains over the crosshead sheaves and device position the carriage in place through the bottom of connect the chains to the carriage weldment the inner upright 5 3 11 Mast Installation 1 Clean and lubricate the bearing surfaces of the base and tilt cylinder mounting brackets with wheel bearing grease 2 Lift the mast by a link chain wrapped twice around the four upper channel crossmembers 3 Position the mast into place on the lift truck and secure the base mountings 4 Connect the cylinder hose to the hoist cylinder IMPORTANT Prior to connecting the tilt cylinders to the mast make sure the cylinders bott
41. nd Reassembly 13 Bleeding the Cylinder cece cee cece cece n ence tense eres 15 Cylinder SEQUENCING ccc cece ence cece et neeneeeeenees 16 Garage E O A E aner dear 17 Desenplionrsg rssia E EE TEE 17 Carriage Removal seterio rere oa nr A a 17 Cleaning and Inspection 0c cece cece cde e ce cueeeeeunes 18 Carriage Installation cece ete e cece eee e scence eee cence 18 Carriage Chain Adjustment 0 c cece cece cee e cence eeenes 19 Mast Upright Assembly 0 ccc e cece eee e eee eeeenes 19 Upright Description ccc ccc cence c oreraa n kan ta 19 Crosshead Description cc cece cece cece eer eeneernenes 22 Mast Removal ccc ce cece reece cree tee seeeeeteneeueeues 22 Carriage Removal nauvavnenvnurenenerenenenenrnnnennener 22 Crosshead and Cylinder Removal c ce cse cece eens 23 Upright Disassembly 0 0 cc cee cece cece cece eeenreues 23 Cleaning and Inspection 0 cece cece cece rete eeeenes 23 Upright Reassembly cseccce seen eeeee eee nee econ enee 24 Crosshead and Cylinder Installation cesses 25 Carriage Installation rarrovrvnrvavnareavanvnrrearevnerer 26 Mast Installation NRE Ree andres ae dete 26 Load Roller Shimming ccccece ev eceeerececesucueuse 27 Hose Tracking Adjustment cc cc ee eee ceereuceeneucs 27
42. oller clearance no looser than 0 030 inch at the tightest point throughout the travel of the members Refer to Section 5 3 12 Connect chains to the outer upright roller plate anchors 13 Connect chains to the chain anchors on the inner upright lower crossmember 14 Manually retract the upright assembly Check for side play and freedom of movement 5 3 9 Crosshead and Cylinder Installation with uprights lying horizontally 1 Assemble the crosshead chain sheaves in place on the cross head assembly See Figure 35 CAPSCREW CYLINDER ROD p SNAP RING CROSSHEAD LIFTING PAD CROSSHEAD SHEAVE SHEAVE SNAP RING ROLLER Figure 35 Crosshead Assembly 2 Connect the carriage hoist chains to the anchors on the inner upright crossmember See Figure 32 Screw in the stop screws on the inner upright and tighten to a torque of 30 35 ft Ibs 3 Connect a sling around the hoist cylinder and secure it with a suitable lifting device 4 Position the hoist cylinder in place in the bracket at the base of the inner intermediate upright 5 Position the crosshead assembly in place at the top of the hoist cylinder Make sure the crosshead rollers fit into their guides on the inner upright channels 6 Secure the crosshead to the cylinder rod using the snap ring Refer to Figure 35 7 Install the crosshead lifting pad Refer to Figure 35 25 min D Service 5 3 10 Carriage Installation with uprights
43. om even ly Adjust the tilt cylinders as required to prevent the mast from Tracking 5 Connect the tilt cylinders to the tilt cylinder anchor brackets 6 Connect the truck auxiliary hose to the cylinder hose 7 Perform the mast operational inspection and adjustments as described in Section 2 4 8 Lower the carriage Stand on left end of lower carriage bar Measure distance between left bottom of carriage bar and ground Stand on right end of lower carriage bar and Carriage measure distance at same point as before The difference Anchor Pin i between the two measurements should not exceed 06 Pin Retainer See Figure 38 Cotter Pin Capscrew 7 Shim Cotter Pin Roller Nut Figure 36 Carriage Assembly UPRIGHT CARRIAGE a TET A LOWER MEASURE CARRIAGE THIS DISTANCE BAR TWICE CARRIAGE STOP SCREW ASSEMBLIES FOR REASSEMBLY TIGHTEN TOA TORQUE OF 100 110 FT LBS Figure 37 Carriage Stop Screw Assembly Figure 38 Measuring Carriage Looseness 26 l 669223 Rev 1 sam D Service 5 3 12 Load Roller Shimming Each pair of load rollers on the uprights and carriage should be shimmed so that a total clearance no greater than 0 030 inch occurs at the tightest point throughout the travel of the member See Figure 39 This clearance will be achieved if each pair of rollers are shimmed the maximum amount that still permits assembly without mechanical assistanc
44. osshead move within guides on the inner upright assembly to guide the hoist cylinder as it extends and retracts A pair of chain sheaves attached to the crosshead provide a rolling surface for the carriage hoist chains CAPSCREW SNAP RING CROSSHEAD ROLLER CROSSHEAD CHAIN SHEAVE Figure 29 Crosshead Assembly 5 3 3 Mast Removal WARNING Never work on the mast with a load on the forks or attachment or while anyone is near the lift truck control handles 1 Make sure the mast is fully lowered Make sure the mast is straight up not tilted forward or backward 2 Remove the forks or attachment from the mast carriage Remove any auxiliary equipment that would interfere with mast removal 3 Remove the truck auxiliary hose from the hoist cylinder hose See Figure 30 Be prepared to collect oil Cap the cylinder hose and plug the truck auxiliary hose 4 Loosen the hoist cylinder bleed screw no more than required to bleed off any hydraulic pressure that may remain in the cylinder The bleed screw is located on the cylinder shell just below the retainer Tighten the screw 5 Wrap a link chain twice around the four upper mast channel crossmembers and secure with a hoist crane or some other suitable lifting device 6 Disconnect the tilt cylinders from the tilt cylinder anchor brackets 7 Disconnect the mast base mounting brackets 8 Lift off the mast and set it on a work surface with the carriage up If th
45. other carriage chain to achieve equal chain tension 5 IN UNDERCLEARANCE A 2 IN OR 6 IN UNDERCLEARANCE A 3 IN CARRIAGE lt FLUSH Figure 25 Correct Carriage Positions when Mast is Fully Lowered Mast Upright Assembly 5 3 1 Upright Description N SN ADJUSTING NUT FI Figure 26 Carriage Chain Adjusting Nut The Quad Viewmast lis comprised of four upright assemblies 3 Inner Intermediate Upright Assembly outer outer intermediate inner intermediate and inner See Figure 27 1 Outer Upright Assembly The outer upright is mounted to the truck pair of shim adjustable load rollers fits onto stub shafts which are mounted on removable plates See Figure 27 Non adjustable chain anchors are also located on each plate A pair of urethane cushions are attached to the lower cross member to provide a cushion for the outer intermediate upright when the mast is fully lowered Outer Intermediate Upright Assembly The outer intermediate upright assembly telescopes within the outer upright assembly A pair of shim adjustable load rollers is attached to canted stub shafts at the top of the upright and a pair is attached near the bottom of the upright In addition a pair of chain sheaves is located near the bottom of the intermediate upright to provide a rolling surface for the hoist chain A pair of non adjustable chain anchors are located on the top crossmember Bearing blocks item 15 Figure 27 and caps
46. plug and lowering control valve from the cylinder port 2 Adjust as follows e To SLOW the LOWERING SPEED back the nut out while keeping the piston stationery with a screwdriver See Figure 6 To INCREASE the LOWERING SPEED tighten the nut while keeping the piston stationery with a screwdriver 3 Reinstall the valve and tighten to a torque of 10 15 ft Ibs Install the plug and tighten to a torque of 95 100 ft lbs SCREWDRIVER Figure 6 Lowering Control Valve 669223 Rev 1 sim D Service OOM SUON Sequence Valve Actuating Rod Assy Sequence Valve Ball Sequence Valve Plunger Assy Cylinder shell Master plunger Primary plunger Slave plunger Sequence valve actuating rod Spacer f Bearing Plug O ring Back up ring Master plunger retainer Seal Nylon ring Wiper Sequence valve adjusting nut Cotter pin Sequence valve rod spring Bleed screw Seal Valve retaining washer threaded 41 O ring Figure 7 Exploded View of Hoist Cylinder Assembly 669223 Rev 1 Check valve Check valve poppet Sequence valve ball Sequence valve ball spacer Sequence valve ball spring Sequence valve ball plug Sequence valve plunger spring Sequence valve plunger Sequence valve plunger nut O ring plug Relief valve Relief valve O ring Master plunger piston Bearing Nyton ring Seal O ring Back up ring Primary plunger retainer Seal cc w e 2 2 3 a x m lt PRIMARY PL
47. reme care should be used when working on a unit when the carriage with or without load is in a raised position f Slave piston check valve defective will lift through free lift a Sequence rod adjusted too long b Bent plungers f Replace slave piston check valve assembly a Adjust sequence rod Turn clockwise b Repair or replace as necessary A WARNING Extreme care should be used when working on a unit when the carriage with or without load is in a raised position c Slave piston check valve plugged or defective d Master piston ball check not seating properly Master will move during primary stage e Master piston 1 D O ring seal leaking Master will move during primary stage c Replace slave piston check valve assembly d Clean and or replace piston ball check assembly e Replace O ring and back up ring f Relief valve defective Master will move during primary stage g Master seal worn out Master will move during primary stage h Master piston check valve open i Sequence rod out of adjustment Too long a Slave piston check valve defective NOTE Cylinder relief valve will squeal and cylinder will extend slowly b Piston sequence valve defective Master will move during primary stage c Master piston ball check not seating properly Master will move during primary stage d Master piston I D O ring seal leaking Master will move during primary
48. rface of the cylinder shell retainer Load the retainer onto the master plunger then remove the loader APPLY A THICK FILM OF PETROLEUM JELLY MASTER OR PRIMARY PLUNGER RETAINER LOADER 673507 OR 673508 Figure 15 Retainer Loader Place the 3 25 O D retainer loader over the end of the primary plunger Apply a thick film of petroleum jelly to the loader and inner surface of the master plunger retainer Load the retainer onto the primary plunger See Figure 15 Slide the primary plunger into the master plunger Tighten the retainer to a torque of 150 200 ft ibs Place the sequence rod assembly in the primary plunger with the threaded end through the master plunger piston Install the sequence valve spring plunger and nut onto the rod through the bottom of the master plunger piston Tighten the nut to a torque of 7 5 9 ft Ibs See Figure 14 Install the threaded washer and tighten to a torque of 50 55 ft Ibs STAKE THE WASHER IN PLACE Place the 2 50 O D retainer loader over the end of the slave plunger Apply a thick film of petroleum jelly to the loader and inner surfaces of the primary plunger retainer Load the retainer onto the slave plunger See Figure 16 APPLY A THICK FILM OF PETROLEUM JELLY PLUNGER RETAINER LOADER 673498 Figure 16 Retainer Loader 22 Assemble the spring and plug and insert them into the slave plunger piston Screw the slave plunger piston into place Tighten the pis
49. s installed at the top of the sequence valve actuating rod It is held in place by a spring that bears between the spacer and the shoulder of a special adjusting nut threaded onto the upper end of the rod Access to the adjusting nut can be gained by removing the bleed fitting threaded into a port at the top of the slave plunger To turn the nut insert a 3 16 inch long handle Allen wrench Refer to paragraph 5 1 8 for complete adjustment instructions An adjustable lowering control valve is located at the supply port on the cylinder shell It consists of a spring adjustable piston adjusting nut and a threaded cover By adjusting the piston you can control the lowering speed of the cylinder See paragraph 5 1 3 for complete adjusting instructions 5 1 2 Bi Element Seal Assemblies Fig 13 The hoist cylinder assembly contains five Bi Element seal assemblies See Figure 5 Each seal assembly is comprised of a seal element and an anti extrusion element The seals are used in combination with nylon back up rings The seals are installed in the cylinder assembly with the seal element facing the highest pressure ANTI E XTRUSION ELEMENT SEAL ELEMENT HIGHEST PRESSURE INSTALLED NOT INSTALLED Figure 5 Bi Element Seal Assemblies 5 1 3 Lowering Control Valve Removal and Adjustment The lowering control valve components are not serviceable The valve must be replaced as a complete assembly when necessary 1 Remove the
50. stage f Replace relief valve do not adjust or repair g Replace all cylinder seals h Replace check valve i Adjust sequence rod Clockwise a Replace slave piston check valve assembly b Repair or replace valve c Clean and or replace piston ball check assembly d Replace O ring and back up ring 669223 Rev 1 som Troubleshooting PROBLEM Loaded Continued Empty or loaded Master up 1 st slow Primary up 2nd or during master Slave up 3rd Hoist cylinder drifts All plungers down Slave plunger down Master plunger up Master plunger drifts up when load is lifted then stops Approximately 1 2 Spongy or jerky action PROBLEM CAUSE e Master seal worn out Master will move during primary stage f Sequence rod stroke adjusted too short g Bent plungers SOLUTION e Replace all cylinder seals f Adjust sequence rod Turn counter clockwise g Repair or replace as necessary WARNING Extreme care should be used when working on a unit when the carriage with or without load is in a raised position h Check valve defective Open i Relief valve defective Master moves at all times i Worn slave piston seals a Relief valve open a External leak in pressure line b Truck valve defective cycle to full lift height to verify c Slave piston check valve defective NOTE Slave section drops approximately 4 and stops d
51. there are roller clearance as specified in step 2 cracks at the base of the stub shafts the carriage must be 6 din th blies See Fi 23 replaced or repaired Refer to Technical Bulletin 126 for 7 Threa in the carriage Stop a er Be er stub shaft replacement Tighten to a torque of 100 110 ft Ibs 6 Inspect the carriage hoist chains If inspection reveals that CAUTION Failure to thread in the stop screw assemblies one strand of a pair of chains requires replacement both can cause the mast uprights to sequence incorrectly strands of the pair should be replaced 7 Install the carriage hoist chains D e Check for rust and corrosion 8 Lower the carriage and check and adjust the load chains Check for cracked side plates If you find cracked side as shown in Section 5 2 5 plates replace both strands of chains 9 Check the total freedom of the carriage movement as Check for tight joints If tight joints are caused by rust described in Section 5 3 10 step 7 18 669223 Rev 1 cin D Service 5 2 5 Carriage Chain Adjustment The carriage hoist chains should be adjusted so that when the unloaded mast is fully lowered the carriage is positioned as shown in Figure 25 To adjust the carriage chains 1 2 3 3 IN UNDERCLEARANCE Locate the adjusting nuts on the carriage See Figure 26 Adjust one carriage chain to achieve the correct carriage position when fully lowered as shown in Figure 25 Adjust the
52. they were disassembled Tighten the nut until a measurement of 2 80 is attained from the bottom of the spring to the top of the nut See Figure 14 Install a new cotter pin and bend the pin ends around the nut Slide the assembly into the slave plunger ADJUSTING NUT SEQUENCE VALVE SPRING ae SPACE SLAVE PLUNGER n Q N St X NY N EE STEG Ct SEQUENCE VALVE SPRING MASTER PLUNGER SEQUENCE VALVE PLUNGER NUT TORQUE TO 10 15 FT LB PLUG SPRIN BALL SPACER BALL THREADED WASHER TORQUE TO 50 55 FT LB MASTER PLUNGER PISTON Figure 14 Sequence Valve Rod Assembly 15 Reinstall the ball ball spacer spring and plug in the master plunger piston correctly 16 Screw the piston into the master plunger As the piston is threaded on the plug will snap into one of the two holes in the plunger Use a screwdriver or punch to push the plug in and keep turning the piston until it seats Then back off no more than 1 2 turn until the plug snaps into one of the holes See Figure 11 Install the relief valve on the master plunger piston and tighten to a torque of 12 17 ft Ibs A WARNING Makesure the plug is securely in the plunger hole Failure to do this can cause the cylinder piston to work loose inside the cylinder See Figure 13 Make sure the ball seats 18 19 20 21 master plunger Apply a thick film of petroleum jelly to the loader and inner su
53. to read the applicable Service Sections of the manual before repairs are initiated If problem diagnosis is difficult call one of the Cascade Service Departments listed on the back cover To arrive at the total Standard Labor Time for a job list each operation and add the times As an example to replace bushings your list should look something like this 5 2 Carriage Removal and Installation 15 5 4 Carriage Chain Replacement 10 Total Standard Labor Time hours 25 Standard Labor Times Paragraph Number Times hours 51 5 Cylinder Removal and Installation 1 0 51 5 Steps 1 7 Replace Cylinder Retainer Seals 20 5 1 6 Cylinder Disasembly Service and Reassembly 3 0 51 7 Cylinder Bleeding Procedure 05 3 52 Carriage Removal Inspection and Installation 1 5 53 3 Mast Removal and Installation 1 5 5 3 4 Mast Disassembly Service and Reassembly 80 53 5 Crosshead Removal Adjustment and Installation 00 ccc cece eee n eee eee e eee a 75 53 13 Hose Tracking Adjustment 0008 3 54 Carriage Chain Replacement Two 1 0 54 4 Outer Upright Chain Replacement Two 20 669223 Rev 1 31 Do you have questions you need answered right now Call your nearest Cascade Service Department Cascade Corporation P O Box 20187 2201 N E 201st Ave Portland OR 97230 Tel 503 666 1511 800 227 2233 Toll Free CAS CADE Telex 360411
54. ton until it seats then back off until the plug pops into a plunger hole 669223 Rev 1 san D Service 5 1 6 Cylinder Disassembly Service 23 24 25 and Reassembly Cont WARNING Make sure the plug is securely in the plunger hole Failure to do this can cause the cylinder piston to work loose inside the cylinder Slide the slave plunger into the primary plunger Tighten the retainer to a torque of 100 150 ft Ibs Place the 5 25 1 D piston loader in the cylinder shell The loader must cover all of the threads but not contact the thread relief chamfer The length of the stop fins can be trimmed with a sharp knife if more engagement is needed The piston will not enter the shell if the loader contacts the thread relief chamfer Apply petroleum jelly to the master plunger seals and loader I D Slide the master plunger into the cylinder shell Tighten the retainer to a torque of 250 300 ft lbs See Figure 17 PLACE THE PISTON LOADER 673463 IN THE CYLINDER SHELL STOP FINS Pa CYLINDER DO NOT ALLOW LOWER SHELL EDGE OF LOADER TO CONTACT THREAD RELIEF CHAMFER INSERT MAST PLUNGER INTO THE CYLINDER SHELL APPLY A THICK FILM OF PETROLEUM JELLY Figure 17 Master Plunger Loader To install the cylinder on the mast reverse the removal instructions Section 5 1 5 CAUTION Be sure the cylinder is properly seated in the mast support casting with the pin in the hole CYLINDER
55. unger Assembly 4 To remove the piston depress the plug protruding through a hole at the base of the master plunger with a screwdriver or a punch See Figure 11 Use a spanner wrench to un screw and remove the piston from the plunger You may need a helper to hold the plunger with a strap wrench NOTE When you have turned the piston the first 180 use your screwdriver or punch to prevent the plug from snapping into the hole on the other side of the plunger Be prepared to catch the sequence valve plug spring spacer and ball when you remove the piston from the plunger SCREWDRIVER OR PUNCH PLUG SLAVE PLUNGER PISTON SPANNER WRENCH STRAP WRENCH Figure 11 Remove the Piston from the Plunger 5 Remove the two remaining retainers items 2 and 3 Figure 9 with a claw type spanner wrench Pull the master primary and slave plungers apart 669223 Rev 1 6 To remove the slave plunger piston depress the plug pro 7 truding through the hole near the base of the slave plunger with a screwdriver or a punch See Figure 11 Use a spanner wrench to unscrew and remove the piston Also remove the sequence valve rod and component pieces at this time Remove all seals from the pistons and the three retainers CAUTION To prevent damage to the pistons pry up the seals using a dull screwdriver Cut the seals with wirecutters or a knife DO NOT SCRATCH THE GROOVE Remove the threaded washer and setscrew ret
56. ure the cylinder sequences properly The master and slave plungers should lower first then the primary plunger should lower Make sure the mast channels and carriage lower freely without binding Refer to Section 5 1 4 O Make sure the cylinder hose is not twisted and is traveling smoothly in the hose guides Check the hose to be sure itis not scuffing Minor adjustments to the hose can be made by loosening the hose clamp and twisting the hose slightly to fitin the guides Refer to Section 5 3 13 Be sure the urethane cushions at the base of the outer and intermediate channels are not flattened or distorted O Check crosshead roller clearance to assure proper operation without binding Refer to Section 5 1 9 After each 100 hours of lift truck operation in addition to the daily inspection O Inspect and lubricate the full length of each pair of hoist chains with SAE 40 oil CAUTION The chains must be coated with a film of lubricant at all times O Check each pair of hoist chains for wear and stretch Refer to Section 5 4 3 3 500 Hour Inspection ee After each 500 hours of lift truck operation in addition to the daily and 100 hour inspection O Check the clearances for load rollers Refer to Section 5 3 12 669223 Rev 1 sein Troubleshooting The following table lists problems that may be encountered on your Quad Viewmast II the probable causes and the recom mended corrective action that should be taken to r
57. uter intermediate CAUTION Pull on the hoist chains to keep them straight Use a sling and hoist or some other appropriate lifting device to lift the inner intermediate out of the outer intermediate upright Set it on a work surface Remove the pins and chain anchors on the top crossmember of the outer intermediate upright Remove the hoist chain Remove the capscrews securing the roller plate to the outer upright and remove the plate NOTE As you pull out the plate the hoist chain will come with it 669223 Rev 1 11 Use a sling and hoist or some other appropriate lifting device to slide the outer intermediate upright out of the outer upright 5 3 7 Cleaning and Inspection 1 10 Inspect the rollers on the crosshead Remove the load rollers and chain sheaves from the up rights carriage and crosshead Note the number of shims on the rollers so that an appropriate number of shims can be installed during reassembly Thoroughly clean the upright carriage and crosshead assemblies with cleaning solvent Inspect the rolling surfaces of the upright channels Exces sive wear grooves or scoring could be the result of faulty load rollers and or improper mast lubrication Inspect the load rollers and chain sheaves Roller and sheave assemblies with visible flat spots excessive wear or cracks should be replaced Inspect the load roller and chain sheave bearings by turning them on a s
58. xcessive replace both strands of chains e Check for worn broken or misaligned chain anchors Replace or adjust as required 23 sin D Service 5 3 8 Upright Reassembly with uprights fying horizontally 1 Lubricate the full length of each upright channel with LOAD ROLLER chassis lube or Kendall SR 12X Cascade part No 599474 as shown in Figure 33 2 Assemble the upright load rollers onto their stub shafts using an appropriate number of shims See Figure 32 These shims should be installed to provide a clearance no looser than 0 030 inch at the tightest point throughout the travel of the member Refer to Section 5 3 12 for load roller shimming 3 Assemble the mast chain sheaves and rollers on their stub shafts See Figure 32 LUBRICATE ONLY WHERE INDICATED BY THE HEAVY LINE FOR THE FULL LENGTH OF EACH UPRIGHT UPRIGHT CHANNEL SECTION OUTER INTERMEDIATE UPRIGHT CUTOUT INNER INTERMEDIATE UPRIGHT INNER INTERMEDIATE UPRIGHT CUTOUT COTTER PIN INNER UPRIGHT CARRIAGE CHAIN ANCHOR gj k CAPSCREW NG TORQUE TO 60 65 FT LB h CHAIN ANCHOR BLOCK CHAIN ANCHOR PIN COTTER PIN ANCHOR Figure 32 Mast Lubrication typical 24 669223 Rev 1 Section SP WI 5 3 8 Upright Reassembly Cont with uprights lying horizontally device to position the outer intermediat
59. y DO NOT WELD ANY HORIZONTAL SEAMS See Figure 2 Weld the mounting brackets and crossmember with a 25 in minimum fillet holding a close arc Weld in the flat position only Do not oscillate or use a wash bead pattern Make the weld in three passes Let the weld slow cool Remove slag and inspect the weld The following defects are not allowed undercut overlap stress cracks and porosity Clean the weld area and repaint with Cascade paint part number 668209 2 The measurement shown in Figure 3 should be taken after welding and cooling the mast This dimension must be maintained for the uprights to slide together 3 Reassemble the mast as described in Section 5 3 8 669223 Rev 1 CLAMP GROUND HERE WARNING DO NOT WELD THESE AREAS HORIZONTAL WELDS WILL REDUCE THE STRUCTURAL STRENGTH OF THE CHANNEL WARNING WELD ON VERTICAL SEAMS ONLY Figure 2 Clamp Ground and Weld TOP VIEW OUTER UPRIGHT MEASURE INSIDE TO INSIDE OF OUTER UPRIGHT AT TWO PLACES Figure 3 Dimensional Inspection un 2 Installation Instructions 2 3 Mast Installation 1 Lubricate the bearing surfaces of the base and tilt cylinder mounting brackets with chassis grease 2 Lift the mast by a link chain wrapped twice around the f OUTER upper channel crossmembers Position the mast into place on the lift truck and secure the base mountings UPRIGHT MAST CYLINDER HOSE IMPORTANT Prior to
60. y be adjusted by turning the special adjusting nut at the top of the sequence valve actuating rod View C The trapped sequence oil is at a pressure greater than that from the truck This pressure intensification results because the area of the piston that forms the cavity between the cylinder shell and the master plunger is less than the area of the base of the master plunger piston Remember that pressure equals force divided by area Since the area of the piston in the sequence oil cavity is less the pressure in the cavity is greater Thus as soon as the sequence valve ball is unseated the pre viously trapped high pressure sequencing oil flows past the unseated sequen e valve ball to the primary plunger cavity and seats the unseated check valve Oil from the truck can thus no longer flow to the plunger cavities and truck pressure begins to extend the master plunger View D As the master plunger extends the sequencing oil flows past the unseated sequence valve ball and extends the slave plunger from within the extended primary plunger This occurs until the cylinder is fully extended Since the volume of the sequencing oil cavity is nearly identical to the volume of the slave plunger cavity master and slave plungers extend at the same speed The volume of oil required to lift the master plunger is approximately twice that required to extend the primary plunger the first plunger to extend Thus the master plunger extends at hal

669223_45C Quad Mast Service

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