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667415_M4Q Quad Lift Mast Service Manual

1. 4 Inspect all welds between the carriage side 3 4 CARRIAGE REMOVAL amp DISASSEMBLY plates and the carriage bars If any weld seams See Figure 3 4 are cracked the weld must be stripped out and the seam rewelded Use E 70XX low hydrogen 1 Remove the snap rings from the chain anchors welding rod Pre heat to 300 wrap with and pull the chain anchors out of the carriage asbestos and allow to slow cool 2 Secure the carriage with an overhead crane 5 Inspect the stub shafts If they are damaged or Remove the carriage by pulling it out the there are any cracks at the base of the stub bottom of the mast channels shaft the carriage must be replaced 3 Remove the two middle and two lower roller assemblies 3 6 CARRIAGE ASSEMBLY amp INSTALLATION 4 Remove the two upper roller assemblies by removing the capscrews that connect the re 1 Secure the carriage with an overhead crane taining plates to the stub shafts Pull the roller assemblies off the stub shafts 2 Coat the stub shafts with wheel bearing grease 3 5 CARRIAGE INSPECTION 3 Reinstall the middle and lower roller assemblies See Figure 3 4 by sliding the thrust washer shims roller and plug in that order on the shaft 1 Inspect the roller bearings by placing the roller assembly on a stub shaft and manually turning 4 Slide the thrust washer inner shims roller and the roller If there is a noticeable restriction or outer shim in that order on each uppe
2. Extend the mast to approximately 1 2 of its overall lift height Steel Setscrew Figure 2 7 Brass Wear Plug NOTE A tool for adjusting the brass wear plugs may be fabricated from a six point 7 8 socket See figure 2 8 Figure 2 8 Wear Plug Tool Page 10 Trouble Shooting amp Maintenance Section 2 b Loosen the steel setscrew and remove the wear plug c Install the new wear plug and thread it in until it bottoms out Unthread it 1 4 turn and tighten the steel setscrew 3 Brush the carriage chains and the bootstrap chains with SAE 30 engine oil Lubricate With Wheel Bearing Grease Bootstrap Chain e Figure 2 9 Bootstrap amp Carriage Chains Intermediate gt Channel Outer 4 Grease all chain sheaves with wheel bearing E es ON grease through the grease fitting on the end of E Ea ea iaa the sheave shafts Use one of the following WHF adaptors for easy access to the grease fittings 7 a Alemite no 321990 90 adaptor on a 7 l A a With j Wheel Bearing flexible hose Grease b Alemite no 322120 90 adaptor perma nent attachment to the grease gun Figure 2 10 Chain Sheaves c Universal no 31 90 adaptor 5 Grease the carriage rollers with wheel bearing grease through the grease fittings in the back of d Lincoln no 5855 adaptor extension push the stub shafts Use one of the adaptors listed type adaptor does not lock
3. Inspection oda a Paes oh eee had i aaee eee 4 6 Upright Assembly 02 335 AAA See eee Os 4 7 Carriage Installation o oa hea ie ce hae Ses 4 8 Mast Installation le oh Ao seis he ee e 4 9 Mast Ajos Med ari tn i ee Selene e ais 4 10 Safety Inspection ssid DS A Gas AN 4 11 SECTION 5 CYLINDER SERVICE T trod tion 1 a E AR A ee A A AA i 5 1 Mast Removal 0 e SA A E a eee 5 5 Cylinder Removal oia o A ERAS 5 6 Cylinder Disassembly o cit dr Alen edites 5 7 Inspection amp Service oi usssu cease is AA 5 11 Cylinder Assembly ice 5 2 ie ede eee ed oes ee ar eae aes 5 12 Cylinder Installation cocotero ene hee 5 13 Mast Installation seses etia iae oes A wats 5 15 Safety Inspection ir Sd eR oe es aS ee ee ee Re 5 17 Final Inspection 261 226 ele Fo GES Se wie ESO ERIE DORE ES wae 5 18 Litho in U S A 10 74 Cascade Corporation INDEX Page An Yu W Form 5068 ATTENTION Do not install the Quad Mast on a truck having a rated capacity greater than 6 000 Ibs at 24 1 1 INTRODUCTION 1 2 The following instructions outline the recom mended installation procedures for installing the Cascade Quad Lift Mast 1 3 Masts supplied complete with mounting brackets base tilt cylinder and crossbar are ready for installation 1 4 Masts purchased without mounting brackets must have a crossbar bracket installed see sub section 1 8 in addition to the mounting and anchor brackets 1 5 BASE MOUNTING amp ANCHOR BRACKET I
4. crossmember E q A b The top and bottom of the outer inter Figure 4 15 Bearing Strip mediate channel crossmember 3 Inspect the exterior and interior faces of the c The back of the crosshead two intermediate channels Inspect the exterior face of the inner channel and the interior face If any of these pads are missing or damaged of the outer channel If there are any wear they must be replaced grooves or vertical scoring marks on the chan nel surfaces the brass wear plugs are probably worn and the steel setscrew is contacting the i Contact Pad channel surface Replace the wear plugs and buff the channel surface to eliminate burrs 4 Inspect and tighten the capscrew latch pin on the inner intermediate channel If it is bent it must be replaced with a grade 5 or better 1 2 Inner UNC x 3 4 socket head not knurled lote modisto capscrew l Channel Capscrew Latch Pin UNC x 4 Socket Head Not Knurled Grade 5 or Better Outer Intermediate Channel Contact Pad Figure 4 16 Capscrew Latch Pin Crosshead 5 Inspect the capscrew latch pin that was re moved from the outer intermediate channel If it is bent it must be replaced with a grade 5 or better 5 8 UNC x 1 socket head not knurled capscrew Figure 4 17 Contact Pads Section 4 Channel Service Page 31 8 Inspect the crosshead wear shoes for excessive wear If dur
5. mediate channel At the same time the cross head begins carrying the inner intermediate channel up with it When the latch was tripped to release the two channels it also locked the inner intermediate channel to the crosshead Channel Service Section 4 d As the crosshead carries the inner inter mediate channel up the bootstrap chain con nected between the inner intermediate channel and the outer channel pulls the outer inter mediate channel up e The mast will now continue rising until the cylinder reaches the top of its stroke f As the mast is lowered all three channels will descend until the outer intermediate chan nel and the inner intermediate channel simul taneously reach their collapsed position As they reach this collapsed position the capscrew latch pin in the outer intermediate channel crossmember trips the latch mechanism on the inner intermediate channel releasing the cross head and locking the two intermediate chan nels together g At the point the two intermediate channels are collapsed the inner channel is still partially extended and the carriage is still at the top of the inner channel When the inner channel reaches its collapsed position the latch mech anism on the inner channel is tripped by the capscrew latch pin on the inner intermediate channel releasing the carriage from the inner channel and locking the two inner channels together h The carriage will now continue to lower unt
6. t extend to full Latch jammed Inspect and adjust latch lift height mechanisms following pro cedures outlined in sub section 4 10 steps 3 4 and 10 If a latch is damaged re place following procedures outlined in sub section 4 7 steps 2 and 19 Inspect capscrew latch pins and replace if damaged or missing using only cap screws that meet specifica tions listed in sub section 2 4 step 3 Truck reservoir low on oil Add oil meeting truck manufacturer s specifi cations Valve porting in hoist cylin Overhaul hoist cylinder as der inner plunger plugged or outlined in section 5 valve cartridge faulty Mast action spongy or Air in hydraulic system Bleed air from hoist cylin jerky der as outlined in sub section 1 12 step 6 Mast channels improperly Coat all sliding surfaces lubricated with graphite base grease 30 graphite base recom mended Brass wear plugs improperly Adjust mast as outlined in adjusted sub section 2 8 step 6 Fitting in hoist cylinder Bootstrap chains too loose Adjust bootstrap chains as port bent or broken or improperly adjusted outlined in sub section 2 8 step 3 3 1 INTRODUCTION 3 2 This section outlines disassembly techniques inspection procedures and assembly techniques for servicing the Quad Lift Mast carriage Before attempting to remove the carriage from the mast channels the mast must be removed from the lift truck and placed on a work surface with the car riag
7. the side plate clearances do not meet this specification move the crosshead from side to side in the channel measure this movement and proceed as follows a If the crosshead moves more than 1 16 or has more than 1 16 of play from side to side it must be adjusted as outlined in sub section 4 7 steps 13 and 14 After this adjustment is made recheck the clearance between the crosshead and the side plates Carriage Service Page 23 Carriage Side Plates Must Clear The Crosshead By 1 4 to 1 16 Inner Intermediate Side Plates Channel e E ezz Crosshead gt e M O Carriage Carriage TOP VIEW Figure 3 6 Side Plate Clearances b If the crosshead does not move more than the allowable 1 16 from side to side readjust the inner channel as outlined in sub section 4 7 step 8 as outlined in sub secti NOTE If the steel setscrew touches the chan nels sliding surface before tightening the wear plug or if the brass has worn through in the inside of the wear plug it must be replaced Once the carriage is properly shimmed and located in the channel move it the full length of the channel to check for restrictions and proper roller action If the carriage does not roll freely the full length of the channel check the inner channel for obstructions recheck the carriage adjustment and if necessary recheck the carriage roller assemblies Reinstall the latch pin on the back o
8. 273 9137 Cascade GmbH D 41199 Monchengladbach Klosterhofweg 52 Germany Tel 21 66 602091 FAX 21 66 680947 Cascade UK Ltd 15 Orgreave Crescent Dore House Industrial Estate Handsworth Sheffield S13 9NQ England Tel 742 697524 FAX 742 695121 Cascade Japan Ltd 5 5 41 Torikai Kami Settsu Osaka Japan 566 Tel 81 726 53 3490 FAX 81 726 53 3497 Cascade Africa Pty Ltd P O Box 625 Isando 1600 60A Steel Road Sparton Kempton Park South Africa Tel 975 9240 FAX 394 1147 10 74 Cascade N V Kirkkokatu 1 48100 Kotka Finland Tel 52 184393 FAX 52 184833 Cascade Scandinavia Hydraulik A B Musk tgatan 19 E8 9 25466 Helsingborg Sweden Tel 42 151135 FAX 42 152997 Cascade Korea Room 508 Pum Yang Bldg 750 14 Bang Bac Dong Se Cho Ku Seoul Korea Tel 2599 7131 ext 512 FAX 2533 8089 Cascade Xiamen Wanshan No 1 Workshop Huli Road Xiamen 361006 Fujian PRC Tel 592 562 4600 FAX 592 562 4671 Part Number 667415
9. 5 or Better Washer Figure 4 1 Lifting Procedure CAUTION It is important that the mast be properly secured in a stable upright position before proceeding 2 Disconnect the forks or attachment from the carriage 3 Disconnect and cap the supply hose from the lift truck CAUTION Recheck the chains and overhead crane being used to hold the mast in an upright position Section 4 CHANNEL SERVICE 4 Disconnect the tilt cylinders 5 Disconnect the base mounting brackets 6 Lay the mast on a work surface with the carriage facing down 4 5 UPRIGHT DISASSEMBLY See Figure 4 3 1 Disconnect the mast hose and remove the fittings from the bulkhead and cylinder port Cap the cylinder port Hose Guide R H Bulkhead j Bracket SK Bulkhead Fitting No 8 JIC To sra Male Ta 8 cay Connector 90 Fitting Figure 4 2 Mast Hosing NOTE The cylinder port contains a washer spring and spacer Care should be taken to avoid losing these parts during disassembly See figure 4 4 Page 26 Channel Service Section 4 a ees o SO Latch Mechanism Bearing Strip Contact Pad Capscrew Latch Pin Sheave Assembly Brass Wear Plug _ Inner Intermediate Channel 3 pa Ea Latch ER Mechanism ON mr j Me l Shim Bearing Strip Assembly wi r min l r lt l 7 6 Brass Wear Plug dl 9 Contact Pad B
10. 7 steps 13 and 14 e When the mast is fully collapsed the bottom of the carriage bar must not go below the bottom of the outer channel for 3 underclearance masts or lower than 2 below the outer channel for 5 underclearance masts f All chain anchors must be securely anchored g The capscrews retaining the wear shoes to the crosshead must be tight Cycle the mast raising it to its full height The mast must sequence as follows CAUTION Check for overhead obstructions before rasising mast a The carriage travels the full height of the collapsed mast by chain action The chain is pulled by the crosshead and the crosshead is raised directly by the cylinder b As the carriage reaches the top of the inner channel the latch pin engages with the latch mechanism on the inner channel tripping the latch and releasing the inner channel from the inner intermediate channel At the same time the carriage side plates contact the inner channel crossmember raising the inner channel and the carriage by chain action When the latch mechanism is tripped it also locks the carriage to the inner channel c The inner channel will rise partially out of the mast before the remaining channels begin sequencing As the crosshead reaches the top of the inner intermediate channel the capscrew latch pin on the back of the crosshead trips the latch mechanism on the inner intermediate channel releasing it from the outer inter
11. Carriage Side Plates Must Clear The Crosshead By 1 4 2 1 16 Inner Intermediate Crosshead Carriage Side Plates Carriage Figure 2 21 Crosshead Clearances Page 14 10 Adjust the bootstrap chains according to the following guidelines by adjusting the chain anchors on the outer channel crossmember Outer Channel 5 A ecw E ag Bootstrap Chain Anchor Bootstrap Chain Figure 2 22 Bootstrap Chain Anchor a Both chains must be under equal tension b The contact pad on the bottom of the outer intermediate channel crossmember must just touch the outer channels crossmember when the mast is fully collapsed See figure 2 23 Outer Intermediate Channel Crossmember Outer Channel Crossmember rA With Bootstrap Chain Properly Adjusted Outer Intermediate Channe Crossmember Just Touches Outer Channel Crossmember Figure 2 23 Bootstrap Chain Adjustment 11 Inspect the mast hose fittings and hose guides for wear or damage If there is visible wear or damage they must be replaced Reference sub section 1 11 Trouble Shooting amp Maintenance Section 2 2 8 500 HOUR MAINTENANCE amp INSPECTION 2 9 Every 500 truck operating hours or every ten weeks the Quad Lift Mast should be serviced and inspected following the steps listed in this sub section Unless otherwise indicated these pro cedures should be performed while the mast is in its completely lowe
12. Lae ae at the bottom of the inner intermediate chan Channel nel and the top of the outer intermediate channel d If the inner intermediate channel is off center more than 1 16 from side to side adjust the side wear plugs accordingly Inner Intermediate Channel Must Be Centered From Side to Side to Within 1 16 in Outer NOTE Only tighten and adjust the wear plugs Intermediate at the bottom of the inner intermediate chan Channel nel and the top of the outer intermediate channel Vg t Me Figure 4 24 Channel Assembly b If the inner intermediate channel is more than 1 16 off center front to back loosen the wear plugs and remove the channel Add or subtract shims behind the four bearing strips as required to center the channel Reinstall the channel in the outer intermediate channel NOTE The inner intermediate channel must be centered from front to back at both the top Figure 4 26 Channel Clearances Section 4 NOTE The inner intermediate channel must be centered from side to side at both the top and bottom end of the outer intermediate channel e When the inner intermediate channel is completely centered in the outer intermediate channel back each wear plug off 1 4 turn and tighten the steel setscrews NOTE If the steel setscrew touches the oppos ing channel surface before it tightens the wear plug the wear plug must be replaced Install the inner
13. channel in the inner inter mediate channel as follows see figure 4 27 CAUTION Make sure the inner channel is securely fastened to an overhead crane before attempting to install it NOTE To allow easier installation of the inner channel place small blocks under the assem bled upright so it is approximately two inches off the work surface Before proceeding make sure the assembled upright is again securely fastened to the work surface a Pull the inner intermediate channel approx imately 1 3 of the way out of the outer intermediate channel b Place two shims each behind two bearing strips and replace the bearing strips on the interior face of the inner intermediate channel c Place two shims each behind two bearing strips and replace the bearing strips on the exterior face of the inner channel d Coat the exterior surface of the inner channel with graphite base grease 30 graph ite base recommended e Slide the inner channel into the inner inter mediate channel Adjust the inner channel in the inner inter mediate channel as follows a Fully tighten the wear plugs on the front and back sides of both channels Do not tighten the steel setscrews NOTE Only tighten and adjust the wear plugs at the bottom of the inner channel and the top of the inner intermediate channel Channel Service Page 35 Inner Channel Bearing Strips and Shims Inner Intermediate
14. of paint and weld splatter All mast channels are lubricated with graph ite base grease 30 graphite base recom mended Do you have questions you need answered right now Call your nearest Cascade Service Department Cascade Corporation 2201 NE 201st Troutdale OR 97060 Tel 1 800 CAS CADE 503 669 6300 FAX 503 669 6338 Cascade N V European Headquarters P O Box 3009 1300 El Almere Damsluisweg 56 1332 ED Almere The Netherlands Tel 31 36 549291 1 FAX 31 36 5492964 Cascade France S A R L 11 Rue Jean Charcot Zone Industrielle Sud or B P 22 91421 Morangis Cedex France Tel 1 64547500 FAX 1 64547501 HYCO Cascade Pty Ltd 87 Antimony Street Carole Park Brisbane 4300 Australia Tel 7 271 1966 FAX 7 271 3830 Sunstream Industries PTE Ltd No 3 Tuas Link 1 Singapore 2263 Tel 863 3488 FAX 863 1368 cascade cos TM Cascade Corporation 1974 Cascade Canada Inc 5570 Timberlea Blvd Mississauga Ontario Canada L4W 4M6 Tel 905 629 7777 FAX 905 629 7785 Cascade N V Benelux Sales and Service P O Box 3009 1300 El Almere Damsluisweg 56 1332 ED Almere The Netherlands Tel 31 36 5492950 FAX 31 36 5492974 Cascade Hispania S A Avenida De La Fabregada 7 Hospitalet De Llobregat Barcelona Spain Tel 3 335 5158 FAX 3 335 4756 HYCO Cascade NZ Ltd 23 Haseler Cresent P O Box 38 440 Howick Auckland New Zealand Tel 9 273 9136 FAX 9
15. onto gun in step 4 for easy access Section 2 Trouble Shooting Maintenance Page 11 Lubricate With Wheel Bearing Grease Figure 2 11 Carriage Lubrication Points 6 Inspect all latches and latch pins for damage and for correct positioning as listed below a The latch mechanism on the inner channel should be engaged with the capscrew latch pin on the inner intermediate channel With Channels Completely Z gt Lowered Inner Se Channel Latch Should Engage Inner Inter mediate Channel Capscrew Latch Pin ae Inner Intermediate Channel Figure 2 12 Inner Channel Latch b The latch mechanism on the inner inter mediate channel should be engaged with the capscrew latch pin on the outer intermediate channel With Channels Completely Lowered Inner Inner Intermediate Channel Channel Latch Should Engage Outer Intermediate Channel Capscrew Latch Pin Outer Intermediate Channel Figure 2 13 Inner Intermediate Channel Latch c Both latches on the mechanisms should be interlocked and connected with the spring Capscrew Latches Latch Pin Figure 2 14 Latch Mechanism d If the latches are damaged or not properly positioned they must be replaced and or ad justed reference sub section 4 7 steps 2 and 19 for installation reference sub section 4 10 steps 3 and 4 for adjustment Page 12 Trouble Shootin
16. shim in that order on each upper stub shaft Reinstall the retaining plate and cap Channel Service Page 39 screws on each stub shaft Before proceeding make sure both upper rollers turn without restriction Carriage t Chains Chain Anchor CN Plug Figure 4 38 Carriage 5 Slide the carriage back into the bottom of the inner channel If the carriage enters the channel freely re move and add shims behind the rollers until the carriage will just enter the channel without mechanical assistance NOTE All rollers on the same side of the carriage must be shimmed equally All six rollers on the carriage must be shimmed within one shim of being equal Slide the carriage to both ends of the mast to check clearances between the carriage side plates and the upper and lower channel cross members The carriage plates must clear both cross members by 1 4 1 16 on both sides If necessary remove the carriage and adjust the shims behind the rollers accordingly following the procedures outlined in steps 4 5 and 6 Page 40 Channel Service Section 4 ment as outlined in sub section 4 7 steps 13 and 14 Side Plates Must Clear Crossmembers By 1 4 1 16 9 Once the carriage is properly shimmed and located in the channel move it the full length of the channel to check for restrictions and proper roller action If the carriage does not roll freely check the inner channel for obstruc tions re
17. shoe on the crosshead using two shims between the wear shoe and crosshead b Place the crosshead in the mast assembly and engage the wear shoe with the inner intermediate channel c Engage the other wear shoe with the opposite channel member of the inner inter mediate channel just above the crosshead d Hold two shims behind the wear shoe and slide it down into the correct position on the crosshead e Fasten the wear shoe to the crosshead with two capscrews and two lockwashers f Tighten the capscrew latch pin on the back of the crosshead Wear Shoe Crosshead tered in the inner intermediate channel back Figure 4 30 Crosshead Installation each wear plug off 1 4 turn and tighten the steel setscrews 14 Adjust the crosshead to the following specifica NOTE If the steel setscrew touches the op tions by adding or removing shims behind the wear shoes Section 4 Channel Service Page 37 15 a The crosshead must be centered within 1 16 between the inner intermediate channel members b When moved from side to side the cross head must not have more than 1 16 looseness or play NOTE If the crosshead requires more than four shims on either side to meet these specifications the wear shoes must be re placed Reinstall both sheaves in the lower crossmem ber of the outer intermediate channel as follows a Reinstall the bearing in t
18. sub section 4 10 steps 3 4 and 10 Adjust crosshead as out lined in sub section 2 6 step 9 Capscrew latch pin dam aged Carriage latch pin damaged continued on page 19 Latch mechanism damaged or improperly positioned Carriage chain out of ad justment Latch pin hitting crosshead Bootstrap chain out of ad justment Replace capscrew latch pins using only capscrews that meet specifications outlined in sub section 2 4 step 3 Replace latch mechanism as outlined in sub section 4 7 steps 2 and 19 Adjust mast as outlined in sub section 4 10 steps 3 4 and 10 Adjust as outlined in sub section 2 6 step 10 Adjust as outlined in sub section 2 6 step 8 Adjust shims behind cross head wear shoes as outlined in sub section 2 6 step 9 Adjust carriage position relative to crosshead by readjusting inner channel Reference sub section 4 8 step 8 Page 20 Trouble Shooting amp Maintenance Section 2 PROBLEM POSSIBLE CAUSE SOLUTION Mast locked in partially ex Latches jammed Inspect and adjust latch tended position mechanisms following pro cedures described in sub section 4 10 steps 3 4 and 10 If latches are damaged replace following proce dures described in sub section 4 7 steps 2 and 19 Inspect all latch pins and re place if damaged or missing Use only capscrews that meet specifications listed in sub section 2 4 step 3 Mast won
19. the fully collapsed position The intermediate plunger of the cylinder should fully extend before the inner plunger begins extending If the cylinder is not sequencing correctly remove it from the mast reference sub section 5 6 and disassemble reference sub section 5 7 Inspect the valve porting in the base of the inner plunger If there are no obstructions in the valve porting replace the valve cartridge CAUTION Make sure all persons are clear of the mast during testing and cylinder bleeding oneratinn nl dada During the masts first extension check to make sure the hose and hose brackets clear the crossmem bers 5 18 FINAL INSPECTION 5 19 In addition to the cylinder testing procedures outlined in sub section 5 17 every Quad Lift Mast should be rechecked to insure that l The mast hose is properly fitted in the hose guides and remains in the guides during opera tion reference sub section 5 15 steps 1 through 10 The crossbar bracket is securely mounted to the outer channel reference sub section 1 8 All hose brackets hoses etc clear the crossbar bracket during operation The hoist cylinder is bled and free of air the bleeder screw is tight and there is no leakage occurring reference sub section 5 17 step 3 All No Hand Hold decals are legible in their proper location and the paint masks have been removed reference paragraphs 4 12 and 4 13 The chains are free
20. the wear plugs tightened measure the location of each channel member in relation to its mating channel If a channel is more than 3 32 off center from front to back the bearing strips are excessively worn and the mast should be completely disassembled inspected and overhauled as outlined in section 4 See figure 2 28 h When each channel member is centered Trouble Shooting Maintenance Section 2 from front to back unthread each wear plug 1 4 turn and tighten the steel setscrews Center Each Channel If a Channel is More Than 3 32 Off Center From Front to Back Replace Bearing Strips From Side to Side TOP VIEW Figure 2 28 Channel Adjustment NOTE If the steel setscrew touches the chan nel s sliding surface before it tightens the wear plug the wear plug must be replaced i Slowly lower the mast until the crosshead is between the carriage side plates Turn the truck off The side plates must clear the crosshead by 1 4 1 16 If the side plate clearances do not meet these specifications readjust the side wear plugs in the inner channel reference sub section 4 8 step 8 Carriage Side Plates Must Clear The Crosshead By 1 4 to 1 16 Inner Intermediate Channel Carriage Side Plates Carriage TOP VIEW Figure 2 29 Crosshead Adjustment j Carefully cycle the mast If the mast appears to be binding or will not completely lower with just
21. Channe Must Be Centered From Front to Back to Within 1 16 in Outer Channel TS Figure 4 22 Channel Clearances NOTE The outer intermediate channel must be centered from front to back at both the top and bottom end of the outer channel c When the outer intermediate channel is centered front to back tighten all wear plugs in the sides of both channels Do not tighten the steel setscrews NOTE Only tighten and adjust the wear plugs at the bottom of the outer intermediate chan nel and the top of the outer channel d If the outer intermediate channel is off center more than 1 16 from side to side adjust the side wear plugs accordingly NOTE The outer intermediate channel must be centered from side to side at both the top and bottom end of the outer channel e When the outer intermediate channel is completely centered in the outer channel back each wear plug off 1 4 turn and tighten the steel setscrews Channel Service Outer Inter mediate Channel Must Be Centered From Side to Side to Within 1 16 in Outer Channel We Ihe Figure 4 23 Channel Clearances NOTE If the steel setscrew touches the oppos ing channel surface before it tightens the wear plug the wear plug must be replaced Install the inner intermediate channel in the outer intermediate channel as follows see figure 4 24 CAUTION Make sure the inner intermediate
22. Channel Channel Figure 4 27 Channel Assembly b If the inner channel is more than 1 16 off center front to back loosen the wear plugs and remove the channel Add or subtract shims behind the four bearing strips as required to center the channel Reinstall the inner channel in the inner intermediate channel See figure 4 28 c When the inner channel is centered front to back tighten all wear plugs in the sides of both channels Do not tighten the steel setscrews Page 36 Channel Service Section 4 Inner Channel Must Be Centered From Front to Back to Within 13 1 16 in Inner Inter mediate Channel Figure 4 28 Channel Clearances NOTE Only tighten and adjust the wear plugs at the bottom of the inner channel and the top of the inner intermediate channel d If the inner channel is off center more than 1 16 from side to side adjust the side wear plugs accordingly Inner Channel Must Be Centered From Side to Side to Within 1 16 in Inner Inter mediate Channel Figure 4 29 Channel Clearances NOTE The inner channel must be centered from side to side at both the top and bottom end of the inner intermediate channel e When the inner channel is completely cen posing channel surface before it tightens the wear plug the wear plug must be replaced Install the crosshead as follows a Reinstall one wear
23. F wrap with asbestos and allow to slow cool Page 4 3x3 x5 Block A 7 Steel 1x5 x22 we Bar A 7 Steel Weld on Vertical Seams Only Figure 1 3 Fabricated Crossbar Bracket NOTE Cover all exposed components near the weld chain cylinder etc to protect from weld splatter Weld the bar to the blocks to form the crossbar bracket Use the welding procedures described in step 3 and weld on vertical seams only NOTE If the mast is to be repainted the cylinder rods and chain must be completely covered Replace any melted grease on the mast chan nels with graphite base grease 30 graphite base recommended 1 11 MAST HOSING INSTALLATION See Figure 1 5 NOTE The right hand hose guide has a bulkhead bracket welded to the bottom See figure 1 5 Bolt the right hand hose guide to the two mounting plates on the outer channel Bolt the left hand hose guide to the two mounting plates on the outer intermediate channel Carefully remove the protective plug from the port at the base of the hoist cylinder installation Section 1 NOTE This plug retains a spacer spring and washer Make sure these parts are correctly located in the port befor proceeding See figure 1 4 Washer Spring EN S OY Spacer Figure 1 4 Hoist Cylinder Port 4 Thread a male connector into the cylinder port 5 Attach a 90 fitting to the male connector as shown in figure 1 5 Ho
24. N Never work on the mast while the lift truck is running or while anyone is near the lift truck control handles b Loosen the steel setscrews in the brass wear plugs on both sides of the channel members Page 16 Steel Setscrew Figure 2 27 Brass Wear Plug c Beginning with the outer intermediate channel center each channel from side to side in its mating channel by tightening and adjust ing the side brass wear plugs See figure 2 8 for wear plug tool NOTE If the brass has worn through on the inside of the wear plug it must be replaced If more than one wear plug is to be replaced they should be replaced one at a time d When all the channels are centered un thread each wear plug 1 4 turn and tighten the steel setscrews NOTE If the steel setscrew touches the chan nel s sliding surface before it tightens the wear plug the wear plug must be replaced If more than one wear plug is to be replaced they should be removed and installed one at a time e Loosen the steel setscrews in all brass wear plugs on the front and back of the channel members f Beginning with the outer intermediate chan nel center each channel from front to back in its mating channel by tightening and adjusting the wear plugs NOTE If the brass has worn through on the inside of the wear plug it must be replaced If more than one wear plug is to be replaced they should be removed and installed one at a time g With
25. NSTALLATION 1 6 Weld the base mountings and tilt cylinder anchor brackets to the mast with E 70XX low hydrogen welding rod Preheat to 300 F wrap with asbestos and allow to slow cool NOTE Cover all exposed components near the weld chain cylinder etc to protect from weld splatter Tilt Cylinder Anchor Brackets Va nt y Base Mountin St g E y Brackets 1 Sample Con figuration Only Exact Configuration Will Depend Upon Lift Truck Manufacturer Figure 1 1 Mounting Brackets Section 1 INSTALLATION 1 7 Replace any melted grease on the mast channels with graphite base grease 30 graphite base recommended 1 8 CROSSBAR BRACKET INSTALLATION 1 9 All Quad Lift Masts must have a crossbar bracket installed near the tilt cylinder anchor brackets Some tilt cylinder anchor brackets incor porate the crossbar bracket as an integral part of the bracket assembly Integral Crossbar Bracket Figure 1 2 Integral Crossbar Bracket 1 10 If the crossbar bracket is not an integral part of the tilt cylinder anchor bracket a bracket may be fabricated and installed as follows 1 Fabricate a 1 x 5 x 22 bar from A 7 steel 2 Cut two 3 x 3 x 5 blocks from A 7 steel 3 Weld a block to each outer upright channel not more than 6 above the cylinder anchor brackets See Figure 1 3 Use E 70XX low hydrogen welding rod and weld on vertical seams only Preheat to 300
26. T Outer Intermediate Channel Crossmember Outer Channel Crossmember Lue With Bootstrap Chains Properly Ad justed Outer Intermediate Channel Crossmember Just Touches Outer Channel Crossmember Adjustment For Adjustment for Masts With Masts With 3 Underclearance 5 Underclearance Figure 4 45 Bootstrap Chain Adjustment 2 Adjust the carriage to the following specifica tions by adjusting the carriage chain anchors in the cylinder bracket a The yoke must be evenly centered in the y carriage b For masts with 3 underclearance adjust the carriage so the bottom of the lower fork bar is even with the bottom of the outer channel when the mast is fully collapsed c For masts with 5 underclearance adjust the carriage so the bottom of the lower fork Figure 4 47 Carriage Positioning bar is 2 below the bottom of the outer channel when the mast is completely collapsed CAUTION Before proceeding make certain both nuts on each carriage chain anchor and on NOTE To prevent damage to the carriage latch each bootstrap chain anchor are tight Section 4 Figure 4 48 Latch Positioning 3 Inspect the latch mechanism on the inner intermediate channel The latch throat that engages the pin must be horizontal as shown in figure 4 48 If the capscrew latch pin holds the latch in a non horizontal position add or subtract shims under the contact pad on the top of the ou
27. ap pears to bind during op eration Carriage adjusted too tight in inner channel Remove hose inspect guides and reinstall as out lined in sub section 1 11 Hose guides bent or improp erly installed Mast hose comes out of hose guides during oper ation Hose twisted when tight ened at bulkhead fitting Remove hose and reinstall as outlined in sub section l 11 Hose not lying properly in hose guides Mast hose chafing or show ing visible wear spots Replace latch as outlined in sub section 4 7 steps 2 and 19 Adjust mast as outlined in sub section 4 10 steps 3 4and 10 Latch mechanism damaged Mast out of adjustment continued on page 18 Latch spring broken or missing Page 18 PROBLEM i POSSIBLE CAUSE SOLUTION Trouble Shooting amp Maintenance Section 2 Latch mechanism damaged continued Latch pin damaged or miss ing Crosshead out of adjust ment Inspect capscrew latch pins on inner intermediate chan nel crossmember outer in termediate channel cross member and back of cross head If damaged or missing replace using only cap screws meeting specifica tions outlined in sub section 2 4 step 3 Inspect latch pin on back of carriage and replace if dam aged or missing Replace damaged latches as outlined in sub section 4 7 steps 2 and 19 Adjust mast as outlined in
28. b section 3 4 7 Disconnect the carriage chains from both sets of chain anchors and pull the chains free of the sheaves Clean the chains in kerosene and soak in SAE 30 engine oil while servicing the mast 8 Remove the carriage chain anchors from the cylinder base in the outer intermediate chan nel Carriage Chain E Carriage Chain Anchor a en Outer Intermediate Channel _ Figure 4 5 Bootstrap Chain Figure 4 7 Carriage Chain Anchors Page 28 9 Remove the two capscrews that retain the crosshead to the cylinder s inner plunger Slide the crosshead to the top of the mast 10 Secure the crosshead with a strap and an overhead crane Unthread the capscrews retain ing the wear shoes and remove the crosshead from the mast Figure 4 8 Crosshead Removal 11 Remove the setscrew and the jamscrew from both sheave brackets in the crosshead Tap both sheave shafts out and remove the sheave components Sheave Bearing Thrust Washer Figure 4 9 Crosshead Channel Service Section 4 12 Secure the cylinder with straps and an over head crane Slide the cylinder out of the cylinder base and lift it out of the mast NOTE If the cylinder is to be disassembled loosen the retainer on the cylinder shell with the proper spanner wrench before sliding the cylinder out of the base 13 Remove the capscrew latch pin from the upper crossmember of the outer interm
29. ch pins on the outer 4 Check the latch pin on the back of the carriage intermediate channel crossmember and the and replace if damaged or missing back of the crosshead If damaged or missing Sd they must be replaced with a grade 5 or better 5 8 UNC x 1 socket head not knurled capscrew Inspect the capscrew latch pin on the inner intermediate channel crossmember If damaged or missing it must be replaced with a grade 5 or better 1 2 UNC x 3 4 socket head not knurled capscrew Y UNC x Socket Head Capscrew Not Knurled Grade 5 or Better Figure 2 4 Carriage Latch Pin 5 Check the bootstrap chains to make sure they Inner are under equal tension and if necessary Intermediate adjust as outlined in sub section 2 6 step 10 Channel e Outer Intermediate Channel 5 8 UNC x 1 Socket Head Capscrew Not Knurled Grade 5 or Better Crosshead Figure 2 3 Latch Pin Location Figure 2 5 Bootstrap Chain Section 2 6 Start the lift truck and raise the mast to its full height Inspect all channels for lubrication If any part of a sliding surface is not completely coated with grease apply graphite base grease 30 graphite base recommended CAUTION Before greasing the channel tum the lift truck off and make sure no one is near the lift truck control handles 7 Lower the mast If the mast does not sequence or operate properly ref
30. channel is securely fastened to an overhead crane before attempting to install it a Pull the outer intermediate channel approx imately 1 3 of the way out of the outer channel b Place two shims each behind two bearing strips and replace the bearing strips on the interior face of the inner intermediate channel c Place two shims each behind two bearing strips and replace the bearing strips on the exterior face of the inner intermediate channel d Coat the exterior surface of the inner intermediate channel with graphite base grease 30 graphite base recommended e Slide the inner intermediate channel into the outer intermediate channel Adjust the inner intermediate channel in the outer intermediate channel as follows a Fully tighten the wear plugs on the front and back sides of both channels Do not tighten the steel setscrews Page 34 Channel Service Section 4 rage ST A A A A A A a and bottom end of the outer intermediate channel D Inner Intermediate Channel Must Be Centered From Front to Back to Within 1 16 in Outer Intermediate Channel Inner Intermediate Channel Bearing Strips and Outer Intermediate Channel Figure 4 25 Channel Clearances c When the inner intermediate channel is centered front to back tighten all wear plugs in the sides of both channels Do not tighten the steel setscrews B NOTE Only tighten and adjust the wear plugs
31. check the carriage adjustment and if Side Plate necessary recheck the carriage roller assemblies 10 Check to make sure the carriage latch pin does not hit or touch the crosshead If the latch pin does come into contact with the crosshead Figure 4 39 Carriage Clearances recheck the crosshead adjustment as outlined in sub section 4 7 step 14 8 Slide the carriage up until the crosshead is l between the carriage side plates The side plates 11 Replace both chain anchors in the yoke must clear the crosshead by 1 4 1 16 If making sure the snap rings are securely in their the side plate clearances do not meet this grooves See figure 4 38 specification readjust the side wear plugs in the inner channel to center the carriage around the crosshead as follows 4 9 MAST INSTALLATION a Loosen the steel setscrews in the side wear o e ofthe inner channel 1 Reposition the mast on the work surface so the carriage is facing down b Adjust the wear plugs until the carriage side plates are centered around the crosshead c Back each wear plug off 1 4 turn and tighten the steel setscrews Carriage Side Plates Must Clear The Inner 7 Crosshead By Intermediate 1 4 to 1 16 2 Crosshead Carriage Side Plates Bulkhead Bracket Carriage TOP VIEW Bulkhead Fitting No 8 JIC Figure 4 40 Carriage Clearances NOTE If the carriage is centered in respect to the inner chan
32. e base of the inner plunger and replace the valve cartridge d Latch mechanisms and installation refer ence sub section 4 7 steps 2 and 19 Latch mechanism adjustment reference sub section 4 10 steps 3 4 and 10 Page 46 Channel Service Section 4 4 11 SAFETY INSPECTION 4 12 Every Quad Lift Mast has No Hand Hold decals part no C 655248 located on the side of the outer channel and on the back of the three upper crossmembers See figure 4 53 If any of these decals are missing contact the Cascade parts depot for replacements 4 13 In addition to the mast inspection pro cedures described in sub section 4 10 the mast should be rechecked to insure that 1 The mast hose is properly fitted in the hose guides and remains in the guides during opera tion reference sub section 4 9 steps 1 through 10 No Hand Hold 2 The crossbar bracket is securely mounted to Decals the outer channel reference sub section 1 8 3 All hose guides hoses etc clear the crossbar bracket during operation 4 The hoist cylinder is bled and free of air reference sub section 4 10 step 7 5 The hoist cylinder bleeder screw is tight and no leakage is occurring reference sub section Figure 4 53 No Hand Hold Decals 4 10 step 7 7 The chain is free of paint and weld splatter 6 All No Hand Hold decals are legible and in their proper location and the paint masks have 8 All mast channels are lubr
33. e bottom of the intermediate plunger NOTE Take special precautions to prevent scratching or gouging the plunger while remov ing the retaining ring 6 Lay the two plungers in a set of V blocks and secure to the workbench with straps CAUTION Always use an overhead crane to position the assembled plungers NOTE The plunger must not be clamped in a Intermediate RR SS sea A Ring Plunger l i Te Inner is Inner Plunger _ Plunger A Retainer _ Back Up Ring _ O Ring Intermediate Plunger Bleeder A Screw Piston Washer Halves _ Retaining Spring e Ring Spacer a x av 5 Piston Halves Figure 5 5 Hoist Cylinder eS Nylon Ring A a Seal 0 Valve Cartridge O Ring 8 o Washer S 2 Snap Ring Page 50 vice Clamping may damage the chrome surface or cause distortion requiring the replacement of the plunger assembly Remove the plug from the inner plunger as follows a Thread two socket head capscrews 1 2 UNF x 1 into the holes on the top of the plug b Secure the inner plunger with a strap wrench to prevent it from turning c Use a bar between the two capscrews to unthread the plug d Remove and discard the O ring Using a spanner wrench and strap wrench remove the inner plunger retainer Inner Plunger IA pt Inner Plunger Retainer Intermediate Plunger Figure 5 6 Cylinder Disasse
34. e channel in the outer channel as follows see figure 4 21 CAUTION Make sure the outer intermediates channel is securely fastened to an overhead crane before attempting to install it a Place two shims each behind two bearing Channel Service Section 4 strips and replace the bearing strips on the interior face of the outer channel b Place two shims each behind two bearing strips and replace the bearing strips on the exterior face of the outer intermediate channel c Coat the exterior surface of the outer intermediate channel with graphite base grease 30 graphite base recommended d Slide the outer intermediate channel into the outer channel Outer Intermediate Channel Bearing Strips and Channel Figure 4 21 Channel Assembly 8 Adjust the outer intermediate channel in the outer channel as follows a Fully tighten the wear plugs on the front and back sides of both channels Do not tighten the steel setscrews Section 4 NOTE Only tighten and adjust the wear plugs at the bottom of the outer intermediate chan nel and the top of the outer channel b If the outer intermediate channel is more than 1 16 off center front to back loosen the wear plugs and remove the channel Add or subtract shims behind the four bearing strips as required to center the channel Reinstall the outer intermediate channel in the outer chan nel l Outer Inter mediate
35. e facing up 3 3 MAST REMOVAL 1 Secure the mast to an overhead crane using the lifting technique outlined in sub section 1 12 steps J and 2 See figure 3 1 UNC x 2 Capscrew Grade 5 or Better Washer Figure 3 1 Lifting Procedure CAUTION It is important that the mast be properly secured in a stable upright position before proceeding 2 Disconnect the forks or attachment from the carriage 3 Disconnect and cap the supply hose from the lift truck and the cylinder supply hose See figure 3 2 CAUTION Recheck the chains and overhead crane being used to hold the mast in an upright position Section 3 CARRIAGE SERVICE XS Guide R H J amp Bulkhead SS Bulkhead Fitting No 8 JIC D 3 Bracket 7 o gt Male E Ya T Connector SS 90 Fitting Figure 3 2 Mast Hosing 4 Disconnect the tilt cylinders 5 Disconnect the base mounting brackets 6 Remove the latch pin from the back of the carriage Latch Pin Figure 3 3 Carriage Latch Pin Page 22 Carriage Service Section 3 7 Lay the mast on a work surface with the 2 Inspect each roller for excessive wear If there carriage facing up is a visible flat area or a crack in the roller the roller assembly must be replaced NOTE Take precautions to prevent bending the hose brackets while positioning the mast on 3 Inspect the latch pin If it is bent or damaged it the work surface must be replaced
36. e of the inner plunger Place a new O ring and reinstall the washer and snap ring in the port See figure 5 9 Place a new seal and nylon ring on the base of the inner plunger as follows NOTE The seal used on the base of the inner plunger and the seal used in the inner plunger retainer are nearly identical in appearance and size but are not interchangeable To assure proper cylinder operation it is extremely important that these seals be used in their correct locations The correct seal for use on the base of the inner plunger has the sealing lip on the O D of the seal as shown in figure 5 12 Cylinder Service Section 5 Nylon Ring Seal Figure 5 13 Inner Plunger Base c Hook one edge of the seal in the seal groove with the open end of the seal facing the bottom of the plunger Manually press the seal into the groove using a circular pattern in applying pressure Saat tee 4 Place a new back up ring and O ring in that Retainer order on the O D of the intermediate plunger retainer 5 Place a new seal nylon ring and wiper ring in that order in the intermediate plunger re tainer s I D seal groove The open end of the Sealing Lip seal should face the threaded end of the retainer Wiper Ring Use this Seal on Base of inner Plunger Nylon Ring YH sea ES Sealing Lip Figure 5 12 Seals a Lubricate the base of the inner plunger with petroleum jelly cut with hydraulic oil b H
37. e thread on the O D of the plug it must be replaced Figure 4 12 Latch Mechanism NOTE During reassembly notice how far the steel setscrew will thread into the plug If the 17 Secure the outer channel to the work surface setscrew touches the channel before tightening Use a pry bar between the channel cross the plug the plug must be replaced members to begin separating the channels Pry Between Crossmembers To Separate Channels Steel Setscrew Figure 4 14 Brass Wear Plug NOTE If any of the wear plugs require replacement it is a good preventive mainte nance procedure to replace the entire set of plugs in each channel 2 Inspect the bearing strips from each channel If the tread on the bearing strip is not plainly visible it must be replaced NOTE If any of the bearing strips require replacement it is a good preventive mainte nance procedure to replace the entire set of Figure 4 13 Channel Separation bearing strips used on the mast Page 30 Channel Service Section 4 6 Rotate each sheave on its respective shaft The sheave should turn freely with no restrictions If there is a restriction or catch in the rotation replace the sheave bearing Replace the sheave roller if it is visibly worn or damaged Replace the shaft if it is visibly worn or damaged 7 Inspect the contact pads in the following locations a The top of the inner intermediate channel
38. ediate chan nel Capscrew Latch Pin Outer Intermediate ____ _ Channel Figure 4 10 Capscrew Latch Pin 14 Remove the capscrew and retaining plate from the latch bracket on the inner channel cross member Pull the pivot pins out of engagement and at the same time remove the latch mechanism c Retaining apscrew ey 7 Plate re ___Spring er Pivot Pin _ Setscrew Jamscrew Figure 4 11 Latch Mechanism 15 Remove the setscrew and jamscrew from both upper and both lower sheave brackets on the inner channel Tap the sheave shafts out and remove the sheave components Section 4 Channel Service Page 29 16 Remove the latch mechanism on the inner 18 Individually pull each channel out the top of intermediate channel crossmember by remov the upright assembly beginning with the inner a ing the capscrew and retaining plate on the channel back side of the latch bracket NOTE In most cases it will be necessary to use Retaining Plate a pry bar against the channel crossmember to separate the channel from the upright assembly CAUTION Before completely removing a channel secure it with an overhead crane 4 6 INSPECTION 1 Inspect the brass wear plugs in each channel If the brass has worn through on the inside of the wear plug it must be replaced If the brass has not worn through inspect the plug s wear Pivot Pin surface If the wear surface has worn down to th
39. el bearing grease Use one of the following adapters for easy access to the grease fittings a Alemite no 321990 90 adaptor on a flexible hose b Alemite no 322120 90 adaptor perma nent attachment to grease gun c Universal no 31 90 adaptor d Lincoln no 5855 adaptor extension push type adaptor does not lock onto gun Reconnect the forks or attachment to the carriage Carefully raise the carriage to the top of its free lift position height of collapsed mast and then lower the carriage to its lowest position Check the following points CAUTION Make sure all persons are clear of the mast during testing a The carriage must completely lower with the weight of the forks only If the carriage does not lower refer to the trouble shooting guide in section 2 b The carriage side plates must maintain a 1 4 1 16 clearance between the inner channel crossmembers If the side plates do not maintain the required clearance between the crossmembers readjust as outlined in sub section 4 8 step 7 c The carriage side plates must maintain a Page 44 1 4 1 16 clearance on both sides of the crosshead If the side plates do not maintain this clearance readjust as outlined in sub section 4 8 step 8 d The carriage must not touch the cylinder shell If the carriage is scraping against the cylinder shell the crosshead is too loose and must be adjusted as outlined in sub section 4
40. er to the trouble shoot ing guide in sub section 2 10 8 Make sure the mast hose is not twisted and is traveling correctly in the hose guides If the hose does not lay correctly in the hose guides it must be reinstalled to prevent chafing and damage reference sub section 1 11 Hose Guide R H Bulkhead 7 Bracket Bulkhead Fitting Hose ki No 8 JIC Guide lo N 90 Fitting Figure 2 6 Mast Hosing 2 6 100 HOUR MAINTENANCE amp INSPECTION 2 7 Every 100 truck operating hours or every four weeks the Quad Lift Mast should be serviced and inspected following the steps listed in this sub sec Trouble Shooting amp Maintenance Page 9 tion Unless otherwise indicated these procedures should be performed while the mast is in its completely lowered position the carriage com pletely lowered and the lift truck turned off CAUTION Never work on the mast while the lift truck is running or while anyone is near the lift truck control handles 1 Fully extend the mast and coat all sliding surfaces with graphite base grease 30 graph ite base recommended 2 Inspect the sliding surfaces for scoring If there are score marks on any of the channels the wear shoes or brass wear plugs in the mating channel may be excessively worn If the wear shoes require replacement the mast must be overhauled as outlined in section 4 If the brass wear plugs require replacement proceed as follows a
41. f the carriage Reinstall both chain anchors in the yoke making sure the snap rings are securely in their grooves Inspect the chains to make sure they are not twisted and are lying properly in the sheaves 3 7 MAST INSTALLATION l Thread a 3 4 UNC x 2 1 2 capscrew grade 5 or better with a large flatwasher into the hole on each side of the mast as shown in figure 3 1 CAUTION The capscrews must be threaded into the holes until they bottom out before the mast is lifted Page 24 Carriage Service Section 3 2 Using suitable chains lift the mast into installa b For masts with 3 underclearance adjust tion position the carriage so the bottom of the lower fork bar is even with the bottom of the outer amp 3 Connect the supply hose to the bulkhead channel fitting on the right hand hose bracket Adjustment For Adjustment For 4 Lubricate the interior diameters of the base Masts With Masts With mounting brackets with wheel bearing grease 3 Underclearance 5 Underclearance and mount on the truck 5 Lubricate the interior diameters of the tilt cylinder anchor brackets with wheel bearing grease and attach the tilt cylinders 3 8 CARRIAGE ADJUSTMENT 1 With the mast in the fully lowered position adjust the carriage to the following specifica tions by adjusting the chain anchors in the Carriage cylinder base ye a The yoke must be evenly centered in the Even mae dr carriage See fi
42. g 8 Maintenance Section 2 7 Lubricate all mating surfaces on the latch mechanisms with SAE 30 engine oil 8 Adjust the carriage position according to the following specifications by adjusting the car riage chain anchors located in the cylinder base Carriage Carriage Chain Anchor Outer Intermediate Channel _7 Figure 2 15 Carriage Chain Anchors a The yoke must be evenly centered in the carriage as shown in figure 2 16 CORRECT Figure 2 16 Carriage Yoke Position b For masts with 3 underclearance adjust the carriage so the bottom of the lower fork bar is even with the bottom of the outer channel See figure 2 17 c For masts with 5 underclearance adjust the carriage so the bottom of the lower fork bar is 2 below the bottom of the outer channel See figure 2 17 Adjustment For Adjustment for Masts With Masts With 3 Underclearance 5 Underclearance Carriage Figure 2 17 Carriage Positioning 9 Push the crosshead from side to side If it moves more than 1 16 or it is mare than 1 16 off center in relation to the inner intermediate channel adjust as follows Crosshead Hoist Cylinder Figure 2 18 Crosshead Section 2 a Block the carriage up b Disconnect the carriage chains by removing the two small chain anchors from the yoke Snap Rings Carriage Chains Carriage Chain Anchors Figure 2 19 Carriage Chain Anc
43. g suitable chains lift the mast into installa tion position Figure 1 8 Hoist Cylinder Bleeder Screw 3 Connect the supply hose to the bulkhead fitting on the right hand hose bracket 7 Run the lift truck at normal operating volume and pressure and slowly open the truck control 4 Lubricate the interior diameters of the base valve in the raise position Keep the valve mounting brackets with wheel bearing grease open until a clear flow of oil is obtained and mount on the truck around the bleeder screw Page 6 Installation Section 1 CAUTION The cylinder must be free of air for safe operation 8 Tighten the bleeder screw during cylinder extension and check for leakage 9 Carefully sequence and tilt the mast to its full extent to check for obstructions and proper operation If the cylinder or mast does not sequence or operate properly refer to the trouble shooting chart sub section 2 10 CAUTION Check for overhead obstructions before raising mast 10 During the first extension of the mast make sure the hose and hose brackets clear the crossmember 1 13 The mast should now be ready for operation In addition to the previously mentioned pro cedures Cascade recommends that the supply hose be secured to the truck cowling to prevent the hose from being damaged while the mast is in operation 1 14 SAFETY INSPECTION 1 15 Every Quad Lift Mast has No Hand Hold decals part no C 655248 located on
44. gure 3 7 CORRECT Figure 3 8 Carriage Adjustment c For masts with 5 underclearance adjust the carriage so the bottom of the lower fork bar is 2 below the bottom of the outer channel NOTE To prevent damage to the carriage latch pin the carriage must not be allowed to go lower than these specifications CAUTION Before proceeding make certain both nuts on each chain anchor are tight 3 9 FINAL INSPECTION 1 Carefully sequence and tilt the mast to its full extent to check for obstructions and proper mast sequencing If the mast is not operating properly refer to the trouble shooting chart in sub section 2 10 2 Before placing the mast back into service complete the safety inspection procedures out Figure 3 7 Carriage Yoke Position lined in sub section 1 14 of this manual 4 1 INTRODUCTION 4 2 This section outlines all necessary procedures for disassembling repairing and assembling the channel sections of the Quad Lift Mast 4 3 Before disassembling the mast the following items should be on hand or readily available a wear shoes b shims c wear plugs d crosshead wear shoes e crosshead shims Refer to the Quad Lift Mast parts manual Cascade form 5038 for specific part numbers 4 4 MAST REMOVAL 1 Secure the mast to an overhead crane using the lifting technique outlined in sub section 1 12 steps 1 and 2 See figure 4 1 UNC x 2 Capscrew Grade
45. h Service Manual M4Q Quad Lift Mast 5 Manual Number 667415 Cascade Cascade is a Registered Trademark of Cascade Corporation Quad Lift Mast Service Manual Sub Section SECTION 1 INSTALLATION Introduction 0 icc ew be a a eee ees 1 1 Base Mounting amp Anchor Bracket Installation 1 5 Crossbar Bracket Installation 0 eee eee eee 1 8 Mast Hosing Installation lt lt oooooomomr rr 1 11 Mast Installati n oo s be a ar o 8S 1 12 Safety Inspection oirlo da A A Be 1 14 SECTION 2 TROUBLE SHOOTING MAINTENANCE TntEOUCtON iii E a e RE Bees SS 2 1 Daily Inspection reece soiree E AAA 2 4 100 Hour Maintenance amp Inspection lt ooooooooo ooo 2 6 500 Hour Maintenance amp Inspection Includes Mast Adjustments 2 8 Trouble Shooting Guide lt o ooo lt oooooooooono os 2 10 SECTION 3 CARRIAGE SERVICE Introduction secesi a A a tota 3 1 Mast Removal eseo eea i a a a ai 3 3 Carriage Removal amp Disassembly oo lt lt oooooommo 3 4 Carriage Inspection ias ddr eae ewes 3 5 Carriage Assembly amp Installation oo eee loe 3 6 Mast Installation AA ARA 3 7 Carriage Adjustment dr dr sd es 3 8 Final Inspections ssec esmu rnia n a e EDE AAA ARA 3 9 SECTION 4 CHANNEL SERVICE Introduction e sereni noe ls ERAS EE RGA OY 4 1 Mast Removal es 4 cud vexe ox a sehen seule Aia 4 4 Upright Disassembly ose es deo RA 4 5
46. he sheave b Coat the shaft with wheel bearing grease c Place one retainer on each side of the sheave and replace the sheave in its bracket d Replace the shaft so the grease fitting is toward the outside e Replace and tighten the setscrew After the setscrew is tightened replace and tighten the jamscrew f Rotate both sheaves to make sure they are turning without restrictions Outer Intermediate Channel Setscrew A Jamscrew ON Sheave 9 Bearing Retainer Figure 4 31 Outer Intermediate Sheave 16 Reinstall the bootstrap chain as follows a Thread the chains through the sheaves in the lower part of the outer intermediate channel b Connect the chains to the chain brackets on the lower crossmember of the inner inter mediate channel c Connect the chains to the chain anchors on the outer channel Chain Anchor Outer Channel Chain Anchor Inner Inter mediate Channel Bootstrap Chain Sheave Outer Intermediate Channel Figure 4 32 Bootstrap Chain Location 18 NOTE If the chain will not reach the chain anchor pry the outer intermediate channel and the inner intermediate channel out a few inches d Inspect the chains to make sure they are not twisted and are lying properly in the sheaves Push all channel members into the completely collapsed position and turn the mast over on the work surface so the channel crossme
47. hors c Remove the two capscrews that retain the crosshead to the cylinder plunger Wear Shoe Crosshead Figure 2 20 Crosshead Adjustment Trouble Shooting Maintenance Page 13 d Slide the crosshead part way up the mast and secure it in this position with a chain e Remove the capscrews that retain one wear shoe and slide the wear shoe free of the crosshead f Add the necessary number of shims behind the wear shoe slide it back into position on the crosshead and reinstall the capscrews NOTE If the crosshead requires more than four shims behind each wear shoe to meet specifications the wear shoe must be replaced g Repeat this procedure with the other wear shoe and recheck the tolerances The crosshead must not move more than 1 16 from side to side and must be centered to within 1 16 between the inner intermediate channel h Reconnect the crosshead to the plunger If the original capscrews are not used the replace ments must be grade 5 or better 1 2 UNF x 1 socket head capscrews i Reconnect the carriage chain anchors to the yoke j Slowly raise the carriage until the crosshead is between the carriage side plates Turn the lift truck off The side plates must clear the crosshead by 1 4 1 16 If the side plate clearances do not meet these specifications adjust the side wear plugs in the inner channel reference sub section 4 8 step 8 TOP VIEW
48. icated with graphite been removed base grease 30 graphite base recommended Section 5 5 1 INTRODUCTION 5 2 This section outlines procedures for over hauling the Quad Lift Mast hoist cylinder 5 3 Before the cylinder is disassembled a com plete set of soft parts O rings seals back up rings etc should be in stock or readily available A new valve cartridge for the base of the inner plunger should also be available Refer to the Quad Lift Mast parts manual Cascade form 5038 for specific part numbers 5 4 To service the hoist cylinder the mast should be removed from the lift truck and the cylinder should be removed from the mast 5 5 MAST REMOVAL 1 Thread a 3 4 UNC x 2 1 2 capscrew grade 5 or better with a large flatwasher into the hole on each side of the mast as shown in figure 5 1 CAUTION The capscrews must be threaded into the holes until they bottom out before the mast is lifted Y UNC x 2 Capscrew Grade 5 or Better Washer Figure 5 1 Lifting Procedure 2 Using suitable chains secure the mast to an overhead crane 3 Disconnect the forks or attachment from the carriage CYLINDER SERVICE 4 Disconnect and cap the supply hose from the lift truck CAUTION Recheck the chains and overhead crane being used to hold the mast in an upright position 5 Disconnect the tilt cylinders 6 Disconnect the base mounting brackets and remove the mast from the
49. il it is at the bottom of the mast i During the first extension check to make sure the hose and hose brackets clear the crossmembers Beginning with the mast in its completely lowered position bleed the cylinder as follows CAUTION Make sure all persons are clear of the mast during testing a Loosen the bleeder screw located near the top of the mast hoist cylinder as shown in figure 4 50 CAUTION Do not unthread the bleeder screw more than 1 tum when bleeding the hoist cylinder Keep hands clear of the mast while operating the truck valve b Run the lift truck at normal operating volume and pressure and slowly open the truck control valve in the raise position Keep the Section 4 valve open until a clear flow of oil is obtained around the bleeder screw CAUTION The cylinder must be free of air for safe operation Figure 4 50 Bleeder Screw 9 Figure 4 51 Latch Mechanism c Tighten the bleeder screw while the cyl inder is extending and check for leakage When the mast is fully lowered recheck the latch mechanisms They should be in the positions described in steps 3 and 4 If they are not in this position adjust as outlined in the same steps Raise the mast until the crosshead has begun raising the inner intermediate channel Turn the lift truck off and inspect the latch mech anism on the inner intermediate channel A CAUTION Make sure the lift truck is off and no one
50. ing reassembly the crosshead requires more than four shims behind each wear shoe to tighten it to specifications the wear shoes must be replaced See figure 4 9 9 Inspect the latch mechanisms Replace any component that is visibly damaged See figures 4 11 and 412 4 7 UPRIGHT ASSEMBLY 1 Reinstall both sheaves in the crosshead as follows a Reinstall the bearing in the sheave b Coat the shaft with wheel bearing grease c Place one thrust washer on each side of the sheave and reinstall the sheave in its bracket d Reinstall the shaft so the grease fitting is toward the outside e Reinstall and tighten the setscrew After the setscrew is tightened reinstall and tighten the jamscrew f Rotate each sheave to make sure it is turning without restriction Bearing Sheave G ee Oo Thrust Washer Figure 4 18 Crosshead 2 Reinstall the latch mechanism on the inner intermediate channel as follows a Engage the two latches and latch spring as shown in figure 4 19 b Coat the pivot pins with wheel bearing grease c Slide the latches into the latch bracket so the spring is toward the back side cross member side of the channels d Reinstall the two pivot pins with the notched ends toward the back side of the channel e Engage the keeper plate in the pin notches and reinstall the capscrew and lockwasher in the keeper plate f Manually trip the latch several times to be sure it i
51. is near the lift truck control handles before inspecting the latch mechanism a The latch mechanism must be engaged with the latch pin on the back of the carriage and the two latches must be interlocked Channel Service 11 Page 45 b The latch throat that engages the pin must be completely horizontal If the latch pin holds the latch in a non horizontal position add or subtract shims under the contact pad on the back of the crosshead until the latch is in the proper position when engaged with the cross head latch pin CAUTION If the latches are not properly adjusted they could over travel causing latch failure and incorrect mast sequencing With the mast in the same position as in step 10 check the latch mechanism on the inner channel The latch mechanism should be en gaged with the carriage latch pin and the two latches should be interlocked Figure 4 52 Latch Mechanism 12 If the mast does not sequence properly re check the following points a Adjustment and installation of the carriage chains reference sub section 4 7 step 22 and sub section 4 10 step 2 b Bootstrap chain adjustment and installation reference sub section 4 7 step 16 and subsection 4 10 step 1 c Cylinder sequencing The intermediate plunger should fully extend before the inner plunger begins extending If the cylinder is not sequencing correctly disassemble as outlined in section 5 Inspect the valve porting in th
52. lift truck 7 Disconnect and cap the mast hose from the bulkhead fitting and from the cylinder port Bulkhead j Bracket Dy Bulkhead Fitting La No 8 JIC Bpi o Male TA HA Oe Connector NS 90 Fitting Figure 5 2 Mast Hosing 8 Remove the male connector from the cylinder port and cap the port NOTE The cylinder port contains a washer spring and spacer Care should be taken to avoid losing these parts during disassembly Page 48 9 Lay the mast on a work surface with the carriage facing up CAUTION Always use an overhead crane to lift the mast 5 6 CYLINDER REMOVAL 1 Slide the carriage to the top of the mast 2 Remove the two capscrews that retain the crosshead to the cylinder s inner plunger Slide the crosshead to the top of the mast Capscrews Crosshead ea a o e f a A En Inner Plunger Figure 5 3 Crosshead 3 Loosen the intermediate plunger retainer with the proper spanner wrench before sliding the cylinder out of the base 4 Secure the cylinder with straps to an overhead crane Slide the cylinder out of the cylinder base and lift out of the mast 5 7 CYLINDER DISASSEMBLY 5 8 Care must be taken during cylinder disas sembly and assembly to prevent damage to the chrome surfaces of the plungers and the I D of the shell Minor nicks and scratches may be repaired by using fine emery paper Nicks or scratches that cannot be easil
53. lubrication 11 Thread the inner plunger retainer into the intermediate plunger and tighten with a span ner wrench Page 53 Cy Plug S Ring O va Inner Plunger i Inner Plunger OS Retainer il EN Intermediate Plunger Figure 5 16 Cylinder Assembly 12 Replace the plug in the inner plunger as 13 follows a Place a new O ring on the plug b Thread two socket head capscrews into the holes on the top of the plug c Secure the inner plunger with a strap wrench to prevent it from turning d Thread the plug into the plunger Tighten the plug by using a bar between the two capscrews Lay the shell in three or more V blocks and secure it to the workbench with straps NOTE The cylinder must not be clamped ina vice Clamping may distort the shell requiring the replacement of the shell assembly 14 Reinstall the piston half retaining ring and the Page 54 Cylinder Service Section 5 two piston halves on the base end of the 2 Reinstall the cylinder in its bracket intermediate plunger CAUTION Use an overhead crane to lift and 15 Slide the assembled plungers into the shell Use position the cylinder petroleum jelly cut with hydraulic oil for assembly lubrication 3 Fasten the crosshead to the inner plunger by reinstalling the two capscrews and lockwashers CAUTION Always use an overhead crane to If the original capscrews are not used the lift the as
54. ly removed by fine emery paper the shell must be replaced Inspect the O D and I D of the intermediate plunger Minor scratches or abrasion spots may be removed by rubbing lightly with fine emery paper If there are scratches or abrasion spots that cannot be easily removed by fine emery paper the plunger must be replaced If the chrome surface has visibly deteriorated on any part of the O D the plunger must be replaced Inspect the O D of the inner plunger Minor scratches or abrasion spots may be removed by rubbing lightly with fine emery paper If there are scratches or abrasion spots that cannot be easily removed by fine emery paper the plunger must be replaced If the chrome surface has visibly deteriorated on any part of the O D the plunger must be replaced Inspect the two intermediate plunger piston halves If they are visibly worn or have any scratches or gouges in their surface they must be replaced on Plunger Piston Halves gt gas Ring lt Piston Halves A reall Figure 5 11 Piston Halves 6 Thoroughly clean all parts before reassembling 5 12 CYLINDER ASSEMBLY 1 Lay the intermediate plunger in a set of V Page 52 blocks and secure to the workbench with straps NOTE The plunger must not be clamped in a vice Clamping may damage the chrome surface or cause distortion requiring the replacement of the plunger assembly Install a new valve cartridge in the bas
55. mbers are underneath the mast CAUTION Do not attempt to reposition the mast without an overhead crane Hand trip the latch on the inner intermediate channel so the capscrew latch pin may be Page 38 Channel Service Section 4 replaced in the outer intermediate channel crossmember Reinstall the capscrew latch pin and lockwasher Capscrew Latch Pin 5 8 UNC x 1 Socket Head Capscrew Not Knurled Grade 5 or Better Figure 4 33 Capscrew Latch Pin 19 Reinstall the latch mechanisms on the inner channel as follows a Engage the two latches and the latch spring as shown in figure 4 34 Capscrew Retaining Plate Spring a Latch ca Qy Pivot Pin Inner Channel Jamscrew Figure 4 34 Latch Mechanism b Coat the pivot pins with wheel bearing grease c Slide the latch mechanism into the bracket on the inner channel When the latches are located in the bracket one latch must be engaged with the capscrew latch pin on the inner intermediate channel and the spring must be on the front side away from the channels of the latches d Reinstall the two pivot pins with the notched ends facing the outside of the bracket e Engage the keeper plate in the pivot pin notches and reinstall the capscrew and lock washer in the keeper plate 20 Reinstall the cylinder in its bracket CAUTION Use an overhead crane to lift and position the cylinder 21 Fasten the cr
56. mbly 9 Remove the back up ring and O ring from the O D of the retainer by carefully prying up Cylinder Service Section 5 with a screwdriver and cutting them with a Knife Discard these parts NOTE Take special precautions to avoid scratching the seal groove Scratches in the seal groove will allow oil leakage and will require the replacement of the retainer Wiper Ring Nylon Ring lt Sea Inner Plunger Retainer rr DIOR Ring mas _ O Ring Figure 5 7 Inner Plunger Retainer 10 11 12 Remove the wiper ring nylon ring and seal from the I D of the retainer by carefully prying them out with a screwdriver Discard these parts NOTE Take special precautions to avoid scratching or gouging the seal grooves Scratches or gouges will allow oil by pass and will require the replacement of the retainer Pull the inner plunger out through the top of the intermediate plunger Remove the nylon ring and seal from the base of the inner plunger by carefully prying them up with a screwdriver and cutting them with a knife TA Inner Plunger gee Ring Ss Figure 5 8 Inner Plunger Seal NOTE Take special precautions to avoid scratching the seal groove Scratches in the seal groove will result in cylinder mis sequencing and require the replacement of the plunger c YUU LUUII 5 a51 vi art uyv 13 Remove the small snap ring in the base of the inner
57. nel crossmembers and requires more than 1 16 adjustment of the inner channel to center it around the crosshead recheck the crosshead wear shoes and adjust Figure 4 41 Mast Hosing Section 4 Channel Service Page 41 CAUTION Always use an overhead crane when positioning the mast NOTE The right hand hose guide has a bulkhead bracket welded to the bottom Bolt the right hand hose guide to the two mounting plates on the outer channel Bolt the left hand hose guide to the two mounting plates on the outer intermediate channel Reinstall the spacer spring and washer in the cylinder port making sure the parts are clean and that no dirt or contamination is contained in the port See figure 4 42 Washer EN 3 DY Spacer Spring Figure 4 42 Hoist Cylinder Port 10 CAUTION The spacer spring and washer must be properly installed in that order in the cylinder port for proper operation Thread a male connector into the cylinder port Attach a 90 fitting to the male connector Connect the mast hose to the 90 fitting Connect the short side of the bulkhead fitting to the other end of the hose Loop the hose in the hose guides as shown in figure 4 41 Secure the bulkhead fitting to the bulkhead bracket with a jam nut NOTE The hose must not be twisted when connected to the bulkhead bracket Twists in the hose will result in hose chafing and cause the h
58. ook one edge of the nylon ring in the seal groove Manually press the ring into the groove using a circular pattern in applying pressure Figure 5 14 Intermediate Plunger Retainer Section 5 Cylinder Service 6 Slide the retainer on to the intermediate plunger Use petroleum jelly cut with hydraulic D oil for assembly lubrication 7 Place a new back up ring and O ring in that order on the O D of the inner plunger retainer 8 Place a new seal nylon ring and wiper ring in that order in the inner plunger retainer s I D seal groove The open end of the seal should face the threaded end of the retainer See figure 5 15 NOTE The seal used on the inner plunger retainer and the seal used on the base of the inner plunger are nearly identical in appearance and size but are not interchangeable To assure proper cylinder operation it is extremely important that these seals be used in their correct locations The correct seal for use in the inner plunger retainer has the sealing lip on the I D of the seal as shown in figure 5 12 Wiper Ring Nylon Ring c Seal TT Sealing Lip Figure 5 15 Inner Plunger Retainer 9 Slide the retainer on to the inner plunger Use petroleum jelly cut with hydraulic oil for assembly lubrication 10 Place the base end of the inner plunger in the top end of the intermediate plunger and slide the two plungers together Use petroleum jelly cut with hydraulic oil for assembly
59. or diameters of the base mounting brackets with wheel bearing grease and mount on the truck 15 Lubricate the interior diameters of the tilt cylinder anchor brackets with wheel bearing grease and attach the tilt cylinders 5 16 The cylinder is now ready for testing Never Page 56 Cylinder Service place the mast back into operation without follow ing the testing and inspection procedures described in sub section 5 17 5 17 SAFETY INSPECTION 1 Make sure the carriage chains are lying properly in their sheaves CAUTION Make sure all persons are clear of the mast during testing 2 Beginning with the mast in its completely lowered position bleed the cylinder as follows WA pudibisay wawww AAEE a Loosen the bleeder screw located near the top of the cylinder as shown in figure 5 22 CAUTION Do not unthread the bleeder screw more than 1 turn when bleeding the cylinder Keep hands clear of the mast while operating the truck valve Figure 5 22 Hoist Cylinder Bleeder Screw b Run the lift truck at normal operating volume and pressure and slowly open the truck control valve in the raise position Keep the valve open until a clear flow of oil is obtained around the bleeder screw CAUTION The cylinder must be free of air for safe operation c Tighten the bleeder screw during cylinder extension and check for leakage Section 5 3 Slowly raise the mast to its full height and then lower to
60. ose to dislodge from the guides during operation Thread a 3 4 UNC x 2 1 2 capscrew grade 5 or better with a large flatwasher into the hole on each side of the mast as shown in figure 4 43 CAUTION The capscrews must be threaded into the holes until they bottom out before the mast is lifted UNC x 2 Capscrew Grade 5 or Better Figure 4 43 Lifting Procedure 12 13 14 15 Using suitable chains lift the mast into installa tion position Connect the supply hose to the bulkhead fitting on the right hand hose bracket Lubricate the interior diameters of the base mounting brackets with wheel bearing grease and mount on the truck Lubricate the interior diameters of the tilt cylinder anchor brackets with wheel bearing grease and attach the tilt cylinders 4 10 MAST ADJUSTMENT l Adjust the bootstrap chains to the following specifications by adjusting the chain anchors on the outer channel crossmember a Both chains must be under equal tension b The contact pad on the bottom of the outer intermediate channel crossmember must just touch the outer channel crossmember when the mast is fully lowered Page 42 Channel Service Section 4 pin the carriage must not be allowed to go lower than these specifications Outer Channel CORRECT Bootstrap Chain Anchor Bootstrap Chain i 44 B trap Chain Anch Figure 4 44 Bootstrap Chain Anchor INCORREC
61. osshead to the cylinder s inner plunger by replacing the two capscrews and lockwashers If the original capscrew are not used the replacements must be grade 5 or better 1 2 UNC x 1 socket head capscrews Y UNCx1 Socket Head Grade 5 or Better Hoist Cylinder Inner Plunger Figure 4 35 Crosshead 22 Install the carriage chain as follows a Reinstall the chain anchor in the base of the cylinder brackets F gi Carriage _ p Chain E Intermediate Channel Carriage Chain Anchor Figure 4 36 Carriage Chain Anchor Section 4 b Connect the chains to these chain anchors c Thread the chains through the sheaves as shown in figure 4 37 Sheave Top of Inner Channel Carriage Chain Sheave Chain Crosshead Anchor Cylinder Base Chain Anchor Carriage Sheave Bottom of Inner Channel Figure 4 37 Carriage Chain Location d Connect the small chain anchors to the chains to prevent them from slipping back through the sheaves e Inspect the chains to make sure they are not twisted and are lying properly in their sheaves 4 8 CARRIAGE INSTALLATION Secure the carriage with an overhead crane Coat the stub shafts with wheel bearing grease Reinstall the middle and lower roller assemblies by sliding the thrust washer shims roller and plug in that order on the shaft Slide the thrust washer inner shims roller and outer
62. ove the carriage chains Inspect and service the chains as fol lows a Inspect the side plates on the chain links for cracks caused by corrosion If a cracked side plate is found both chains must be replaced See figure 2 24 b Manually flex the chain joints to check for tight spots caused by bent pins plates or peened plate edges If cleaning does not free a joint both chains must be replaced c Wash the chains in kerosene wipe dry and soak in SAE 30 engine oil for 30 minutes Install the chains on the mast Adjust the carriage position according to the following Trouble Shooting Maintenance Page 15 guidelines by adjusting the chain anchors located in the cylinder base Sheave Top of Inner Channel Carriage Chain Sheave Chain Crosshead Anchor Cylinder Base Chain Anchor Carriage Sheave Bottom of Inner Channel Figure 2 26 Carriage Chain Installation a The yoke must be evenly centered in the carriage as shown in figure 2 16 b For masts with 3 underclearance adjust the carriage so the bottom of the lower fork bar is even with the bottom of the outer channel See figure 2 17 c For masts with 5 underclearance adjust the carriage so the bottom of the lower fork bar is 2 below the bottom of the outer channel Adjust the mast channels as follows a Extend the mast approximately 1 2 of the overall lift height and turn the truck off CAUTIO
63. plunger Remove the washer O ring and valve cartridge Discard the O ring and valve cartridge Base of Inner K Plunger ME Valve H T Cartridge O Ring ED Washer CAOS Snap Ring CS Figure 5 9 Inner Plunger Valve amp Port 14 Slide the intermediate plunger retainer off the 15 intermediate plunger See figure 5 4 Remove the back up ring and O ring from the O D of the retainer by carefully prying up with a screwdriver and cutting them with a knife Discard these parts NOTE Take special precautions to avoid scratching the seal groove Scratches in the seal groove will allow oil leakage and will require the replacement of the retainer Nylon Ring Seal Intermediate Plunger Retainer X z 4 E Ring Figure 5 10 Intermediate Plunger Retainer 16 Remove the wiper ring nylon ring and seal from the I D of the retainer by carefully prying them out with a screwdriver Discard these parts NOTE Take special precautions to avoid scratching or gouging the seal grooves Scratches or gouges will allow oil by pass and will require the replacement of the retainer 5 11 INSPECTION amp SERVICE ae Inspect and clean the valve ports in the base of the inner plunger See figure 5 9 Inspect the 1 D of the shell Minor scratches or abrasion spots may be removed by rubbing lightly with fine emery paper If there are scratches or abrasion spots that cannot be easi
64. pring aN S Spacer Figure 5 19 Cylinder Port CAUTION The spacer spring and washer must be properly installed in that order in the cylinder port for proper operation 5 Thread a male connector into the cylinder port Guide R H Bulkhead Bracket pat NN Fitting No 8 JIC SA Male ez T Connector on 90 Fitting Figure 5 20 Mast Hosing 6 Attach a 90 fitting to the male connector on amp the cylinder 7 Connect the mast hose to the 90 fitting 8 Connect the short side of the bulkhead fitting to the other end of the mast hose 9 Loop the hose in the hose guides as shown in figure 5 20 10 Secure the buikhead fitting to the bulkhead with a jam nut NOTE The hose must not be twisted when connected to the bulkhead bracket Twists in the hose will result in hose chafing and cause the hose to dislodge from the guides during operation 11 Thread a 3 4 UNC x 2 1 2 capscrew grade 5 or better with a large flatwasher into the hole on each side of the mast as shown in figure 5 21 UNC x 2 Capscrew Grade 5 or Better Figure 5 21 Lifting Procedure CAUTION The capscrews must be threaded into the holes until they bottom out before the mast is lifted 12 Using suitable chains lift the mast into installa tion position 13 Connect the supply hose to the bulkhead fitting on the right hand hose bracket 14 Lubricate the interi
65. r stub catch the roller assembly must be replaced shaft Reinstall the retaining plate and cap Stub Shaft Roller Outer Shim Retaining Plate Latch Pin G Snap Ring Thrust Washer Carriage Chain s Shims Anchor j Roller Figure 3 4 Carriage Section 3 Side Plate screws on each stub shaft Before proceeding make sure both upper rollers turn without restriction Slide the carriage back into the bottom of the inner channel If the carriage enters the channel freely re move and add shims behind the rollers until the carriage will just enter the channel without mechanical assistance NOTE All rollers on the same side of the carriage must be shimmed equally All six rollers on the carriage must be shimmed within one shim of being equal Slide the carriage to both ends of the mast to check clearances between the carriage side plates and the upper and lower channel cross members The carriage side plates must clear hath errocemoam hare 1 A 1 16 an kath hey VULL iUDOIIW11tUvio vy LT Wil UVelil sides If necessary remove the carriage and adjust the shims behind the rollers accordingly following the procedures outlined in steps 4 5 and 6 Side Plates Must Clear Crossmembers By 1 4 1 16 Figure 3 5 Side Plate Clearances 8 Slide the carriage up until the crosshead is between the carriage side plates The side plates must clear the crosshead by 1 4 1 16 If
66. rass Wear Plug Sy 4 _ Outer Intermediate Channel ERNST S 3 A NG p 2 Capscrew Bootstrap Chain Anchor Latch Pin Bearing Strip Bootstrap Chain Shim Brass i Wear y Plug Outer Channel Carriage Chain Y E 2 Brass Wear Plug eJ S at 5 o DN va Carriage Chain Anchor Bootstrap Chain Anchor Bootstrap Chain Figure 4 3 Quad Lift Mast Section 4 Channel Service Page 27 4 Remove the setscrew and the jamscrew from both sheave brackets in the base of the outer intermediate channel Tap both sheave shafts out and remove the sheave components from the brackets Outer Intermediate Washer Channel Spring aN a lt q Y Spacer o Sheave Setscrew Shaft ag Figure 4 4 Hoist Cylinder Port Os O 2 Remove both hose guides Sheave 3 Disconnect and remove the bootstrap chains Clean the chains in kerosene and soak in SAE 30 engine oil while servicing the mast Bearing OLED S Retainer NOTE The chain may be loosened for removal by prying the two intermediate channels out a gt Figure 4 6 Outer Intermediate Sheave few inches with a pry bar 5 Reposition the mast on the work surface with the carriage facing up CAUTION Always use an overhead crane to lift the mast 6 Remove the carriage following the procedures outlined in su
67. red position the carriage completely lowered and the lift truck turned off CAUTION Never work on the mast while the lift truck is running or while anyone is near the lift truck control handles 1 Complete all 100 hour maintenance and in spection procedures with the exception of steps 3 8 and 10 2 Remove the bootstrap chains see figure 2 5 from the mast Inspect and service as follows a Inspect the side plates on the chain links for cracks caused by corrosion If a cracked side plate is found both chains must be replaced See figure 2 24 b Manually flex the chain joints to check for tight spots caused by bent pins plates or peened plate edges If cleaning does not free a joint both chains must be replaced Figure 2 24 Chain Link Inspection c Wash the chains in kerosene wipe dry and soak in SAE 30 engine oil for 30 minutes 3 Install the chains on the mast and adjust according to the following guidelines by adjust ing the chain anchors on the outer channel crossmember Section 2 Chain Anchor Outer Channel Chain Anchor Inner Inter Bootstrap mediate Chain Channel Sheave Outer Intermediate Channel Figure 2 25 Bootstrap Chain Installation a Both chains must be under equal tension b The contact pad on the bottom of the outer channel crossmember must just touch the outer intermediate channel crossmember when the mast is fully lowered Block the carriage up and rem
68. s working properly and the spring is securely engaged with both latches Retaining Plate Pivot Pin Figure 4 19 Latch Mechanism 3 Unthread the wear plugs in each channel until they are flush with the channel surface NOTE Before attempting to unthread the wear plugs loosen the steel setscrews 4 Reinstall both the upper set and the lower set of sheaves in the inner channel as follows a Reinstall the bearing in the sheave b Coat the shaft with wheel bearing grease c Place one thrust washer on each side of the sheave and reinstall the sheave in its bracket d Reinstall the shaft so the grease fitting is toward the outside of the mast Page 32 e Reinstall and tighten the setscrew After the setscrew is tightened reinstall and tighten the jamscrew f Rotate each sheave to make sure it is turning without restrictions Thrust Washer Setscrew Qe Be at pee Or gt e Bearing Grease Fitting Setscrew Jamscrew Ue L 7 3 NY Co shaft Ey Grease Fitting Thrust Washer Bearing Figure 4 20 Inner Channel Sheaves 5 Lay the outer channel on a work surface with the crossmember facing up CAUTION Use an overhead crane to position the channel on the workbench 6 Secure the channel to the work surface in a position that will allow the remaining channels to be installed from the top of the outer channel 7 Install the outer intermediat
69. se Guide R H Bulkhead ig Bracket ee Fitting No 8 JIC 90 Fitting Figure 1 5 Mast Hosing Section 1 Installation Page 5 6 Connect the hose to the 90 fitting 5 Lubricate the interior diameters of the tilt cylinder anchor brackets with wheel bearing 7 Connect the short side of the bulkhead fitting grease and attach the tilt cylinders to the other end of the hose 8 Loop the hose in the hose guides as shown in figure 1 5 9 Secure the bulkhead fitting to the bulkhead Lubricate With Wheel Bearing Grease bracket with a jam nut NOTE The hose must not be twisted when connected to the bulkhead bracket Twists in the hose will result in hose chafing and cause the hose to dislodge from the guides during operation 1 12 MAST INSTALLATION 1 Thread a 3 4 UNC x 2 1 2 capscrew grade 5 or better with a large flatwasher into the hole on each side of the mast as shown in figure 1 6 CAUTION The capscrews must be threaded Figure 1 7 Lubrication Points into the holes until they bottom out before the mast is lifted 6 Loosen the bleeder screw located near the top of the mast hoist cylinder See figure 1 8 CAUTION Do not unthread the bleeder screw UNC x 2 more than 1 tum when bleeding the hoist Capscrew Grade cylinder Keep hands clear of the mast while 5 or Better operating the truck valve MT Figure 1 6 Lifting Procedure 2 Usin
70. sembled plungers replacements must be a grade 5 or better 1 2 UNF x 1 socket head capscrew Inner Plunger and A Intermediate Plunger Assembled Y UNF x1 Socket Head Capscrew Grade 5 or Better 24 __ Intermediate Plunger SSS Retainer W A Piston Halves Crosshead Inner Plunger Figure 5 18 Cylinder Installation 4 Slide carriage to the bottom of the mast 5 15 MAST INSTALLATION 1 Reposition the mast on the work surface with the carriage facing down CAUTION Always use an overhead crane when lifting or repositioning the mast Figure 5 17 Cylinder Assembly NOTE The right hand hose guide has a bulkhead bracket welded to the bottom 16 Thread the intermediate plunger retainer into the shell and tighten with a spanner wrench 2 Bolt the right hand hose guide to the two mounting plates on the outer channel 5 13 CYLINDER INSTALLATION 3 Bolt the left hand hose guide to the two mounting plates on the outer intermediate 5 14 To install the cylinder as outlined below channel the mast should be still lying on a work surface with the carriage facing up 4 Replace the spacer spring and washer in the cylinder port making sure the parts are clean 1 Slide the carriage and crosshead to the top of and that no dirt or contamination is contained the mast in the port See figure 5 17 Section 5 Cylinder Service Page 55 Washer S
71. ter intermediate channel cross member until the latch is properly adjusted CAUTION If the latches are not properly adjusted they could over travel causing latch failure and incorrect mast sequencing A a b The two latches must be properly inter locked as shown in figure 4 48 and the spring must be securely engaged with both latches c Before proceeding lubricate the latch spring and all mating surfaces with SAE 30 engine oil Inspect the latch mechanism on the inner channel with the mast completely collapsed Figure 4 49 Latch Positioning a The latch must be engaged with the cap screw latch pin on the inner intermediate channel The latch throat that engages the pin must be completely horizontal If the capscrew Channel Service Page 43 latch pin holds the latch in a non horizontal position add or subtract shims under the contact pad of the inner intermediate channel crossmember until the latch is properly ad justed CAUTION If the latches are not properly adjusted they could over travel causing latch failure and incorrect mast sequencing b The two latches must be properly inter locked as shown in figure 4 49 and the spring must be securely engaged with both latches c Before proceeding lubricate the latch spring and all mating surfaces with SAE 30 engine oil Grease the sheaves on the mast and on the crosshead through the grease fittings in the sheave shafts with whe
72. the side of the outer channel and on the back of the three upper cross members See figure 1 9 1 16 If any of these decals are missing contact the Cascade parts depot for replacements 1 17 In addition to the normal mast and lift truck inspection procedures the Quad Lift Mast should be rechecked to insure that 1 The mast hose is properly fitted in the hose guides and remains in the guides during opera tion 2 The crossbar bracket is securely mounted to the outer channel 3 All hose brackets hoses etc clear the crossbar bracket during operation 4 The hoist cylinder is bled and free of air 5 The hoist cylinder bleeder screw is tight and no leakage is occurring 6 All No Hand Hold decals are legible in their proper location and have the paint masks removed 7 The chain is completely free of paint and weld splatter 8 Mast channels are properly relubed with graph ite base grease 30 graphite base recom mended No Hand Hold Decals Figure 1 9 No Hand Holds Decal Location Section 2 TROUBLE SHOOTING amp MAINTENANCE 2 1 INTRODUCTION 2 2 For efficient operation and in the interest of safety it is essential that the Quad Lift Mast be inspected and serviced on a routine basis in conjunction with the lift truck s preventative main tenance schedule 2 3 In this section the minimum required main tenance and inspection procedures are outlined for daily inspec
73. the weight of the forks on the carriage recheck the brass wear plugs to make sure they have been unthreaded 1 4 turn Section 2 Trouble Shooting amp Maintenance Page 17 2 10 TROUBLE SHOOTING GUIDE PROBLEM POSSIBLE CAUSE SOLUTION Caution operator on results of ramming For repair refer to section 3 Shock loading from ram ming operation Carriage roller failure Lubricate every 100 hours or four weeks as outlined in sub section 2 6 For repair refer to section 3 Insufficient lubrication Remove carriage from mast and adjust shims behind rollers as outlined in section 3 Carriage rollers improperly shimmed or excessively worn Carriage side plates hitting or scraping channel cross members Replace roller following ser vice procedures outlined in section 3 Flat spot in carriage rollers Roller bearing faulty Inspect and adjust cross head as outlined in sub section 2 6 step 9 Crosshead too loose Carriage scraping against front of hoist cylinder Inspect and adjust cross head as outlined in sub section 2 6 step 9 Crosshead too loose or not properly shimmed Stub shaft broken Roller bearing or roller as sembly damaged Carriage side plates scraping against crosshead Remove inspect repair and or adjust carriage as outlined in section 3 Carriage hangs up or
74. tion 100 hour maintenance and 500 hour maintenance These recommended mainte nance periods are for masts operating under normal conditions Masts operating under severe condi tions or in corrosive or extremely dusty atmo spheres should be inspected and serviced at more frequent intervals 2 4 DAILY INSPECTION 2 5 At the beginning of each shift of operation the mast should carefully be inspected following Figure 2 1 Carriage Chains the points outlined in this sub section Unless otherwise indicated all inspection procedures should be carried out while the mast is completely collapsed the carriage is in its lowest position and the lift truck is turned off CAUTION Never work on the mast while the lift truck is running or while anyone is near the lift truck control handles 1 Inspect the carriage chains to make sure they are under equal tension If adjustment is necessary follow the procedures outlined in sub section 2 6 step 8 2 Inspect the latch mechanisms on the inner channel and on the inner intermediate channel for damage If damaged they must be replaced reference sub section 4 7 steps 2 and 19 for latch installation reference sub section 4 10 steps 3 and 4 for adjustment Latch _ Mechanism Inner Channel Mechanism Intermediate Channel Figure 2 2 Latch Mechanisms Page 8 Trouble Shooting amp Maintenance Section 2 3 Inspect the capscrew lat
75. y removed with emery paper will require the replacement of the entire component Cylinder Service Section 5 5 9 While disassembling the cylinder place all parts in clean containers Dirt and contaminants may cause damage to the cylinder components and result in mis sequencing of the cylinder 5 10 To disassemble the cylinder proceed as follows l Lay the cylinder in three or more V blocks and secure it to the workbench with straps NOTE The cylinder must not be clamped in a vice Clamping may distort the cylinder shell requiring the replacement of the shell as sembly 2 Pull the intermediate plunger partially out of the cylinder Inner Plunger and Intermediate Plunger en csemmbied E Intermediate Plunger Retainer Piston Halves Figure 5 4 Cylinder Disassembly Section 5 3 Using the proper spanner wrench unthread the intermediate plunger retainer from the shell Support the intermediate plunger so it doesn t drop when the retainer is unthreaded Leave the retainer on the intermediate plunger Remove the two plungers as an assembly from the shell NOTE The piston halves on the intermediate plunger will disengage as the plunger is re moved The end of the shell should be located directly over a workbench or table to avoid damage to the piston halves as they fall Y Wiper Ring Cylinder Service Page 49 5 Remove the piston halves retaining ring from th

667415_M4Q Quad Lift Mast Service Manual

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