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667433R1_C- Triple Mast Service Manual

1. CYLINDER SHELL Figure 19 Sequence of Hoist Cylinder Plunger Extension The sequencing of the hoist cylinder is controlled by an inter sequence valve The sequence valve is preset at the factory and should not require adjustment However if the cylinder is disassembled the sequence valve can be adjusted according to the following procedures 1 Remove the bleed fitting at the top of the slave plunger 2 Insert a 3 16 inch long handle hex socket wrench 662611 into the bleed hole and engage the adjusting nut 3 Turn the adjusting nut counterclockwise until it bottoms The nut is crimped slightly to prevent free turning so it may be a little stiff Don t force the nut after it bottoms See Figure 20 MAST I BEAM FLANGE i SETSCREW GUIDE d The tire should never touch the guide at these points Figure 21 Triple Lift Crosshead Adjustment 060 CROSSHEAD ASSEMBLY HEX SOCKET WRENCH 7 662611 N DON T FORCE THE NUT AFTER IT BOTTOMS Figure 20 Turning the Adjusting Nut Counterclockwise 4 Turn the adjusting nut clockwise two full turns to provide an initial adjustment Remove the wrench and instal the bleed fitting 5 Operate the cylinder with about a half capacity ipad to check for proper sequencing If the slave plunger extends too fast and the master plunger does not extend at all the sequence valve is not opening Turn the adjusting nut clockwise one turn only Reinstall the bleed fi
2. HOSE CLAMP co SETSCREW SNAP RING OUTER UPRIGHT VALLI AT IETIEITUTTETHIIIETIL IT 1221 ET WZ7YIZTZIZTIT NUT ju dins WASHER E JA AUXILIARY JUMPER HOSE BETWEEN TRUCK CONTROL VALVE AND BOOTSTRAP HOSE CROSSHEAD CHAIN SHEAVE Figure 30 Rear View of Mast Assembly MARKED OUTSIDE S 1 6 Disconnect the tilt cylinders from the tilt cylinder anchor brackets SNAP RING 7 Disconnect the mast base mounting brackets ROLLER ASSEMBLY 8 Lift off the mast and set it on a work surface with the carriage up the mast is equipped with a hose reel block Figure 29 Crosshead Assembly under the mast sufficiently to clear the reel or remove the reel Make sure the mast assembly does not rest on the bootstrap hose guides Remove the hose guides if necessary 5 3 3 Mast Removal Pese d 9 WARNING 5 3 4 Carriage Removal T Never work on the mast with a load on the with mast removed from the truck forks or attachment or while anyone is near the lift truck control handles 1 Connect a sling to the carriage and secure it with some suitable lifting device 1 Make sure the mast is fully lowered Make sure the mast is straight up not tilted forward or backward 2 Remove the forks or attachment from the mast carriage Remove any auxiliary equipment that would interfere with mast removal 2 Remove the pins that secure the carriage hoist chains to the chain anchors loc
3. e Service Manual 30C 55C 80C Viewmast ll Triple Free lift Roller Masts Serial Numbers 658437 through 692673 Manual Number 667433 Rev 1 Cascade shi sa 1 Introduction This manual provides the installation instructions and main tenance troubleshooting and service procedures for the Cascade Viewmast 11 a three stage full free lift roller mast Viewmast I provides exceptional visibility for the lift truck driver The mast carriage and upright channels are all roller mounted which results in smooth operation and long service life A unique three stage hoist cylinder provides fast operation CATALOG AND SERIAL NUMBERS LEFT HAND SIDE OF OUTER UPRIGHT CHANNEL NAMEPLATE and uniform lifting and lowering speeds of the carriage In any communication about your Cascade Viewmast l always refer to the mast catalog and serial numbers stamped on the mast nameplate If the nameplate is missing these numbers are also stamped on the left hand side plate of the upper crossbar cascade SERIAL NUMBER CATALOG 2227 2 22512 O E M ee NUMBER NUMBER ADDITIONAL EQUIPMENT oc NE 2 0 HOSE pmo aacnest MAXIMUM HYDRAULIC PRESSURE Ll THE RATED CAPACITY OF THIS MAST IS VIEWMAST SEE TRUCK NAMEPLATE FOR TRUCK CAPACITY NOTE O S H A PROVIDES MODIFICA TIONS AND ADDITIONS WHICH AFFECT CAPACITY ANDSAFE OPERATION SHALL NOT BE PERFORMED BY THE CUSTOMER OR USER WITHOUT MANU
4. 110 ft Ib MAKE SURE CARRIAGE STOP SCREW ASSEMBLY IS IN THIS POSITION AFTER THE CARRIAGE INSTALLATION CARRIAGE SIDE PLATE STOP BLOCK ON INNER CHANNEL TORQUE TO 100 110 FT LBS INNER UPRIGHT CHANNEL Figure 41 Carriage Stop Screw Assembly 6 Roll the carriage hoist chains over the crosshead sheaves and connect the chains to the carriage lower fork bar See Figure 42 CARRIAGE HOIST CHAIN LOWER FORK BAR CHAIN ANCHOR Figure 42 Carriage Hoist Chain Anchor 5 3 11 Mast Installation 1 Clean and lubricate the bearing surfaces of the base and tilt cylinder mounting brackets with wheel bearing grease 2 Lift the mast by a link chain wrapped twice around the three upper channel crossmembers 3 Position the mast into place on the lift truck and secure the base mountings 4 Connect the bootstrap hose to the base of the hoist cylinder If the hose guides were removed during disassem bly install them now IMPORTANT Prior to connecting the tilt cylinders to the mast make sure the cylinders bottom even ly Adjust the tilt cylinders as required to prevent the mast from racking 5 Connect the tilt cylinders to the tilt cylinder anchor brackets 6 Connect the truck auxiliary hose to the bootstrap hose 7 Perform the mast operational inspection and adjustments as described in Section 2 4 667433 Rev 1 8 Lower the carriage Stand on left end of lower ca
5. 2000 psi 55C 2100 psi 80C 2200 psi d Reduce load to specified capacity e Remove mechanical bind by replacing freeing plungers and rollers A WARNING Extreme care should be used when working on a unit when the carriage with or without load is in a raised position a Sequence rod adjusted too long b Bent plungers a Adjust sequence rod Turn clockwise b Repair or replace as necessary A WARNING Extreme care should be used when working on a unit when the carriage with or without load is in a raised position c Master piston ball check not seating properly Master will move during primary Stage d Master piston 1 0 O ring seal leaking Master will move during primary stage e Relief valve defective Master will move during primary stage C Clean and or replace piston ball check assembly d Replace O ring and back up ring e Replace relief valve do not adjust or repair f Master seal worn out Master will move during primary stage g Master piston check valve open h Sequence rod out of adjustment Too long a Piston sequence valve defective Master will move during primary stage b Master piston ball check not seating properly Master will move during primary stage c Master piston 1 0 O ring seal leaking f Replace all cylinder seals g Replace check valve h Adjust sequence rod Clockwise a Repair or replace valve b Clean and or repla
6. Air in cylinder a Bleed air from cylinder load is lifted then stops Approximately 1 2 Spongy or jerky action a Air in cylinder a Bleed air from cylinder b Sticky or defective truck relief valve b Remove and check truck relief valve If contaminated oil caused the malfunction WARNING Extreme care should be drain and flush the system change the used when working on a unit when the filter and refill with fresh oil carriage with or without load is in a raised position Bent or damaged cylinder plunger s c Disassemble check and repair cylinder assembly WARNING Extreme care should be used when working on a unit when the carriage with or without load is in a raised position d Load rollers improperly adjusted or d Adjust or repair as necessary defective WARNING Extreme care should be used when working on a unit when the carriage with or without load is in a raised position e Mast channels improperly lubricated e Lubricate mast A WARNING Extreme care should be used when working on a unit when the carriage with or without load is in a raised position f Low battery charge f Charge battery g Low pump volume g Install accumulator h Low oil level h Fill oil reservoir and bleed cylinder i Insufficient hydraulic tank capacity or i Install larger tanks or battles baffles j improperly sequencing mast cylinder Adjust sequence rod k Other k Contact Cascade Cor
7. Total Standard Labor Time hours 20 Standard Labor Times Paragraph Number Times hours 51 4 Cylinder Removal mast mounted on truck 10 5 1 4 Cylinder Retainer Seal Replacement Steps Ae ee eee 1 0 5 1 5 Cylinder Disassembly Service and Reassembly 20 5 1 6 Lowering Control Valve Service 0 5 51 7 Bleeding the Cylinder 0 3 54 8 Cylinder Sequencing 0 3 51 9 Crosshead Adjustment 0 5 5 2 2 Carriage Removal mast mounted on truck 10 5 2 4 Carriage Installation mast mounted on truck 10 5 2 5 Carriage Chain Adjustment 0 5 5 3 3 Mast 1 0 53 4 Carriage Removal 0 3 5 3 5 Crosshead and Cylinder Removal 0 5 53 6 Upright Disassembly 15 5 3 8 Upright Reassembly 20 5 3 9 Crosshead and Cylinder Installation 0 5 53 10 Carriage Installation 0 3 667433 Rev 1 Do you have questions you need answered right now Call your nearest Cascade Service Department Cascade Corporation P O Box 20187 2201 N E 201st Ave Portland OR 97230 Tel 503 666 1511 800 227 2233 Toll Free Telex 3060411 Cable Cascade Ptl Cascade Scandinavia Hydraulik A B Musk tgatan 17 E 8 9 25255 Helsingborg Sweden Tel 042
8. see Figure 8 Avoid excessive stretching of the seal Using a lubricant such as STP or hydraulic oil will ease seal installation 5 Replace the bearing on the piston at the base of the master plunger 6 Remove the relief valve located on the bottom of the master plunger piston See Figure 9 it is recommended that the relief valve be replaced Tighten to torque 15 20 ft Ibs 7 If you are going to replace the check valve and or the O ring and back up ring between the master piston and its plunger do so now according to the following procedures If any of these components are not to be replaced proceed to Step 8 a Remove the O ring plug from the base of the master piston See Figure 9 MASTER PLUNGER MASTER PLUNGER PISTON SEQUENCE VALVE PLUNGER SPRING Je RELIEF SEQUENCE VAL i VALV PLUNGER 5 SEQUENCE VALVE ROD NUT O RING PLUG Figure 9 Sequence Valve Plunger Assembly and Relief Valve 667433 Rev 1 b Remove the nut retaining the sequence valve plunger and spring Remove the sequence valve plunger and spring See Figure 9 c Depress the sequence valve plug protruding through a hole near the base of the master plunger with a screw driver or a punch Then using a spanner wrench in the holes provided in the piston unthread and remove the piston from the plunger See Figure 10 You may need a helper to hold the plunger with a strap wrench When you have turned the piston the first
9. the hoist cylinder The free lift portion of the extending sequence ends when the cross head lifting pad contacts the upper crossmember of the in ner upright CROSSHEAD LIFTING PAD CARRIAGE INNER UPRIGHT BOOTSTRAP HOIST CHAIN CYLINDER SHELL INTERMEDIATE UPRIGHT C FULLY EXTENDED Continued hoist cylinder ex tension causes the inner up right and carriage to be drawn upward with the crosshead lift ing pad The extending inner upright also causes the boot strap chains to draw the inter mediate upright and hoist cyl inder shell upward The speed of the extending intermediate upright is half that of the inner upright This phase of mast extension continues until the mast is fully extended The sequencing of the hoist cylinder is independ ent of mast operation that is the master plunger does not necessarily reach the end of its stroke at the end of the free lift portion of mast ex tension The lowering of the mast is a reversal of extension 21 D Service 5 3 2 Crosshead Description The crosshead shown in Figure 29 is attached to the top of the hoist cylinder Rollers attached to the crosshead move within guides on the inner upright assembly to guide the hoist HOSE cylinder as it extends and retracts A pair of chain sheaves gt GUIDE attached to the crosshead provide a rolling surface for the carriage hoist chains BOOTSTRAP HOSE CAPSCREW i 6
10. 151135 Telex 72565 caschbg s Cascade Hydraulics Ltd 7615 Kimbel Street Mississauga Ontario Canada L5S 1A8 Tel 416 677 9695 Direct Parts Line 416 677 9686 416 677 9684 Te Ac 06 968715 vz cascade rcs TM Cascade 1984 Cascade N V European Headquarters P O Box 50086 1305 AB Almere Haven Achterwerf 240 1357 Almere Haven Netherlands Tel 03240 92911 Telex 40838 case nl Cascade France S A R L 11 rue Jean Charcot Zone Industrielle Sud B P 22 91421 Morangis Cedex France Tel 06 9091139 Telex cascade 690016f Cascade Materials Handling Aust Pty Ltd Incorporated in N S W P O Box 67 Ermington 2115 N S W Australia Tel 02 648 2571 Te Ac 790 24302 Cable Cascaus 3 84 Cascade N V Benelux Sales and Service P O Box 170 1110 AD Diemen Weesperstraat 110 1112 AP Diemen The Netherlands Tel 020 906411 Telex 14495 casc nl Cascade Iberia S A Nave Industrial Calle Cromo 99 Nave G Hospitalet de Llobregat Barcelona Spain Tel 93 3350567 Telex 54018 casc e Cascade Materials Handling Aust Pty Ltd 44E Winterton Road Clayton Victoria 3168 Australia Tel 03 543 4344 Cable Casmel Cascade GmbH Klosterhofweg 52 4050 Monchengladbach 3 B R Deutchland Tel 02166 602091 Telex 0852812 Cascade UK Ltd 15 Orgreave Crescent Dore House Industrial Estate Handsworth Sheffield 513 9NQ England Tel 0742 697524
11. 5 6 7 Telex 547254 cascsh g Cascade Africa Pty Ltd P O Box 625 15 Power Street Isando 1600 South Africa Tel 011 36 5611 2 3 4 5 Te Ac 960 8 8869 Cascade Japan Ltd 4 1 1 Chome Shin Senri Higashamachi Toyonaka Osaka 565 Japan Tel 06 835 2900 Te Ac 781 5287115 Cascade J Cable Cascadecfe Osaka P N 667433 R 1
12. Bulletin 126 for stub shaft replacement Inspect the carriage hoist chains If inspection reveals that one strand of a pair of chains requires replacement both strands of the pair should be replaced Check for rust and corrosion Check for cracked side plates f you find cracked side plates replace both strands of chains Check for tight joints If tight joints are caused by rust or corrosion loosen them with SAE 30 oil or penetrating oil If they cannot be loosened or if tight joints are caused by bent pins or plates or by peened plate edges replace both strands of chains e Check for protruding or turned pins Replace both strands of chains e Check for chain side wear If pins and outside plates show signs of wear check for misalignment of sheaves anchors or other components Correct the misalignment If wear is excessive replace both strands of chains e Check for worn broken or misaligned chain anchors Replace or adjust as required 5 2 4 Carriage Installation with the mast installed on the truck 1 Make sure the inner upright channel members are lubricated with chassis lube or Kendall SR 12X Cascade part number 599474 See Figure 24 CHANNEL SECTION LOAD ROLLER LUBRICATE ONLY WHERE INDICATED BY THE HEAVY LINE FOR THE FULL LENGTH OF EACH UPRIGHT Figure 24 Mast Lubrication typical 2 Assemble the load rollers onto their stub shafts using an appropriate number of shims See
13. Cleaning and inspection Cont 7 Inspect the stub shafts assembly with a damaged stub shaft or a cracked stub shaft base should be repaired or replaced Refer to Technical Bulletin 126 for stub shaft replacement 8 Inspect the cushions on the lower crossmember of the upright channels f the cushions are damaged crushed or missing replace them 9 Inspect the crosshead lifting pad If it is damaged or crushed replace it 10 Inspect the bootstrap hoist chains Refer to Section 5 4 1 5 3 8 Upright Reassembly with uprights lying horizontal 1 Lubricate the full length of each upright channel with chassis lube or Kendall SR 12X Cascade part no 599474 as shown in Figure 35 2 Assemble the upright load rollers onto their stub shafts using an appropriate number of shims See Fiugre 34 These shims should be installed to provide a clearance no looser than 0 030 inch at the tightest point throughout the travel of the member Refer to Section 5 3 12 for load roller shimming 3 Assemble the mast chain sheaves on their stub shafts at the base of the intermediate upright See Figure 34 UPRIGHT CHANNEL SECTION LOAD ROLLER LUBRICATE ONLY WHERE INDICATED BY THE HEAVY LINE FOR THE FULL LENGTH OF EACH UPRIGHT Figure 35 Mast Lubrication typical 4 Connect the bootstrap hoist chains to the outer upright anchors using new cotter pins 5 Using a sling and hoist or some other appropriate lifting device positi
14. Figure 22 The shims should be installed to provide a total clearance no looser than 0 030 inch at the tightest point throughout the travel of the carriage Refer to Section 5 3 12 for load roller shimming 3 With a sling position the carriage assembly in place on blocks in front of the mast 4 Raise the inner upright sufficiently for the carriage load rollers to be fitted within the inner upright channels Lower the inner upright over the carriage 5 Lift the carriage the full length of the inner upright channel and check side play and freedom of movement Adjust load roller clearance as specified in step 2 6 Thread in the carriage stop screw assemblies See Figure 41 Tighten to a torque of 100 110 ft Ibs CAUTION Failure to thread in the stop screw assemblies can cause the mast uprights to sequence incorrectly 7 Install the carriage hoist chains 8 Lower the carriage and check and adjust the load chains as shown in paragraph 5 2 5 9 Check the total freedom of the carriage movement as de scribed in Section 5 3 10 step 7 667433 Rev 1 sim D Service 5 3 5 2 5 Carriage Chain Adjustment The carriage hoist chains should be adjusted so that when the unloaded mast is fully lowered the carriage is positioned as shown in Figure 25 To adjust the carriage chains 1 Locate the carriage chain anchors on the inner upright See Figure 26 2 Adjust one carriage chain anchor nut to achieve the co
15. Figure 38 7 Install the crosshead lifting pad Refer to Figure 38 5 3 10 Carriage Installation with uprights lying horizontal 1 Assemble the carriage load rollers onto their stub shafts using an appropriate number of shims See Figure 40 The shims should be installed to provide a clearance no greater than 030 inch at the tightest spot throughout its travel Refer to Section 5 3 12 for load roller shimming 2 Make sure the carriage stop screw assemblies are retracted to clear the inner upright stop blocks See Figure 32 3 Connect a sling to the carriage With a suitable lifting 26 CARRIAGE HOIST CHAIN CARRIAGE CHAIN ANCHOR COTTER PIN Carriage weldment Roller 6 req d Roller shim as req d Keeper shim as req d Keeper 2 req d Capscrew 4 req d Chain anchor 2 req d Snap ring 2 req d Pin 2 req d Cotter pin 4 req d Carriage hoist chain POWMANATARWN gt NOTE Items 3 and 14 should be removed replaced in equal numbers Figure 40 The Carriage Assembly device position the carriag place through the bottom of the inner upright 4 Roll the carriage the full length of the inner upright channel and check side play and freedom of movement Adjust the load roller clearances as specified in Section 5 3 12 667433 Rev 1 sim D Service 5 3 10 Carriage Installation Cont 5 Thread in the carriage stop screw assemblies See Figure 41 Torque to 100
16. SS Refer to your truck service manual for procedures s i d 3 Connect the tilt cylinders to the cylinder anchor brackets BI U E OUTER 9 UPRIGHT 4 Before connecting the truck hose to the mast bootstrap connect the truck hose to the truck return fitting and actuate the control valve to flush the system with hydraulic oil 5 Connect the lift truck hose to the mast bootstrap hose LIFT TRUCK See Figure 4 The lift truck hose can be SAE 100 R2 HOSE FROM or R9 NOTE Use as few fittings as possible and always TRUCK CONTROL use 45 elbows instead of 90 elbows Keep the hose VALVE lengths to a minimum Avoid sharp bends or pinch points when routing the hose Figure 4 Cylinder and Truck Hose Connection 2 4 Operational Inspection and Adjustments CAUTION The factory set adjustments may not be correct for your truck Check each of the following before using the mast for the first time D Bleed air from the mast cylinder as described in Section 5 1 7 Do not use bleed screw on side of cylinder shell D The hoist cylinder must sequence as described Section 5 1 8 D Inspect the chains and check chain tension as described in Section 5 4 1 D Check crosshead rollers for proper adjustment as described in Section 5 1 9 O Inspect the cylinder hose for correct tension tracking over the rollers Refer to Section 5 3 13 D Inspect the bootstrap hose for correct tracking in the hose guides Adjustments to
17. and chain sheaves Roller rights carriage and crosshead Note the number of shims on the rollers so that an appropriate number of shims can be installed during reassembly 2 Thoroughly clean the upright carriage and crosshead assemblies with cleaning solvent 3 Inspect the rolling surfaces of the upright channels Exces sive wear grooves or scoring could be the result of faulty load rollers and or improper mast lubrication BOOTSTRAP HOIST CHAIN INTERMEDIATE UPRIGHT INTERMEDIATE UPRIGHT CUTOUT INNER UPRIGHT DOWEL PIN Inspect the rollers on the crosshead ex corren PIN SJ NUT sheave assemblies with visible flat spots excessive wear or cracks should be replaced Inspect the load roller and chain sheave bearings by turning them on a shaft Roller and sheave assemblies with rough ness or noticeable restrictions to turning should be replaced If they do not turn freely or are damaged or excessively worn replace the roller assemblies Torque the roller nut to 30 35 ft Ibs OUTER UPRIGHT CUTOUT OUTER UPRIGHT CHAIN SHEAVE LOAD lt ROLLER TORQUE TO 60 65 FT L B CAPSCREW LOCKWASHER ERAIN J 7 BOOTSTRAP ANCHORS CHAIN 2 ANCHOR L SX BLOCK ROLLERS BOOTSTRAP CHAIN ANCHOR COTTER PIN PIN Figure 34 Exploded View of Mast Upright Assembly 24 667433 Rev 1 sein D Service 5 3 7
18. crossmember 6 For carriage cleaning and inspection refer to Section 5 2 3 5 3 5 Crosshead and Cylinder Removal 1 2 3 5 6 with mast removed trom the truck Remove the bootstrap hose from the base of the hoist cylinder Be prepared to collect oil Do not remove the elbow fitting from the cylinder base Cap the fitting with a high pressure steel cap a plastic cap will not afford suffi cient protection to the threads if the fitting is banged during cylinder removal Connect a sling around the hoist cylinder and secure it with some suitable lifting device Remove the pad at the top of the cylinder crosshead Pull the carriage hoist chains through the crosshead sheaves Remove the snap ring that retains the crosshead assembly to the hoist cylinder rod and remove the crosshead With the lifting device secured to the sling lift the cylinder from the mast For cylinder service refer to Section 5 1 667433 Rev 1 Remove the carriage and hoist cylinder 5 3 6 Upright Disassembly with mast removed from the truck Refer to Figure 34 A WARNING Disassembly of the mast up rights with the mast mounted on the truck is NOT recommended Refer to Sections 5 3 4 5 3 5 Manually extend the mast until the bootstrap hoist chain anchor blocks on the inner upright are exposed Remove the pins that secure the bootstrap hoist chains to the chain anchors on the inne
19. lowering control valve components as shown in Figure 17 5 Reinstall the cylinder to the mast by reversing the removal instructions in Section 5 1 4 HOIST CYLINDER BASE SPECIAL WASHER INLET PORT e SPRING ELBOW FITTING Figure 17 Lowering Contro Valve Assembly 667433 Rev 1 1 7 Rlaadin i Bleedain Before the mast is put service air must be from the hoist cylinder according to the following procedures 1 Assemble the forks or attachment onto the mast carriage 2 Without a load on the forks extend and retract the mast through one complete cycle 3 With the mast fully lowered check the truck hydraulic tank and top off if necessary 4 Extend and retract the mast completely at least four more times This action will force air in the system to the cylinder center cavity under the bleed fitting 5 Extend the carriage to about 10 inches off the ground 6 The Customer User Kit 661506 includes a metal hex tube wrench 661507 and a length of clear plastic hose 661922 Slide the plastic hose through the hex tube wrench and onto the bleed fitting located at the top of the cylinder cross head Put the other end of the tube in a container to collect oil See Figure 18 CLEAR PLASTIC HOSE 661922 HEX TUBE WRENCH 661507 BLEED TO CONTAINER FITTING Figure 18 Hoist Cylinder Bleed Kit WARNING Stay clear of the carriage and the forks or a
20. on your Quad Viewmast 11 the probable causes and the recom mended corrective action that should be taken to restore the mast to normal operating condition NOTE Any time oil is added to the truck reservoir check the hoist cylinder for possible entrapment of air Refer to Section 5 1 7 PROBLEM PROBLEM CAUSE SOLUTION Hoist cylinder doesn t lift load or won t move e Empty e Loaded Mis sequencing e Empty or light load Primary up 1st Slave up 2nd Master up 3rd if at all e Loaded Primary 1 1 Master Slave 2nd Slave stops short of full lift a Plugged inlet hose b Insufficient oil c Bent or jammed plungers a Unplug hose or replace b Check truck hydraulic system for correct oil level in tank defective pump or pump drive leaks in the lines or disconnected control valve linkage Repair or replace as _necessary c Replace defective plungers A WARNING Extreme care should be used when working on a unit when the carriage with or without load is in a raised position a Plugged piston check valve master may move b Reversed piston check valve master may move c Truck relief setting low d Over capacity e Mechanical bind due to bent plunger s bad rollers and or bad cross head rollers a Unplug check valve or replace b reverse direction of check valve arrow up c Raise truck relief setting to specified level Do not exceed 30C
21. the hose are made by loosening the hose clamp shown in Figure 4 It may be necessary to loosen the connector fitting between the lift truck hose and bootstrap hose to straighten out the hoses 4 667433 Rev 1 9 Periodic Maintenance 3 1 3 2 For proper operation and an extended service lile your Viewmast 11 should be inspected and serviced regularly as part of your normal lift truck maintenance schedule according to the following outlines The recommended inspection intervals are for masts operating under normal conditions If the mast is operating in severe Daily Inspection Perform the following at the beginning of each work shift Extend the carriage a few inches off the ground and make sure the carriage chains are under equal tension Refer to Section 5 4 1 Extend the masttoits full height to make sure the hoist cylinder sequences properly The primary plunger should extend fully then the master and slave plungers should extend together Make sure the mast channels and carriage extend freely without binding Refer to Section 5 1 8 While the mast is extended inspect the upright channels for proper lubrication Refer to Section 5 3 8 step 1 With the mast extended make sure the hoist chains are under equal tension Refer to Section 5 4 1 conditions or very corrosive atmospheres these operations should be performed more frequently WARNING Never work on the mast with a load on the forks ora
22. 1807 use your screwdriver or punch to prevent the sequence valve plug SCREWDRIVER OR PUNCH PLUG MASTER PLUNGER PISTON SPANNER WRENCH STRAP WRENCH Figure 10 Removing the Piston from the Master Plunger from snapping into the hole on the other side of the plunger Be prepared to catch the sequence valve plug spring spacer and ball when the plug clears the plunger d Replace the O ring and back up ring on the piston care fully noting their position See Figure 8 Avoid exces sive stretching of the O ring during installation e If you are not going to replace the check valve proceed to Step g If you are going to replace the check valve remove the threaded washer retaining the valve The washer is staked in one place Remove the valve If the poppet behind the valve falls out it is symmetrical and can be reinstalled either way Replace the check valve using a new O ring See Figure 11 Ac THREADED WASHER 2 4 Q O RING CHECK VALVE PISTON r POPPET S Figure 11 Check Valve Assembly 13 4 5 Service 14 5 1 5 Cylinder Disassembly Service and Reassembly Cont IMPORTANT Make sure you install the check valve with the arrow stamped on the valve body pointing toward the rod end of the cylinder See Figure 11 f Install and torque the threaded washer 40 50 ft Ib 30C 65 70 ft lb 55C and 80C See Figure 8 Stake the washer in p
23. 5 1 8 A lowering control valve is located at the supply port at the base of the cylinder shell It consists of a spacer spring and special washer held in place by an elbow fitting threaded into the port The lowering control valve is a one way flow limiter When the cylinder is extended oil is free to flow unrestricted around and through the special washer However when the cylinder is lowered the oil flow produced by the retracting plungers forces the special washer toward the spacer This forces oil to flow through the orifice in the center of the washer as long as the washer is forced completely against the spacer This restriction allows the mast to lower at a con trolled speed depending upon the weight of the load 5 1 2 Bi Element Seal Assembly Fig 13 The hoist cylinder assembly contains four Bi Element seal assemblies See Figure 5 Each seal assembly is comprised of a seal element and an anti extrusion element The seals are used in combination with nylon back up rings The seals must be installed in the cylinder assembly with the seal element facing the highest pressure NYLON BACK UP RING ANTI EXTRUSION ELEMENT SEAL ELEMENT HIGHEST PRESSURE P NOT INSTALLED INSTALLED Figure 5 Bi Etement Seal Assemblies 667433 Rev 1 Sequence Valve Actuating Rod Assy Sequence Valve Ball CYLINDER SHELL Lowering Control Valve Assy M 1 Sequen
24. Chain anchor block 2 required 13 Capscrew 6 required Capscrew 4 required Outer upright cushion 2 required Lockwasher 4 required Sheave 2 required Dowel pin 2 required Snap ring 2 required Chain anchor 4 required Bootstrap hoist chain 2 required Nut 4 required Bushing blocks 2 required Cotter pin 4 required Capscrew 2 required Pin 6 required Lockwasher 6 required i Figure 27 Exploded View of Mast Upright Assembly 20 667433 Rev 1 s D Service 5 3 1 Upright Description Cont INTERMEDIATE UPRIGHT OUTER d UPRIGHT INNER UPRIGHT BOOTSTRAP CHAIN CROSSHEAD SHEAVE CARRIAGE INTERMEDIATE UPRIGHT SHEAVES A FULLY LOWERED The carriage chains are an chored to the inner upright They are looped around the crosshead sheaves and attached to the carriage The bootstrap chains are an chored to the top of the outer upright They are looped a round the intermediate upright sheaves and attached to the inner upright The hoist cylinder shell rests on a cradle which is integral with the lower crossmember of the intermediate upright Figure 28 Mast Operation 667433 Rev 1 CARRIAGE CARRIAGE INNER UPRIGHT UPPER CROSS MEMBER CROSSHEAD LIFTING PAD HOIST CYLINDER B FREE LIFT When the hoist cylinder is powered from the fully lowered position the carriage is drawn upward within the inner up right at a speed twice that of
25. ER Figure 15 Retainer Loader Place the third largest retainer loader over the end of the primary plunger Apply petroleum jelly to the loader and inner surface of the primary plunger retainer Load the retainer onto the primary plunger Tighten the retainer to a torque of 100 150 ft lbs See Figure 15 667433 Rev 1 4 4 59 Service 1 E VO Rinnan v ITV vy linder Reassembly Cont 14 Place the smallest retainer loader over the end of the slave plunger Apply petroleum jelly to the loader and inner sur face of the slave plunger retainer Load the retainer onto the slave plunger Tighten the retainer to a torque of 100 150 ft lbs See Figure 16 APPLY A THICK FILM OF PETROLEUM JELLY SLAVE PLUNGER RETAINER LOADER Figure 16 Retainer Loader 15 Reinstall the cylinder to the mast by reversing the removal instructions in Section 5 1 4 CAUTION Be sure the cylinder is properly seated in the mast support casting with the pin in the hole CYLINDER SHELL 030 TYP 5 1 6 Lowering Control Valve Service 1 Remove the hoist cylinder from the mast as specified in Section 5 1 4 2 Remove the elbow fitting from the base of the hoist cylinder Be prepared to catch the valve spacer and spring Remove the lowering control valve special washer See Figure 17 3 Clean and inspect the valve components and the cylinder inlet port Replace any defective parts 4 Replace the
26. FACTURER S PRIOR WRITTEN APPROVAL CAPACITY OPERATION AND MAINTENANCE IN STRUCTION PLATES TAGS OR DECALS SHALL BE CHANGED ACCORDINGLY RATEQ CAPACITY OF TRUCK AND MAST COMBINATION 15 A RESPONSIBILITY OF THE ORIGINAL TRUCK MANUFAC TURER amp MAY LESS THAN SHOWN CONSULT TRUCK NAMEPLATE LOAD POUNDS LOAD CENTER INCHES LIFT INCHES mum FOR SERVICE AND PARTS LITERATURE CONTACT cascade corporation 503 666 1511 PORTLAND OREGON U S A A WARNING Do not install a Viewmast li on a truck with a rated capacity greater than the capacities shown by the accompanying chart CASCADE VIEWMAST TRUCK CAPACITY AT 24 INCH LOAD CENTER 3000 Pounds 5500 Pounds 8000 Pounds Rated capacity of the truck mast combination is a responsibility of the original truck manufacturer and may be less than shown on the mast nameplate Consult the truck nameplate 667433 Rev 1 sun 2 Installation Instructions 21 Truck System Requirements achieve the maximum lifting capacity of the mast the truck Cascade Minimum Maximum Fitting relief valve should be set to relieve at the pressures indicated on Viewmast Relief Relief Thread the chart below This chart also indicates the hose and fitting size Pressure Pressure Sizes to use between the truck control valve and the mast bootstrap soc Triple 1650 PSI 2000 PSI 48 3 4 16 hose 1900 PSI 2100 PSI 3 4 16 80C Triple 1800 PSI 2200 PSI 7 8 14
27. Mounting bracket and crossmember welding must be performed by a qualified welder only using the following procedures 2 2 IS a Disassemble the outer channel from the mast prior to welding See Section 5 3 6 for disassembly procedures b Clean all surfaces to be welded Remove paint grease CLAMP and other contaminants GROUND HERE C Locate the mounting brackets and crossmembers on the mast channels Clamp in place with a C clamp Protect the mast channel WARNING inner surfaces from weld splatter DO NOT WELD THESE AREAS HORIZONTAL WELDS WILL d Use only 7018 low hydrogen electrodes AWS E7018 5 32 A REDUCE THE STRUCTURAL diameter Electrodes must be in good condition Bake as STRENGTH OF THE CHANNEL required to remove all moisture per electrode manufacturers procedures e Use DC reverse polarity or an AC welding machine Set the amperage at 175 amps L Preheat the upright and mounting bracets to 100 F Montior with a Tempstick crayon Do not weld in a drafty area WARNING Weld areas that will be vertical seams when the mastis standing upright only DO NOT WELD ANY HORIZONTAL SEAMS e g Weld areas that will be vertical seams when the mast is standing upright only DO NOT WELD ANY HORIZONTAL SEAMS See Figure 2 h Weld the mounting brackets and crossmember with a 25 in minimum fillet holding a close arc Weld in the flat WARNING position only Do not oscillate or u
28. WARNING For proper truck stability or to prevent interference tilt restriction may be required Contact the truck manufacturer or one of the Cascade Service Departments listed on the back cover for the specific tilt modification required Note To achieve the proper tilt restriction contact the lift truck manufacturer or your truck service manual IMPORTANT Standard Viewmast masts are compatible with SAE 10W petroleum base oil per Mil Spec MIL 0 5606 or MIL 02104 B only Use of synthetic or aqueous base hydraulic oil is notrecommended If fire resistant hydraulic oil must be used contact one of the Cascade Service Departments listed on the back cover 22 Mounting Bracket Installation umm mmm ERE If itis necessary to install mounting brackets and crossmembers to fit your truck consult with the nearest Cascade Service Department listed the back cover You must supply dimensions A through F shown below in Figure 1 Failure to install the correct brackets and crossmembers can result in mast structural failure bodily injury and loss of warranty WARNING Failure to install the correct brackets and crossmembers can result in mast structural failure bodily injury and loss of warranty TRUCK COWL FRONT VIEW SIDE VIEW Figure 1 Determining Mounting Bracket and Crossmember Location 667433 Rev 1 2 Installation Instructions e 22 Mounting Bracket Installation Cont 1
29. ated on the lower fork bar See Figure 31 CARRIAGE HOIST CHAIN 3 Remove the truck auxiliary hose from the hoist cylinder bootstrap hose See Figure 30 Be prepared to collect oil Plug the bootstrap hose and cap the truck auxiliary hose 4 Loosen the hoist cylinder bleed screw no more than required to bleed off any hydraulic pressure that may remain in the cylinder The bleed screw is located on the cylinder shell just below the largest piston retainer Tighten the screw n COTTER 5 Wrap a link chain twice minimum around the three upper PIN mast channel crossmembers and secure with a hoist crane some other suitable lifting device Figure 31 Carriage Hoist Chain Anchor 667433 Rev 1 sim D Service 5 3 4 Carriage Removal Cont with mast removed from the truck 3 Unthread the two carriage stop screw assemblies A stop screw assembly is comprised of a nut welded to a socket head capscrew See Figure 32 By backing out the nut that extends through the carriage side plate the socket head of the screw will clear the stop block on the inner channel upright CARRIAGE SIDE PLATE STOP BLOCK ON INNER CHANNEL CARRIAGE STOP SCREW ASSEMBLY UPRIGHT CHANNEL Figure 32 Carriage Stop Screw Assembly 4 With the lifting device secured to the carriage remove the carriage out the ded of the mast assembly 5 Remove the carriage hoist chains from the inner upright lower
30. ce Valve Plunger Assy 30C 2 required with cylinder installed on 68 and 74 inch masts 4 required with cylinders installed on 80 86 92 98 104 and 11 111 inch masts 55C 2 required with cylinders installed 68 74 80 and 83 inch masts 4 required with yclinders installed on 92 101 107 114 119 124 129 and 134 inch masts 80C 4 required with cylinders installed on all masts Figure 6 Exploded View of Hoist Cylinder Assembly 667433 Rev 1 PRIMARY PLUNGER SLAVE PLUNGER MASTER PLUNGER e RE A Sse 1 Cylinder shell 20 Bearing 39 Valve retaining washer threaded 2 lt 2 Master plunger 21 Back up ring 40 O ring plug 3 Primary plunger 22 O ring 41 Sequence valve plunger nut 4 Slave plunger 23 Primary plunger retainer 42 Sequence valve plunger 5 Sequence valve actuating rod 24 Seal 43 Sequence valve plunger spring 6 Spacer 25 Nylon ring 44 Relief valve 7 Primary plunger half ring 26 Primary plunger wiper 45 Relief valve O ring 8 Slave plunger half ring 27 Bearing 46 Bearing 9 Lowering control valve spacer 28 Back upring 47 Nylon ring 10 Lowering control valve spring 29 O ring 48 Seal 11 Lowering controi vaive washer 30 Siave piunger retainer 49 Sequence valve plug 12 Bleed screw 31 Seal 0 Sequence valve ball spring 13 Bieed screw seal 32 Nylon ring 51 Sequence valve ball spacer 14 O ring 33 Slave plunger wiper 52 S
31. ce piston ball check assembly c Replace O ring and back up ring Master will move during primary stage s n 667433 Rev 1 sim Troubleshooting PROBLEM PROBLEM CAUSE SOLUTION e Loaded Continued d Master seal worn out Master will move d Replace all cylinder seals during primary stage e Sequence rod stroke adjusted too short e Adjust sequence rod Turn counter clockwise f Bent plungers f Repair or replace as necessary WARNING Extreme care should be used when working on a unit when the carriage with or without load is in a raised position g Check valve defective Open g Clean or replace as necessary h Relief valve defective Master moves at ail h Replace relief valve Do not adjust or times repair e Empty or loaded a Relief valve open a Replace relief valve do not adjust or Master up 1 st slow repair Primary up 2nd or during master Slave up 3rd Hoist cylinder drifts All plungers down a External leak in pressure line a Tighten or replace as necessary b Truck valve defective cycle to full lift b Repair or replace truck valve height to verify c External leaks at retainers c Replace ail cylinder seals e Slave plunger down Master a Relief valve defective a Replace relief valve do not adjust or plunger up repair b Master piston check valve leaking b Replace check valve Master plunger drifts up when a
32. d primary plunger This occurs until the cylinder is fully extended Since the volume of the sequencing oil cavity is nearly identical to the volume of the slave plunger cavity master and slave plungers extend at the same speed The volume of oil required to lift the master plunger is approximately twice that required to extend the primary plunger the first plunger to extend Thus the master plunger extends at half the speed that the primary plunger extended However since the master and slave plungers extend simultaneously at the same speed the combined speed of the master and slave plungers equals the speed of the primary plunger As a result the cylinder assembly extends and lowers at aconstant speed throughout its complete sequence of operation A relief valve shown in View C is included in the master plunger piston If the pressure of the sequencing oil should exceed a value preset by the relief valve the valve will unseat to allow pressure to be relieved to the base of the cylinder This could occur each time the cylinder is extended or when excessive pressure build up of the sequencing oil such as would occure when the cylinder is at rest is heated by ambient air A check valve is located in the base of the slave plunger piston The check valve allows release of trapped oil which could occur is oil leaks past the seal and gets caught between the piston and retainer The lowering of the cylinder assembly is a reversal of ext
33. e master plunger piston item 35 Figure 6 must be installed with the lip toward the plunger end of the cylinder The master plunger piston also has a static O ring seal to seal between the piston and the master plunger A synthetic bearing is installed on the master plunger piston and cast iron half rings are installed at the base of the primary and slave plungers The master plunger piston also serves as a housing for a poppet Operated check valve a relief valve and a sequence valve assembly The sequence valve assembly ensures the proper sequencing of the cylinder plungers during extension and retraction It is comprised of a spring loaded ball and seat assembly actuated by a spring cushioned plunger The sequence valve plunger is actuated by a rod The valve plunger is attached to the rod at the rod s lower end The rod extends through a square hole in the base of the primary plunger and into the central cavity of the slave plunger and terminates near the top of the slave plunger A spacer and circular plate are installed at the top of the sequence valve actuating rod They are held in place by a spring that bears between the circular plate and the shoulder of a special adjusting nut threaded onto the upper end of the rod Access to the adjusting nut can be gained by removing the bleed fitting threaded into a port at the top of the slave plunger To turn the nut insert a 3 16 inch long handle Allen wrench Refer to Section
34. e that may remain in the cylinder The bleed screw is located on the side of the cylinder shell just below the large piston re tainer Tighten the screw securely RETAINER TORQUE TO 3 Remove the carriage according to the removal procedures specified in Carriage Section 5 2 4 Remove the pad at the top of the cylinder crosshead 100 150 FT LB MASTER PLUNGER 5 Remove the snap ring that retains the crosshead assembly to the hoist cylinder rod 6 Remove the crosshead 7 Wash the cylinder assembly with Solvent to remove any foreign mate rial on the shell Especially clean around the plunger retainers Blow dry with compressed air If you are going to replace the seals O rings and or wipers in the plunger retainers only you can do so with the cylinder in place on the mast according to the following procedures refer to Figure 8 RETAINER TORQUE TO 200 250 FT LB CYLINDER SHELL THREADED WASHER TORQUE TO 40 50 FT LB 30C 65 70 FT LB 55C amp 80C STAKE ONE PLACE SEQUENCE VALVE PLUNGER AND SPRING a Unthread and remove all three retainers Do not remove any of t the cylinder plungers O RING b Replace the seals O rings and or wipers in the retainers as required Carefully note their positions see Figure 8 Avoid excessive stretching of the O ring on the large diameter retainer RELIEF VALVE TORQUE TO 15 20 FT LB NUT TORQUE TO C Ins
35. en sion VIEW A SLAVE PLUNGER PRIMARY PLUNGER MASTER PLUNGER SEQUENCING OIL CAVITY CYLINDER SHELL CHECK VALVE UNSEATED SEQUENCE VALVE BALL SEATED CHECK VALVE POPPET Figure 7 Hoist Cylinder Sequence of Operation 667433 Rev 1 5 VIEW 411 de SEQUENCE VALVE BALL UNSEATED 667433 Rev 1 D Service SLAVE PLUNGER PRIMARY PRIMARY PLUNGER PLUNGER FULLY EXTENDED SLAVE PLUNGER PRIMARY PLUNGER MASTER PLUNGER CHECK Po o VALVE MASTER SEATED PLUNGER SEQUENCE VALVE ADJUSTING BALL UNSEATED NUT SPACER SEQUENCE VALVE ACTUATING ROD SEQUENCE VALVE BALL 4UNSEATEDI SEQUENCE OIL MASTER PLUNGER SEQUENCE VALVE PLUNGER SHIFTED Gam CHECK UPWARD VALVE SEATED CHECK VALVE UNSEATED MASTER PLUNGER PISTON MASTER PLUNGER RELIEF VALVE 11 D Service 12 5 1 4 Cylinder Removal 1 Make sure the hoist cylinder is fully lowered CAUTION Always lubricate new seals wipers with petroleum Jelly or hydraulic oil prior to installation WARNING Never work on the mast with a load on the forks or attachment nor while anyone is near the lift truck control handles RETAINER TORQUE TO 100 150 FT LB N Loosen the bleed screw no more than required to bleed off any hy draulic pressur
36. equence valve ball 15 Back up ring 34 Bleed fitting 53 Sequence valve rod plate 16 Master plunger retainer 35 Master piunger piston 54 Sequence valve rod plate spring 17 Seal 36 Check valve poppet 55 Sequence valve adjusting nut 18 Nylon ring 37 Check valve 56 Adjusting nut cotter pin 19 Master plunger wiper 38 Check valve O ring 57 Elbow fitting 30C 4 required with cylinders installed on all masts 55C 2 required with cylinders installed on 68 74 and 80 inch masts 4 required with cylinders installed 83 22 101 107 114 119 124 129 and 134 inch masts 80C 4 required with cylinders installed on ail masts xin D Service 10 5 1 3 Cylinder Operation Figure 7 View A The entire cylinder assembly is filled with oil at the beginning of its lifting sequence Since the cylinder is fully lowered the check valve is unseated by its actuating poppet in contact with the base of the cylinder shell Since the sequence valve ball is seated oil in the cavity between the cylinder shell and the master plunger referred to as sequencing oil is trapped The master plunger is thus prevented from moving As a result when oil from the truck enters the cylinder through the inlet port it flows through the angled port in the master plunger piston and through the unseated check valve to the primary and slave plunger cavity View B Since the area of the primary plunger piston is greater than that of the slave plunger
37. er of end links CHAIN LENGTH 600 050 9 CARRIAGE CHAIN 667433 Rev 1 D Service 5 4 3 Mast Chain Adjustment The mast chain should be adjusted so that when the unloaded mast is fully lowered all upright channels are even with each other at the bottom within 1 8 inch See Figure 46 1 To adjust raise the mast until the mast chain adjusting nut is just above the outer upright See Figures 46 and 47 Tighten or loosen the adjusting nut to adjust one chain to achieve the equal dimension Adjust the other mast chain until equal tension is achieved 2 Lower the mast and check your adjustment All channels should be even with each other at the bottom within 1 8 inch INTERMEDIATE UPRIGHT HOIST CHAIN ADJUSTING NUTS OUTER UPRIGHT EQUAL 1 8 inch Figure 46 Triple Lift Adjusting Nuts CHAIN ADJUSTING NUT 2 CHAIN ANCHOR Figure 47 Wast Chain Anchor 667433 Rev 1 5 4 4 Carriage Chain Adjustment The carriage chains should be adjusted so that when the unloaded mast is fully lowered the carriage is positioned as shown in Figure 48 To adjust the carriage chains 1 Locate the carriage chain anchors on the inner upright See Figure 49 2 Adjust one carriage chain anchor nut to achieve the correct carriage position when fully lowered as shown in Figure 48 3 Adjust the other carriage chai
38. in Adjusting Nut A pair of bushing blocks are bolted to steel blocks welded on both sides of the upright near the bottom The bushing blocks stabilize the intermediate upright assembly when the mast is extended and tilted back cushion is attached to the intermediate upright lower crossmember to cushion the inner upright when the mast is fully lowered The hoist cylinder rests on a cradle which is integral with the lower crossmember of the intermediate upright assembly Inner Upright Assembly The inner upright assembly telescopes within the inter mediate upright assembly pair of shim adjustable load rollers is attached to canted stub shafts near the bottom of the assembiy A pair of adjustable chain anchors is located near the bottom of the inner upright assembly to which the bootstrap hoist chains are attached in addition a pair of adjustable chain anchors is located on the lower crossmem ber of the inner upright to which the carriage hoist chains are attached 4 Mast Operation Figure 28 illustrates the operation of the Cascade Viewmast ll 19 4 D Service OUTER UPRIGHT NOTE Upright stub shafts are replaceable per Technical Bulletin 126 INTERMEDIATE UPRIGHT INNER UPRIGHT TORQUE 6 7 FT LB MARKED OUTSI DE 8 required Cotter pin 12 required Shim Intermediate upright cushion
39. lace to secure it g Assemble the sequence valve ball ball spacer spring and plug in place onto the master plunger as shown in Figure 12 Then thread the piston onto the master plunger As the piston is threaded on the sequence valve plug will snap into one of the two holes in the plunger With a BALL PISTON BALL SPACER SPRING Figure 12 Sequence Valve Ball Assembly screwdriver or punch push the plug in and keep turning the piston until it seats Then back off no more than 1 2 turn until the plug snaps into one of the holes Use the tools and procedures shown in Figure 10 h Install the sequence valve plunger spring and plunger the hole in the base of the master piston See Figure 13 Install and torque the retaining nut to 7 5 9 ft Ib i Install the O ring plug and torque to 50 55 ft Ib See Figure 13 Figure 13 illustrates the correct orientation of the sequence valve components when the piston 15 assembled onto the master plunger PLUNGER MASTER SPRING SEOUENCE VALVE PLUNGER SB Mer HL p SPRING TORQUE TO 7 5 9 FT LB BALL SPACER O RING PLUG TORQUE TO 50 55 FT LB BALL MASTER PLUNGER PISTON Figure 13 Sequence Valve Assembly Located at the Base of the Master Plunger 8 Place the largest diameter piston loader in the cylinder shell See Figure 14 The loader must cover all of the threads but not contact the thread relief chamfer The length of the sto
40. lower load rollers are held in place by the inner channel when the carriage is assembled onto the mast All six load rollers are interchange able A pair of non adjustable chain anchors are used to connect the carriage chains to the carriage CARRIAGE HOIST CHAIN 2 REQ DJ CHAIN ANCHOR 2 REQ D COTTER PIN n 4 REQ D PIN 2 REO D ROLLER SHIM Figure 22 The Carriage Assembly 667433 Rev 1 CARRIAGE WELDMENT ROLLER 5 2 2 Carriage Removal The carriage may be removed with the mast installed on the truck according to the following procedures 1 Block the carriage off the ground and lower the mast to slacken the carriage chains Connect a sling to the carriage and secure it with some suitable lifting device 2 Remove the snap rings that retain the chain anchors to the carriage lower fork bar Remove the chain anchors NOTE Stub shafts are replaceable per Technical Bulletin 126 ROLLER SHIM AS REQUIRED ROLLER 6 REQUIRED gt KEEPER SHIM QTY AS REQUIRED KEEPER 2 REQUIRED CAPSCREW 4 REQ D A SNAP RING 2 REQ D TORQUE TO 6 7 FT LB V 17 18 sein Service 5 2 2 Carriage Removal Cont 3 Back out the two carriage stop screw assemblies stop screw assembly is comprised of a nut welded to a socket head capscrew See Figure 23 By backing out the nut that extends through the ca
41. moval Plug the bootstrap hose 10 Using a lifting strap and hoist remove the cylinder from the mast 11 Lay the completely collapsed cylinder on 4 X 4 s NOTE Cut 2 two 2 deep U Cuts in each 4 X 4 667433 Rev 1 44 5 Service 5 1 5 Cylinder Disassembly Service and Reassembly 1 Use a claw type spanner wrench to unthread the master plunger retainer Item 16 Figure 6 2 Slide the master primary and slave plungers out of the cylinder shell as an assembly 3 Remove the seal and nylon ring from the piston at the base of the master plunger using the following procedures Be careful not to scratch the seal groove diameter a Pry the seal up from its groove with a dull screwdriver b Cut the seal off the piston groove with wirecutters or a knife Make sure the knife does not scratch the groove or the plunger c Remove the nylon ring IMPORTANT When cylinder components are disassembled and seals O rings and wipers are removed thoroughly wash all metallic parts in solvent Blow dry with compressed air Carefully inspect the plungers cylinder bore piston and disassembled valve components Replace if seriously scored grooved pitted or worn Minor damage to the cylinder bore and plungers can be removed with 400 grit polishing cloth wash after polishing Place components in a clean container until reassembly 4 Instali the new seal and back up ring on the piston carefully noting their position
42. n anchor nut to achieve equal chain tension S IN aaa UM A72 IN 3 IN UNDERCLEARANCE 6 IN DNDERCLEARANCE A 3 IN E CARRIAGE CARRIAGE CHAIN UPRIGHT CHAIN ANCHOR Figure 49 Carriage Chain Adjusting Nut 29 6 Standard Labor Times 30 6 1 6 2 Determining Labor Times Standard Labor Time is the average time required to perform each operation described in Section 5 Service Each Standard Labor Time is identified by the Service Section paragraph number titie that corresponds to that operation The Standard Labor Times are based on the assumption a qualified serviceman is working on a reasonably clean mast with adequate tools We realize the actual time required to perform an operation may occasionally be greater than that listed especially if a first time serviceman lacks the needed tools or if a bolt is frozen But considering all factors that can affect the job Cascade can only honor warranty labor claims based on these carefully evaluated averages We strongly urge servicemen to read the applicable Service Sections of the manual before repairs are initiated If problem diagnosis is difficult call one of the Cascade Service Departments listed on the back cover To arrive at the total Standard Labor Time for a job list each operation and add the times As an example to replace bushings your list should look something like this 52 2 Carriage Removal 10 52 4 Carriage Installation 10
43. on the intermediate upright over the outer upright as shown in Figure 36 6 Position the bootstrap hoist chains over the intermediate upright sheaves as shown in Figure 36 7 Lower the intermediate upright onto the outer upright Hold the hoist chains out the top of the outer upright to keep them straight Roll the intermediate upright part way down the outer upright Adjust load roller clearance as specified in Adjustment Section 5 3 12 8 Using a sling and hoist or some other suitable lifting device position the inner upright so that the inner upright load rollers fit into the cutouts at the top of the intermediate upright Lower the inner upright onto the intermediate upright See Figure 37 667433 Rev 1 INTERMEDIATE UPRIGHT CHAIN SHEAVE INTERMEDIATE BUSHING UPRIGHT BLOCKS INTERMEDIATE UPRIGHT LOAD ROLLER BOOTSTRAP HOIST CHAIN OUTER UPRIGHT LOAD ROLLER OUTER UPRIGHT Figure 36 intermediate Upright Installation CHAIN ANCHOR BOOTSTRAP HOIST CHAIN ANCHOR BLOCK INNER UPRIGHT LOAD INTERMEDIATED UPRIGHT BOOTSTRAP HOIST CHAIN OUTER UPRIGHT Figure 37 Inner Upright installation 9 Attach the bootstrap hoist chain anchor blocks to the inner upright Torque to 60 65 ft Ibs See Figure 37 10 Attach the bootstrap hoist chains to their anchors on the inner upright using new cotter pins 11 Manually retract the upright assembly Check for side play and freedom of mo
44. or adjust as required 5 4 2 Measuring Chain Stretch Regular inspection and lubrication of the hoist chains will increase their service life and reduce downtime If the hoist chains stretch beyond the recommended amount they should be replaced in pairs Chain stretch can be measured with the chain wear scale 661923 included with the Customer User Kit Measure the chains as shown in Figure 45 according to the instructions printed on the chain wear scale without a load on the carriage NEW CHAIN Chain Wear Scale 661923 STRETCHED CHAIN Figure 45 Checking Chain Stretch 1 check the carriage hoist chains raise the carriage a few inches off the ground to put tension on the chains 2 To check the mast hoist chains the mast must be extended sufficiently to expose the chains If the chains are removed from the mast you can check chain stretch without using the chain wear scale Ifthe overall length of a hoist chain exceeds 10396 of its original length the chains should be replaced in pairs The following table provides the length of the hoist chains when new and their limits of stretch HOIST CHAIN TABLE Length of Length of ie geractedi bootstrap 103 limit carriage 103 limit teehee chain when inches chain when inches new inches new inches SOC VIEWMASTS II 68 55C VIEWMASTS II Chain length is measured from hole center to hole cent
45. p fins can be trimmed with a sharp knife if more engagement is needed The piston will not enter the shell if the loader contacts the thread relief chamfer Apply petroleum jelly to the master plunger seals and loader I D 9 10 11 12 13 PLACE THE PISTON LOADER IN THE CYLINDER SHELL STOP FINS DO NOT ALLOW LOWER EDGE OF LOADER TO CONTACT THREAD RELIEF CHAMFER CYLINDER SHELL INSERT PLUNGER ASSEMBLY INTO THE CYLINDER SHELL APPLY A THICK FILM OF PETROLEUM JELLY Figure 14 Master Plunger Loader Slide the master primary slave plunger assembly all the way into the cylinder shell but don t tighten the large diameter retainer See Figure 14 Unthread and remove the upper two retainers then remove the large diameter retainer Do not remove any of the cylinder plungers Replace the seals o rings and wipers in the retainers Lubricate the new seals with petroleum iellv prior to install ation Note the correct seal locations See Figure 8 Avoid excessive stretching of the o ring on the large diameter retainer Place the second largest retainer loader over the end of the master plunger Apply petroleum jelly to the loader and inner surface of the master plunger retainer Load the re tainer onto the master plunger then remove the loader Tighten the retainer to a torque of 200 250 ft lbs See Figure 15 APPLY A THICK FILM OF PETROLEUM JELLY MASTER OR PRIMARY PLUNGER RETAINER LOAD
46. poration 667433 Rev 1 s D Service 54 Hoist Cylinder 5 1 1 Description The hoist cylinder shown in Figure 6 is a three stage displace ment cylinder It consists of a shell with three hollow telescop ing plunger assemblies The slave plunger smallest diameter telescopes into the primary plunger and the primary plunger telescopes into the master plunger largest diameter The shell master plunger and primary plunger are threaded at one end to receive retainers A retainer is threaded into the shell to limit the stroke of the master plunger A retainer is threaded onto the master plunger which secures an aluminum bearing to limit the stroke of the primary plunger retainer is threaded onto the primary plunger which secures an aluminum bearing to limit the stroke of the slave plunger Each retainer has a Bi Element seal assembly to provide a high pressure hydraulic seal between the retainer and its adjacent plunger In addition each retainer has a static non moving O ring assembly and a plunger wiper A piston assembly is threaded onto the base of the master plunger The piston has Bi Element seal assembly to provide a high pressure hydraulic seal between the piston and the cylinder shell IMPORTANT During cylinder operation the pressure pro duced in the cavity between the cylinder shell and the master plunger is greater than that produced at the cylinder base truck pressure Thus the seal assembly on th
47. r paint the chains on initial mast installation Hoist chains must be adjusted with equal tension to ensure proper load distribution and mastoperation To determine equal tension extend the unloaded mast to put the chains under tension Press the center of a strand of chain with your thumb Then press atthe same place on the other chain ofthe pair Each chain in a pair should have equal give Do this with all hoist chains If they do not have equal tension perform the Mast or Carriage chain adjustment in paragraphs 5 4 3 and 54 4 Inspect the hoist chains Ifinspection reveals that one strand of a pair of chains requires replacement both strands of the pair should be replaced e Check for rust and corrosion Check for cracked side plates If you find cracked side plates replace both strands of chains e Check for tight joints If tight joints are caused by rust or corrosion loosen them with SAE 40 oil or penetrating oil If they cannot be loosened or if tight joints are caused by bent pins or plates or by peened plate edges replace both of chains e Check for protruding or turned pins Replace both strands of chains e Check for chain side wear If pins and outside plates show signs of wear check for misalignment of sheaves anchors or other components Correct the misalignment If wear is excessive replace both strands of chains Inspection and Tension Check for worn broken or misaligned chain anchors Replace
48. r upright Remove the bootstrap chain anchors from the inner upright 5 Roll the inner upright toward the top of the mast until the inner upright load rollers are exposed by the cutouts at the top of the intermediate upright Using a sling and hoist or some other appropriate lifting device lift the inner upright out of the intermediate upright and set it on a work surface Roll the intermediate upright toward the top of the mast until the intermediate load rollers are exposed by the cut outs at the top of the outer upright Pull on the bootstrap hoist chains to keep them straight CAUTION Pull on the bootstrap hoist chains to keep them straight Using a sling and hoist or some other suitable lifting device lift the intermediate upright out of the outer upright As soon as the chain sheaves at the bottom of the intermediate upright are clear of the outer upright cutouts pull the bootstrap hoist chains off the sheaves See figure 33 Set the intermediate upright on a work surface Remove the bootstrap hoist chains from the outer upright chain anchors INTERMEDIATE UPRIGHT INTERMEDIATE UPRIGHT CHAIN SHEAVE INTERMEDIATE UPRIGHT LOAD ROLLER BOOTSTRAP HOIST CHAIN OUTER UPRIGHT LOAD ROLLER OUTER UPRIGHT Figure 33 Bootstrap Hoist Chain Routing 23 4 59 Service 5 3 7 Cleaning and Inspection 1 Remove the load rollers and chain sheaves from the up 4 Inspect the load rollers
49. rrect carriage position when fully lowered as shown in Figure 25 3 Adjust the other carriage chain anchor nut to achieve equal Chain tension 5 IN eire ARANGE A72 IN UNDERCLEARANCE 6 IN UNDERCLEARANCE A 3 IN CARRIAGE FLUSH 3 Figure 25 Correct Carriage Positions when Mast is Fully Lowered Mast Upright Assembly 5 3 1 Upright Description The Cascade Viewmast 9 assemblies outer intermediate and inner 1 is comprised of three upright See Figure 27 Outer Upright Assembly The outer upright assembly is mounted to the truck A pair of shim adjustable load rollers is attached to canted stub shafts located near the top of the upright A pair of urethane cushions is attached to the lower crossmember to cushion the intermediate upright when the mast is fully lowered A pair of non adjustable chain anchors is located near the top of the upright to which the bootstrap hoist chains are attached Intermediate Upright Assembly The intermediate upright assembly telescopes within the outer upright assembly A pair of shim adjustable load rollers is attached to canted stub shafts near the top of the upright and a pair is attached near the bottom of the up right In addition a pair of chain sheaves is located near the bottom of the intermediate upright to provide a rolling surface for the bootstrap hoist chain 667433 Rev 1 CARRIAGE CHAIN UPRIGHT CHAIN ANCHOR Figure 26 Carriage Cha
50. rriage bar Measure distance between left bottom of carriage bar and ground Stand on right end of lower carriage bar and measure distance at same point as before The difference between the two measurements should not exceed 47 06 See Figure 43 I o MEASURE THIS DISTANCE TWICE CARRIAGE BAR Figure 43 Measuring Carriage Looseness 5 3 12 Load Roller Shimming Each pair of load rollers on the uprights and carriage should be shimmed so that a total clearance no greater than 0 030 inch occurs at the tightest point throughout the travel of the member See Figure 44 Install a pair of load rollers and use an equal number of shims on each side of the assembly within one shim A standard shim 631881 is 0 030 inch thick To check the clearance pry between the upright and load roller as shown below so the opposite load roller is tight against the upright Measure the clearance for the pair of load rollers at the XXX shown Repeat for each pair of rollers MEASURE CLEARANCE HERE LOAD ROLLERS LOAD ROLLERS Measurements typical for each pair of rollers Figure 44 Roller Clearance 27 D Service 5 4 Hoist Chains 28 4 1 Each pair of hoist chains have been factory lubricated using heat and pressure to force the lubricant thoroughly into the chain links Avoid removal or contamination of this factory applied lubricant Do not wash sand blast etch steam clean o
51. rriage side plate the socket head of the screw will clear the stop block on the inner channel up right You may have to extend the carriage to gain access to the stop screw assemblies Power the hoist cylinder to extend until the inner upright channel clears the carriage load rollers Back the truck away from the carriage 1f the hoist cylinder is inoperative raise the inner upright channel with a hoist crane or some other suitable lifting device CARRIAGE SIDE PLATE STOP BLOCK ON INNER CARRIAGE CHANNEL STOP SCREW ASSEMBLY INNER UPRIGHT CHANNEL Figure 23 Carriage Stop Screw Assembly 5 2 3 Cleaning and Inspection 1 Remove the load rollers and thoroughly clean the carriage assembly with cleaning solvent Note the number of shims on the rollers so that an appropriate number of shims can be installed during reassembly Inspect the rollers for excessive wear or damage Roller assemblies with visible flat spots or cracks should be replaced Inspect the roller bearings by turning the rollers on their shafts Roller assemblies with roughness or noticeable restrictions to turning should be replaced Inspect all welds between the carriag side plates and the carriage fork bars 1f any weld seams are cracked replace the carriage Inspect the stub shafts If they are damaged or if there are cracks at the base of the stub shafts the carriage must be replaced or repaired Refer to Technical
52. se a wash bead pattern WELD ON VERTICAL Make the weld in three passes Let the weld slow cool SEAMS ONLY i Remove slag and inspect the weld The following defects are not allowed undercut overlap stress cracks and porosity Clean the weld area and repaint with Cascade paint part number 668209 Figure 2 Clamp Ground and Weld 2 The measurement shown in Figure 3 should be taken after welding and cooling the mast This dimension must be TOP VIEW maintained for the uprights to slide together 3 Reassemble the mast as described in Section 5 3 8 18 295 015 0C 18 295 0 2 5 015 55C 20 985 045 80 22 4 tt 01 5 dt 045 WEE INSIDE TO INSIDE UPRIGHT OF OUTER UPRIGHT AT TWO PLACES Figure 3 Dimensional Inspection 667433 Rev 1 3 2 Installation Instructions 2 3 Mast Installation e 1 Lubricate the bearing surfaces of the base and tilt cylinder NZ HOSE mounting brackets with chassis grease gt GUIDE 2 Lift the mast by a link chain wrapped twice around the KA upper channel crossmembers Position the mast into place BOOTSTRAP on the lift truck and secure the base mountings A qox HOSE 45 IMPORTANT Ri E Prior to connecting the tilt cylinders to the mast make sure 3 the cylinders bottom evenly Adjust the tilt cylinders as 3 WG HOSE CLAMP required to prevent the mast from racking during tilting I
53. tall the retainers as described 7 5 9 FT LB in section 5 1 5 steps 12 through 15 Tighten all retainers to the torque values shown in Figure 8 If you are going to replace com ponents in addition to those de scribed above the cylinder must be removed from the mast Continue as follows 8 Remove the bootstrap hose from the base of the cylinder Be prepared to collect oil Do not remove the elbow fitting from the cylinder base To gain access to the hose fitting you may have to lift the intermediate channel upright high enough to expose the base of the cylinder Use another lift truck hoist crane or some other suitable lifting device BLEED FITTING TORQUE TO 25 27 FT LB PRIMARY PLUNGER SLAVE PLUNGER WIPER NYLON RING SEAL O RING BACK UP RING WIPER NYLON RING SEAL O RING BACK UP RING WIPER NYLON RING SEAL BACK UP RING CYLINDER BACK UP RING 2 912 O RING E m A Vi O RING CHECK VALVE NS gt Ss A AW cw RING Z HE BEARING l POPPET O RING PLUG TORQUE TO 50 55 FT LB ITEMS INCLUDED IN SERVICE KIT Figure 8 Hoist Cylinder Components 9 Cap the fitting at the base of the cylinder with a high pressure steel cap a plastic cap will not afford sufficient protection to the threads if the fitting is banged during cylinder re
54. the primary plunger begins to extend As the primary plunger reaches the end of its stroke its base contacts the spacer at the top of the sequence valve actuating rod The actuating rod thus shifts upward pulling the sequence valve plunger upward with it The sequence valve plunger unseats the sequence valve ball The point at which this event occurs may be adjusted by turning the special adjusting nut at the top of the sequence valve actuating rod View C The trapped sequence oil is at a pressure greater than that from the truck This pressure intensification results because the area of the piston that forms the cavity between the cylinder shell and the master plunger is less than the area of the base of the master plunger piston Remember that pressure equals force divided by area Since the area of the piston in the sequence oil cavity is less the pressure in the cavity is greater Thus as soon as the sequence valve ball is unseated the pre viously trapped high pressure sequencing oil flows past the unseated sequence valve ball to the primary plunger cavity and seats the unseated check valve Oil from the truck can thus no Seats the unseatec check ON Trom the truck can inus no longer flow to the plunger cavities and truck pressure begins to extend the master plunger View D As the master plunger extends the sequencing oil flows past the unseated sequence valve ball and extends the slave plunger from within the extende
55. ttachment 7 Open the bleed fitting no more than 1 4 turn with the hex tube wrench The weight of the carriage will force air and hydraulic oil out of the cylinder through the bleed fitting 8 If the carriage reaches the bottom of its travel before all the air is bled close the bleed fitting and repeat Steps 5 through 7 9 When the oil stream no longer contains air bubbles close the bleed fitting and torque to 25 27 ft Ib 1O Top off the truck hydraulic tank with clean fresh oil 11 Extend and retract the mast completely If the mast doesn t operate smoothly or if it appears to be spongy repeat Steps 2 through 10 15 som D Service 16 5 1 8 Cylinder Sequencing When the mast is actuated from the fully lowered position the primary plunger should extend from within the master plunger to the end of its stroke Then the master and slave plungers should extend simultaneously to the end of their strokes See Figure 19 The lowering of the plungers is reversal of extension However if adjustment is required do so according to the following procedures WARNING Never work on the hoist cylinder with a load on the forks or attachment or while anyone is near the lift truck control handles THE PRIMARY PLUNGER SHOULD EXTEND FIRST THEN THE MASTER AND SLAVE PLUNGERS SHOULD EXTEND SIMULTANEOUSLY SLAVE PLUNGER PRIMARY PLUNGER PRIMARY PLUNGER r MASTER PLUNGER
56. ttachmentor while anyone is nearthe lift truck control handles Lower the mast and make sure the cylinder sequences properly The master and slave plungers should lower first then the primary plunger should lower Make sure the mast channels and carriage lower freely without binding Refer to Section 5 1 3 Make sure the cylinder hose is not twisted and is traveling smoothly in the hose guides Check the hose to be sure itis not scuffing Minor adjustments to the hose can be made by loosening the hose clamp and twisting the hose slightly to fitin the guides Be sure the urethane cushions at the base of the outer and intermediate channels are not flattened or distorted D Check crosshead roller clearance to assure proper operation without binding Refer to Section 5 1 9 100 Hour Inspection After each 100 hours of lift truck operation in addition to the daily inspection Inspect and lubricate the full length of each pair of hoist chains with SAE 40 oil CAUTION The chains must be coated with a film of lubricant at all times C Check each pair of hoist chains for wear and stretch Refer to Section 5 4 and 100 hour inspection D Check the clearances for load rollers Refer to Section 5 3 12 667433 Rev 1 3 3 500 Hour Inspection E After each 500 hours of lift truck operation in addition to the daily Troubleshooting The following table lists problems that may be encountered
57. tting and retest Continue this process until the cylinder sequences properly See Figure 19 The adjusting nut should be turned 10 turns maximum 6 As soon as the cylinder sequences properly turn the adjust ing nut clockwise one more turn only to assure a positive adjustment 7 Extend and retract the cylinder completely If it does not operate smoothly or if it appears to be spongy bleed air from the cylinder as specified in Section 5 1 7 5 1 9 Crosshead Adjustment The sum total clearance between the tire shoulders and the Mast Beam must be 060 as shown in Figure 21 If one tire is touching the l Beam which is acceptable the other tire should have 060 clearance Adjust the Crosshead to attain the clearance as follows 1 Loosen the setscrew See Figure 21 2 Use an open end wrench to turn the hex nut to attain the clearance shown in Figure 21 3 Tighten the setscrew CAUTION Insufficient tightening can result in the tire loosening and the crosshead jamming between the I Beams MAST BEAM FLANGE CROSSHEAD 27 El SETSCREW 667433 Rev 1 4 5 Service e 5 2 Carriage 5 1 1 Description The carriage shown in Figure 22 is the structure to which hook type forks or the attachment is attached The carriage travels within the channels of the mast inner upright on six shim adjustable load rollers The two upper load rollers are secured to their stub shafts by keepers the four
58. vement Adjust load roller clearance as specified in the Adjustment Section 5 3 12 12 The intermediate upright bushing blocks can be adjusted to fourpositions See Figure 36 Adjust the bushing blocks to the tightest position that allows free travel of the uprights Tighten the capscrews to a torque of 35 40 ft Ibs 2b s D Service 5 3 9 Crosshead and Cylinder Installation with uprights lying horizontal 1 Assemble the crosshead chain sheaves in place on the cross head assembly See Figure 38 CAPSCREW l TORQUE TO m 16 7 ET LB LOCKWASHER T LIFTING PAD I Ku RING lt gt lt SETSCREW TORQUE TO 7 9 FT LB NYLON PELLET CROSSHEAD CHAIN SHEAVE MARKED OUTSIDE SNAP RING 3 4 ASSEMBLY Figure 38 Crosshead Assembly 2 Connect the carriage hoist chains to the brackets on the inner upright assembly See Figure 39 3 Connect a sling around the hoist cylinder and secure it with a suitable lifting device 4 Position the hoist cylinder in place in the bracket at the base of the intermediate upright Make sure the elbow fitting at the base of the cylinder fits into the cutout in the cylinder mounting bracket without binding 5 Position the crosshead assembly in place at the top of the hoist cylinder Make sure the crosshead rollers fit into their guides on the inner upright channels 6 Secure the crosshead to the cylinder rod using the retaining snapring Refer to

667433R1_C- Triple Mast Service Manual

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