Cascade Viewmast II 55C Triple Installation Instructions Manual

a

--TM

Installation

Instructions

30C, 55C,and 80C Triple and

45C Quad Viewmast™ I I

Free-Lift Roller Masts

Field alterations may impair performance or capability snd could result in loss of warranty. Consult Cascade for technical

assistance and approval for any required modifications.

Manual Number 664195

cascade@

corporation

Cascada is a Ragistarmd Tradamark of Cascade Corporation. l Viewmast is a Trademark of Cascade Corporation.

P.O. 90x 20187 l Portland, Oregm 97220 l 603b88-1511

\

WARNING

CASCADE

TRUCK CAPACITY

VIEWMAST I I

AT 24-l NCH

A

Do not install a Viewmast II on any

LOAD CENTER

truck with a capacity greater than the

truck rated capacities shown.

30C Triple

3000 pounds

45C Quad

6000 pounds

55C Triple

6000 pounds

80C Triple

8000pounds

CONTENTS

Introduction

........................

Truck Requirements

.....................

Mast Pre-installation Inspection ..................

Mast Installation

.......................

Operational Inspection and Adjustments ...............

Bleeding the Cylinders

....................

Cylinder Sequencing

....................

Crosshead Adjustment

....................

Hoist Chain Inspection and Tension

...............

Hoist Chain Adjustment

...................

Carriage Chain Adjustment ..................

Hose Tracking Adjustment

..................

Lowering Speed Adjustment

..................

Periodic Maintenance

.....................

Daily Inspection

......................

100 Hour Inspection

....................

500 Hour Inspection

....................

2

3

5

6

7

8

9

10

11

INTRODUCTION

This manual provides the installation instructions, periodic

maintenance, and adjustment procedures for the Cascade 3OC,

55C, and 80C Triple Lift and 4% Quad Lift Viewmast I I,

full freelift roller masts.

Viewmast II masts provide exceptional visibility for the lift

truck driver. The mast carriage and upright channels areall-roller

mounted which results in smooth operation and long service

life. A unique, threestage hoist cylinder provides fast operation

and uniform lifting and lowering speeds.

In any communication about your Cascade Viewmast I I, always

refer to the mast catalog and serial number 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.

2

TRUCK REQUIREMENTS

IMPORTANT

Standard Vtewmast II masts are Intended for use with

petroleum-base hydraulic oils only. If other types of fluids

are used, the mast hoist cylinder must be equipped with

special seals. Consult Cascade Corporation, Appllcatlon

Enqineerlnq Department, for more information.

WARNING

A

For proper truck stability or to prevent interference,

tilt restriction may be required. Contact the truck

manufacturer or Cascade’s Application Engineering

Department for the specific tilt modification required. Note:

To achieve the proper tilt restriction, contact the lift truck

manufacturer, or your truck service manual.

To achieve the maxlmum lifting capacity of the mast, the truck

relief valve should be set to relieve at the pressures indicated

on the chart below. This chart also indicates the hose and

fitting size to use between the truck control valve and the

mast cylinder hose.

MAST PRE-INSTALLATION INSPECTION

1. Prior to installation, perform a visual inspection of the mast

2 When calling Cascade’s Application Engineering Department

assembly. Check for damage that may have occured in

you MUST furnish the dimensions A, B, and C shown in

shipment. Also check the hose guides on the outer and inter-

Figure 1 and described below:

mediate channels. They should-be straight and free of dents.

Make sure the hoist chains are thoroughly lubricated before

mast installation. If the chains are dry, lubricate the full

length of the chains with SAE 30 oil.

WARNING

A

If it is necessary to install the mounting brackets

or crossmember to fit your truck, consult Cas-

cade’s Application Engineering Department at

800-574-5266. FAILURE TO INSTALL THE CORRECT

TILT ANCHOR CROSSMEMBER CAN RESULT IN SER-

IOUS MAST STRUCTURAL FAILURE AND POSSIBLE

BODILY INJURY. AND COULD RESULT IN LOSS OF

WARRANTY.

Read the instructions in paragraph 2

before calling.

Dimension A:

Centerline to Centerline of the tilt

cylinders.

Dimension B: Centerline to Centerline of the mast

mounting.

Dimension C:

Centerline to Centerline of the tilt

cylinders to the mast mounting.

NOTE: For accuracy take these dimensions from a mast

with factory installed brackets.

-TRUCK COWL

FRONT VIEW

SIDE VIEW

Figun 1. Dotormining Mounting Brrekot Location

3

3. Welding must be performed by a qualified welder only,

using the following procedure:

a. Disassemble the outer channel from the mast prior to

welding. See the Triple Lift Viewmast I I Service Manual,

Form 5140, or the Quad Lift Viewmast II Service

Manual, Form 5213, for disassembly procedures.

b. Clamp the welding ground to the outer channel cross-

member, See Figure 2.

WARNING:

C. Use E7018 low hydrogen rod.

d. Preheat to 200” F., and maintain this temperature during

welding. After welding, allow to slow cool.

WARNING

WARNING:

4. The

measurements shown

in Figure 3 should be taken after

welding and cooling the mast. These dimensions ensure

that the mast uprights will slide together easily.

DO NOT WELD

THESE AREAS.

HORIZONTAL WELDS WILL

REDUCE THE STRUCTURAL

Figure 2. Clamp Ground and Weld.

OUTER’

UPRIGHT

n

TOP VIEW

n

MEASURE INSIDE

TO INSIDE OF

OUTER UPRIGHT

THROUGH ENTIRE

Figure 3.

Dimensional Inspection

4

MAST INSTALLATION

1. Lubricate the bearing surfaces of the base and tilt cylinder

mounting brackets with chassis grease.

2 Lift the mast by a link chain wrapped twice around the

upper channel crossmembers. Positlon the mast into place

on the lift truck and secure the base mountings.

Prior to connecting the tilt cylinders to the mast, make sure

required to prevent the mast from “racking” during tilting.

Refer to your truck service manual for procedures.

IMPORTANT

TRIPLE LIFT

QUAD LIFT

OUTER

/UPRIGHT

>

HOSE

GUIDES

CYLINDER

- HOSE

c HOSE CLAMP

LIFT TRUCK

+ HOSEIFROM

TRUCK CONTROL

VALVE)

gura 4. Cyiindor and Truck Hose Connection

3.

4.

Connect the tilt cylinders to the cylinder anchor brackets.

Before connecting the truck hose to the cylinder hose

actuate the truck control valve sufficiently to flush the truck

hose with hydraulic oil.

Connect the lift truck hose to the cylinder hose on the mast.

See Figure 4 or 5. The lift truck hose can be SAE 100 R2

or R9. NOTE: Use as few fittings as possible and always

use 45” elbows instead of 90’ elbows.

Keep the hose

lengths to a minimum. Avoid sharp bends or pinch points

when routing the hose.

5.

I

1 CYLINDER

I;

Id--

LIFT TRUCK

HOSE (FROM

TRUCK

CONTROL

VALVE)

5

- 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.

-Bleed air from the cyhnder according to paragraph

1 below.

-The hoist cylinder must sequence as shown in para-

graph 2.

WARNING

-Inspect the chains and check chain tension. See

paragraph 4.

-Check hoist and carriage chains for proper adjust-

ment. See paragraph 5 and 6.

-Check crosshead rollers for proper adjustment. See

paragraph 3.

1. Bleeding the Cylinder

Before the mast is put in service, air must be bled from the

hoist cylinder according to the following procedures.

a. Assemble the forks (or attachment) onto the mast carriage.

b. Without a load on the forks, extend and retract the mast

through one complete cycle.

C. With the mast fully lowered, check the truck hydraulic

tank and top off if necessary.

d. Extend and retract the mast completely at least four more

times. This action will force air in the system to the center

cavity under the bleed fitting. Quad Lift: Leave the mast in

the extended position 20-30 minutes prior to lowering and

bleeding.

e. Extend the carriage to about 10 inches off the ground.

f. The Customer User Kit (661506) included with the mast,

includes a metal hex tube wrench (661507) and a length

of clear plastic hose (661922). Slide the plastic hose

through the hex tube wrench and onto the bleed fitting

located at the top of the cylinder crosshead. Put the other

end of the tube in a container to collect oil. See Figure 6.

k/

//

TO CONTAINER

,/‘-

BLEED

, FITTING

Figure 6. Hoist Cylinder Bleed Kit

9. Open the bleed fitting no more than one 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.

h. If the carriage reaches the bottom of Its travel before all the

air is bled, close the bleed fitting and repeat Steps e through g.

i. When the 011 stream no longer contarns arr bubbles, close

the bleed frttrng and torque to 25-27 ft.-lbs.

j. Top off the truck hydraultc tank with clean, fresh 011

k. Extend and retract the mast completely. If the mast doesn’t

operate smoothly or if it appears to be “spongy”, repeat

Steps b through j. Quad Lrft: A slight amount of bounce is

normal.

2. Cylinder Sequencing

Never work on the hoist cylinder with a load on

the lift truck control handles.

Before putting the mast in service, operate the mast through a

few complete cycles and check for proper sequencing.

The hoist cylinder is comprised of three plungers: primary,

master, and slave. See Figure 7. 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. NOTE: The master plunger will raise approximately

%” then stop during initial primary movement. This is a

normal sequencing function of the cylinder.

Then the

master and slave plungers should extend simultaneously to

the end of their strokes.

THE PRIMARY

PLUNGER

SHOULD EXTEND

FIRST, THEN THE

MASTER AND

SLAVE PLUNGERS

SHOULD EXTEND

SIMULTANEOUSLY

‘I ;

A

E

PRIMARY

PLUNGER

-i

SLAVE

-PLUNGER

PRIMARY

- PLUNGER

- MASTER

PLUNGER

+ CYLINDER

SHELL

Figure 7. Seqwmco of Hoist Cylinder Plunger Extension

When the cylinder is lowered from the fully extended

position, the slave and master plungers should completely

lower simultaneously, then the primary plunger should

lower. (Depending upon mast lifting height, the plungers

may not completely retract into the cylinder shell.)

6

The sequenctng of the horst cylrnder IS controlled by an

Internal sequence valve. If the plungers do not sequence

properly.

then adjust the sequence valve as follows-

CAUTION

Before proceeding, make sure the cylinder is fully lowered.

i

a. Remove the bleed fitting at the top of the slave plunger.

b. Insert a 3/l 6-inch, long-handle, hex socket wrench (66261 1)

into the bleed hole and engage the adjusting nut.

C. Turn the adjusting nut counterclockwtse 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 8.

CROSSHEAD ASSEMBLY

HEX SOCKET WRENCH

Figure 8. Turning the Adjuettng Nut CounterclockwIa

d. Turn the adjusting nut clockwtse two full turns to provrde

an rnrtral adjustment. Remove the wrench and Install the

bleed flttlng.

e. Operate the cyhnder wrth about a half-capactty load to

check for proper sequencrng. If the slave plunger extends

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 fitting and

retest, Continue this process until the cylinder sequences

properly. See Figure 7.

f. As soon as the cyltnder sequences properly, turn the adjust-

ing nut clockwise one more turn only to assure a posittve

adjustment.

g. Extend and retract the cylinder completely. If it does not

operate smoothly or if it appears to be “spongy”, bleed air

from the cylinder as specified in paragraph 1, “Bleeding

the Cylinder”.

3. Crosshead Adjustment

The sum total clearance between the tire shoulders and the

Mast I-Beam must be ,060” as shown in Figure 9 or 10. If one

tire is touching the I-Beam (which is acceptable) the other tire

should have .060” clearance.

Adjust the Crosshead to attain the clearance as follows.

a Triple Lift: Loosen the setscrew. See Figure 9. Quad Lift:

Loosen the hex locking nut. See Figure 10.

b. Triple Lift: Use an open end wrench to turn the hex nut to

attain the clearance shown .in Figure 9. Quad Lift: Use a

hex socket wrench to turn the shaft to attain the clearance

shown in Figure 10.

C. Triple Lift: Tighten the setscrew. Quad Lift: Tighten the

hex locking nut.

CAUTION

Insufficient tightening can result in the tire loosening and

the crosshead jamming between the I-Beams.

AST I-BEAM FLANGE

MAST I-BEAM FLANGE

\

TIRE

The tire should never touch the guide at these points.

Figure 9. Triple Lift Crosshead Adjustment

MAST I-BEAM FLANGE

/

I

.060' '

MAST I-BEAM FLANGE,

.I I

The tire should never tou;h-tha z Tha

CROSSHEAD

NUTS

---

nts.

I I rcs9 IGUIDE

’

Figure 10. Qued Lift Crossheed Adjustment

7

4. Hoist Chain Inspection and Tension

Both pairs of hoist charns have been factory-lubricated using

heat and pressure to force the lubricant thoroughly into the

chain links, Avoid removal or contaminatron of this factory

applied lubricant, Do not wash, sand blast, etch, steam clean,

or paint the chains on initial mast installation.

Hoist chains must be adjusted with equal tension to ensure

proper load distribution and mast operation. To determine

equal tension, extend the unloaded mast to put the chains

under tension. Press the center of a strand of chain with your

thumb. Then press at the same place on the other chain of the

pair. Each chain in a pair should have equal “give”. Do this

with all hoist chains. If they do not have equal tension perform

the Hoist or Carriaqe chain adjustment.

5. Hoist Chain Adjustment

The hoist 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 l/8 inch.

a To adjust, raise the mast until the hoist chain adjusting nut

is just above the outer upright.

See Figure 11 or 12.

Remove the cotter keys from the chain anchors and adjust

one chain to achieve the equal dimension. Adjust the other

hoist chain until equal tension is achieved.

b. Insert new cotter keys on the chain anchors. See Figure 13.

C. Lower the mast and check your adjustment. All channels

should beeven with each other at the bottom within l/8 inch.

INNER

UPRIGHT

INTERMEDIATE

HOIST CHAIN

ADJUSTING NUTS

EQUAL

+ 118 inch

EQUAL

INNER

UPRlGHT YL

HOIST CHAIN

ADJUSTING ,,,,,TS \

INNER

INTERMEDIATE

UPRIGHT

HOIST CHAIN

ADJUSTING NUTS

EQUAL

+- l/8 inch

w

EQUAL

f I/8 inch

EQUAL

f l/8 inch

IATE

Figure 12. Quad Lift Adjusting Nuts

HOIST CHAIN

ADJUSTING NUT

COTTER KEY

CHAIN

ANCHOR

HOIST CHAIN

Figure 11. Triplo Lift Adjusting Nuts

8

Figure 13. Cottor Key Installation

6. 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 14.

To adjust the carriage chains:

a Remove the cotter keys from the chain anchors,

located on the lower crossmember of the inner upright.

b. Adjust one carriage chain to achieve the correct carriage

position when fully lowered, as shown in Figure 14.

C Adjust the other carriage chain to achieve equal chain

tension.

d. Insert new cotter keys on the chain anchors. See

Figure 13.

3 IN.

5lN. UNDERCLEARANCE, A=2 IN.

UNDERCLEARANCE

5-IN. UNDERCL::RANCE, A=3 IN.

Figure 14. Correct Carriage positions when Mast is fully lowered

7. Mast Upright Channel Lubrication

Lubricate the full length of each upright channel with

chassis lube or Kendall SR-SX as shown in Figure 15.

/

UPRIGHT CHANNEL

SECTION

LUBRICATE ONLY

WHERE INDICATED

BY THE HEAVY

LINE FOR THE FULL

LENGTH OF EACH

UPRIGHT.

LOAD ROLLER

8. Hose Tracking Adjustment

The cylinder hose should travel smoothly and not twist

during mast extension.

Adjust the hose as follows:

Triple Lift:

Loosen the hose clamp shown in Figure 16.

Position the cylinder hose to fit correctly in hose guides,

then tlghten the hose clamp. It may be necessary to loosen

the connector fitting between the lift truck hose and

cylinder hose to straighten out the hoses

OUTER

HOSE

GUIDES

c

, ./

UPRIGHT

CYLINDER

/ HOSE

HOSE CLAMP

LIFT TRUCK

HOSE (FROM

TRUCK CONTROL

,-..-- .c -r_:-I- a :*- ,.__,:-A-- La---

Quad Lift:

Loosen the connector fitting at the cylinder port

shown in Figure 17. Position the cylinder hose to track in the

center of the tires, then tighten fittings. Extend the mast

above freelift.

Loosen the hose clamp at the top of the mast.

Adjust the tension on the hose. The hose must form a smooth

continuous curve over the rollers without contacting the

bracket.

HOSE

CLAMP

u’HOSE TENSION ADJUsTED

PROPERLY FOR A

CONTINUOUS SMOOTH

CURVE OVER ROLLERS

__.__ - - .-..

CYLINDER

CYLINDER HO

gum 15. Mast Lubrication (typical) rlgura i I. uuaa

Lm r;ymaer

9

9. Lowering Speed Adjustment - Quad Mast

The adjustable lowering control valve is located In the

supply port of the cylinder shell. It consists of a spring,

adjustable piston, adjustrng nut and body. By adjusting the

piston you can control the lowering speed of the cylinder.

a. Remove the plug and lowerrng control valve from the

cyl under port.

b. Adjust as follows:

l To SLOW the LOWERING SPEED, back the nut out

while keeping the piston statronery with a screwdriver.

See Figure 18.

l To INCREASE the LOWERING SPEED, tighten the

nut while keeping the piston stationery with a

screwdriver.

c.

Reinstall the valve and tighten to a torque of 10-l 5 ft.-lbs L

BODY

PISTON

NUT

Install the plug and tighten to a torque of 95-100 ft.-lbs.

Figure 18. Lowering Control Valve.

PERIODIC MAINTENANCE

For proper operation and an extended service life, your

Viewmast II should be inspected and serviced regularly as part

of your normal lift truck maintenance schedule according to

the following outlines.

The recommended intervals are for masts operating under

normal conditions. If the mast is operating in severe conditions

or very corrosive atmospheres, these operations should be

performed more frequently.

WARNING

A

Never work on the mast with a load on the forks

or attachment or while anyone is near the lift

truck control handles.

Daily Inspection

Perform the following at the beginning of each work shift:

1. Extend the carriage a few inches off the ground and make

sure the carriage chains are under equal tension.

2 Extend the mast to its full height to make sure the hoist

cylinder sequences properly. The priman/ plunger should

fully extend, then the master and slave plungers should

extend together.

Make sure the mast channels and carriage

extend freely without binding.

3 While the mast is extended, inspect the upright channels for

proper lubrication.

4 With the mast extended, make sure the hoist chains are

under equal tension.

5. 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.

6. Make sure the cylinder hose is not twisted and is traveling

smoothly in the hose guides. Check the hose to be sure it is

not scuffing. Minor adjustments to the hose can be made by

loosening the hose clamp and twisting the hose slightly to

fit in the guides. See Figure 16.

7. Be sure the urethane cushions at the base of the outer and

intermediate channels are not flattened or distorted.

8. Make sure the carriage stop screws are threaded in Place on

the Triple Lift Masts.

100 Hour Inspection

After each 100 hours of lift truck operation, in addition to the

daily inspection:

1. Inspect and lubricate the full length of each pair of hoist

chains with SAE 30 oil.

CAUTION

Thechains must becoated with a film of lubricant at all times.

2 After the first 100 hours and every 500 hours thereafter,

check both pairs of hoist chains for wear and stretch.

WEAR INSPECTION. Check for:

_ Rust and corrosion

-Cracked side plates. If you find cracked side plates, re

place the chains in pairs.

-Tight joints.

If tight joints are caused by rust or

corrosion, loosen them with oil. If they cannot be

loosened or if tight joints are caused by bent pins or

plates or by peened plate edges, replace the chains

in pairs.

-Protruding or turned pins. Replace the chains in pairs.

-Chain side wear. If pin heads and outside plates show

signs of wear, check for misalignment of sheaves,

anchors, or other components. Correct the mis-

alignment.

-Worn, broken, or misaligned chain anchors. Replace

or adjust as required.

If inspection indicates the chains should be replaced, perform

a complete overhaul of the mast as outlined in the service

manual. (Triple-Lift: form 5140; Quad Lift: form 5213)

10

MEASURING CHAIN STRETCH

If the hoist chains stretch beyond the recommended

amount, they should be replaced in pairs. Charn stretch

can be measured with the chain wear scale (661923)

included with the Customer User Krt.

Measure the

chains as shown in Figure 19according to the instructrons

printed on the chain wear scale, without a load on the

carriage.

a. To check the carriage hoist chains, raise the carriage a

few inches off the ground to put tension on the chains.

b. To check the hoist chains, the mast must be extended

sufficiently to expose the chains.

NEW CHAIN

Figure 19. Checking Chain Stretch

STRETCHED CHAIN

500 Hour Inspection

After each 500 hours of lift truck operation, in addition to the

daily and 100 hour inspection

1. Check each pair of hoist chains for wear and stretch using

the chain wear scale (661923).

2. Check the clearances for the load rollers. Each pair of

load rollers on the uprrghts and the carriage should be

shimmed so that a total clearance no greater than 0.030 inch

occurs at the tightest pornt throughout the travel of the

member. See Figure 20. Thrs clearance will be achieved if

each pair of rollers are shimmed the maxrmum amount that

still permits assembly without mechanical assistance. Refer

to the Service Manual (Triple-Lift: form 5140; Quad-Lift:

form 5213) for disassembly and assembly procedures.

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.

LOAD

ROLLERS

I-

MEASURE WHERE

XXX IS SHOWN

A1 + A2 = .030” max.

\

LOAD

ROLLERS

Measurements typical for each pair of rollers.

11

Do you have questions

you need answered right

right now?

Dial Directline

800-547-5266

(toll free)

@Cascade Corporation 1983

NATIONAL

ASSOCIATION

OF SERVICE

MANAGERS

Part No. 664195

Cascade Viewmast II 55C Triple Installation Instructions Manual

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Cascade Viewmast II 55C Triple Installation Instructions Manual

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