NISSAN Forklift Corporation, North America Ea BARRETT FORKLIFT «2080 Prospect Street; Marengo, IL 60152 Industrial Trucks SB 99-028 MECHANICAL Date: March 31, 1999 To: All Dealer Principals, Parts and Service Managers From: Customer Satisfaction Department Subject: New Cascade F-Series Sideshifter Manual NFCNA has started using the New Cascade F-Series Sideshifter on all Nissan and Barrett mast except the Optiview 3V mast. This Sideshifter has been designed for High Visibility Mast of all types. Please add copies of this bulletin into the LM Section of your F03, J01/J02, PO1/P02, NO1 (NX-1) and Class 3 Walkie Service Manuals (WC/WCN/WS/WSN) and also keep a copy with the same model Parts Manuals. Sincerely, Nissan Forklift Corporation Customer Satisfaction Department Phone Number: (815) 568-0061 Fax Number: (815) 568-0187 CUSTOMER SATISFACTION DEPARTMENTJes nem re SER MANUAL F-Series Sideshifter Manual Number 219941 cascade® Cascazeisa Regsue Irsgera of Catcaoe Corson ONTENTS Page INTRODUCTION. ‘Special Definitions z OPERATION Safety Rules 3 incase) UR Trucks 3 Handing Loags. 4 Sideshitter Operation 4 Sefe Operauon and Mamntenance 3 “OSHA Requiations 5 INSTALLATION Truck Requirements, 5 Recommended Hyoraule Supp 6 instalation Procedure. i INSPECTION & MAINTENANCE Daily 3 100.Hour Maintenance. 3 500-Hour Maintenance 3 5{000-Hour Maintenance 3 PARTS Product idenufication 3 Base Unit 70 Cyinder Assemby it Recommended Spare Parts back cover Publications. ack cover Contacting Cascade ‘back cover SSNTRODUCTION ‘This User Manual is for Cascade F-Series Sideshiters, tt contains an Operation Guide, installation Instuctons, and Pans Manual. All specifications are shown in US. and (Metric) units where applicable, IMPORTANT: All hosing and flared fitings on F-Series Sideshiters are JIC as siandard, with face seal 2s an option Special Definitions ‘The statements shown appear throughout this Manual where special emphasis is required. Read all WARNINGS, ‘and CAUTIONS before proceeaing wih any work. Statements labeled IMPORTANT and NOTE are provideo 23s additional information of special significance or 10 make tne job easier. WARNING — A statement preceded by WARNING is information that should be {acted upon to prevent bodily injury. A WARNING is always inside a ruled Dox. A CAUTION ~ A statement preceded by CAUTION is information that should be acted upon to prevent machine damage. IMPORTANT ~ A statement preceded by IMPORTANT is information that possesses special significance. NOTE ~ A statement preceded by NOTE is information that is handy to know and may make the job easier. PERATION This Section contains operating instructions for Cascade F-Senes Sideshifters. it will heip you avoid common errors which often cause damage to the equipment or product being handled This information is intended to simplify operator under- standing about effective and safe Sideshifter use and ‘operation. Read this information thoroughly before ‘operating the Attachment. Se sure you know and understand all operating procedures and safety precau- tions, If you have any questions, or don't understand a Procedure, ask your Supervisor. Emphasize Safety! Most accidents are caused by operator carelessness or misjudgement. You must watch for hazardous situations ang correct them. WARNING: Rated capacity of the ruck! attachment combination is a responsibilty of the original truck manufacturer and may be less than shown on the attacnment nameplate. Consuit the truck nameplate WARNING: Do not operate this attachment unless you are a trained and authorized lift ‘tuck diver Backrest Cylinder Forks 219941 Rev. 0IPERATION. Safety Rules — Industrial Lift Trucks 4 \ey 7 ee lett ead ‘No turing on ramp Watch "= 219941 Rev. 0 3| PERATION. Safety Rules — Handling Loads Limit sideshiting Top of load with raised load. should not extend CAUTION: Do not put side loads on forks. i re 7 ton | wet Center toad prior to traveling. 9 I >| j= T Limit truck movement Fron with raised load. Load weight must not exceed ‘combined truck/attachment capacity (see truck nameplate). ‘Raise load prior to sideshiting. Total fork capacity (LH + RH fork) ‘must be greater than load weight. Check capacity stamp an forks. Sideshifter Operation AUXILIARY VALVE SIDESHIFTING FUNCTIONS A Sideshit Left B Sideshift Right Hoist down Tit ferwara B « Hoist up Tit Back 4 219941 Rev. 0WARNING: The safe operation and maintenance of industrial ¥ucks is regulated by Occupational Safety ‘ang Heakh (OSHA) regulations 1910.17@ ana Amer can National Standards institute (ANSI) Safety Standard for Powered Industrial Trucks, ANSI 856.1-1969, When operating and maintaining industrial tucks equipped with atachmants you should pay particular attention tothe following sections of these regulations. You should be familiar with all sections of these regulations. Ask your employer for the complete regulations. (@) General Requirement (4) Modifications and actions which affect capacity and safe ‘operation shall not be performed by the customer or user without manufacturers prir writen approval. Capacity, operation and ‘maintenance instruction plates, tags or decals shall be changed accordingly. (6) ifthe wuck's equipped win frontend attachments other than factory installed atachments the user shal request thatthe truck be marked to identity the attachments and show tne appropriate weight ofthe tuck and attachment combineton at ‘maximum elevation with load leterally centered. (©) The user shall see that all nameplates ana markings are in place ‘and maintained ina legible condition. (e) Safety Guards @) Ifthe type of oad presents @ hazard, the user shall equip fork ‘wucks with a vertcal load backrest extension in accordance with (2) fotowing (@)(2) Ail new powered industrial rucks acquired and used by ‘an employer afte: February 15, 1972 shall meet the cesign and ‘constructon requirements for powered industrial vucks established in tne “American National Standard for Powered Industial Trucks, Part I, ANSI BS6.1-1969", except for vehicles intended primarily for eartn moving or over the-roe0 hauling, (0) Operator Training (Only rained and auzhonzed operators shall be permited to operate a powered industial suck. Methods shall be devised t ain ‘operators i ue safe operation of powered industria rucks. (cn) Truck Operations. (2) Trucks shail not be driven up to anyone standin bench or other fixed object. (@) No person snail be allowed to stand or pass under the elevated. Porton of any tuck, whether loaded or emp. @) Unausnerized personnel shall nt be permited to ride on Powered incustial wucks. A safe place tonde shall be provides Where riding of tucks is authorized, (@) The employer shat prohibit arms or legs from being places between the uprights of the mast or outside the running lines of the tuck. (6) Wnen a powered industria ruck i left unattended, load tengaging means shal be fly lowered, contro's shall be ‘ewtaized, power shall be shut off and brakes set, Wheels shall be blocked Ifthe wuck is parked on an icine, (Si) A powered industial ruck is unattended wien the operator is 25, {eet or more away om the vehicle which remains in his view, or ‘whenever the operator leaves the vehicle and tis notin his view. (Si) When the operator ofan industrial wuck is d'smounted ena within 25 fee of the buck stl in his view, the oad engaging ‘means shall be fully lowered. controls neuralized and the brakes set to prevent movernent 219941 Rev. 0 frontota [AFE OPERATION AND MAINTENANCE OSHA Regulations — Industrial Trucks and Attachments (Specific Regulations from OSHA 1910.178) (6) Assafe cistance shall be maintained trom the edge of ramps or platforms while on any elevated dock or platform or feight car. Trucks shall nt be used for opening or closing freight doors. (10) load backrest exension shall be used whenever necessary to ‘minimize the possibilty ofthe load o: part of «from fling rearward. (0) Traveling (#) The criver shall be required to stow down and sound the horn at ‘ross isles and other locations where vision is castucted. Ifthe toad being carried obstructs ferwara view, the erwer shall be required to wave with the ioad trang, (71) winen ascending or descending grades in excess of 10 percent. loaded tucks shall be criven with te load upgrade. (Til On al grades the load and load engaging means shall be tikes back if applicable, and raises only as far as necessary to clear the road surface. (0) Loading (1) Onty stabie or safely arranged loads shall be handled. Caution shall be exercised when handling of certer loads which cannot be centered. (2) Only toads within the rated capacity of the tuck shall be hancled. (@) The long or high (including mutiple-tiered) loads which may affect capacity shal be adjustec, (4) Trucks equipped witn atachments shall be operated as partially loaded tucks when nat handling a load. (6) A.load engaging means shall be placed under the load as far 2s ‘possible; the mast shall be carefully tited backward to stabilze the baa, (© Extreme care shall be used when titing the load forward oF backward, partcularly when high tering. Titing forward with load engaging means elevated shall be prohibited except to pick up a load. An elevated load shall not be tted forward except when the load isin a depost postion aver a rack or stack, When ‘stacking otiering, only enough backward tt to stabilize the load shall be used. (0) Operation of the Truck (1) tatany time @ powered industrial tuck is found to be in need of ‘epair. defective. orn any way unsafe, vie wuck shall De taken out Of Service until t nas been restored to Safe operating conaiton, (@ Maintenance of industrial Trucks (1) Any power-operated industral ruck notin safe operating Condition shail be removed trom service. All epars shall be made by authorized personnel (6) All pars of any such industrial tuck requiring replacement shal De replaced oniy by parts equivalent 2s to safety wan those used inthe original design. (6) Industral tucks shail not be atered so thatthe relative positions, (of the various pars are ciferent from what they were when ‘riginaly received from the manufacturer, nor shall hey be atered ‘ether by he adation of ena parts not provided by the manufac: turer or by the elimination of any parts. Additional counter- Weighting of fork tucks shall not be done unless approved by the truck manufacturer. Industral trucks shall be examined before being placed in service ‘and shalt not be placed in service if te examination shows any Condition adversely affecung the safety of te vehicle. Such examinations shall be made at least daly. When industrial tucks are used on a round-the-clock basis, they shall be examined after each shift. Defects when found shall be immediately reported ‘and corrected. ®INSTALLATION Truck Requirements Truck Relief Setting 2000 psi (140 bar) Recommended 3500 psi (240 bar) Maximum. Truck Flow Volume © Min.® Recommended Max. : 1GPM 2GPM 3GPM c (4Umin) (7.5 Umin) (12 Limin) © Cascade F-Series Sidesniters are compatible win SAE 10W, iLO.21046. Use of ‘snot recommended. ‘Special seals may be required, Contact Cascade. © Flow greater nan maximum can result in excessive heating, Minimum Maximum Class 14.94 in, (380.0 mm) =< Recommended Hydraulic Supply The Sideshifter will require one of the hydraulic supply arrangements shown below. All hoses ano fitings snould be at least No. 4 with 3/16 in, (5 mm) minimum 1.0. Refer to Cascade Hose & Cable Ree! Selection Guide, Part No. 212189 to select the correct hose reel for the mast and truck. Berecer, pase yteutc fd meetng i. Spe, M0. 5605 mineuc or aqueous base hydraulic Mid fe resistant nygraunic hud Is fequres, © Flow less then recommended will resutin slow sideshit speed . 1 Feauces system performance and reduced hysraulc sysiom if. 16.00 in, (381.0 mm) Carriage Mount Dimension (A) ITA ('S0) Carriage Clean carriage bars and inspect for damaged notches. Auxiliary Valve Functions Check for compliance with TA (SO) stancarcs: Holst Down | Sideshit Let Hoist Up Tit Back Right Sidesnit [A Ru THINLINE™ 2-Port Hose Reel Supply Group on B Mast Single internat Hose Reeving 219941 Rev. 0Sigvstatation Installation Procedure A WARING: tke sue overneea host has rated capacity of atleast 1000 ibs. (450 kg). 1 Attach overhead hoist 3 luting eye 2 Remove lower hooks Stamped Model / Serial Number, Capacity Data ‘Sticker showing Patents. Service Phone Numbers soa Back (Driver's) View 3 Mount Sideshifter on truck carriage FFA Glass It 60-56 in (15-17 mm) Engage Locator Tab ‘wih Center Notch FTA Class I 32-36 in. (6-9) Truck uaper Camage Bar Install lower hooks BOLT-ON QUICK-DISCONNECT Reverse guides to reduce | Seesiter rooktocamageclesronce ——E wo aman gsmm met sungsenef AEN. PO Anim. en) Max an6in (6 mm) Max sein ismm 4 ‘offset on top Ses Tighten Botts to provides max Tightea capscrews to 120s. (165 Nm) Clearance. 120 futbs. (165 Nm) 219941 Rev. 0 7 aSipestatation Flush supply hoses Install hoses Kit 205826 shown for Itetnal reeving, 8 Zeit E MG Zhen to 145 bs. i tap i] (195.Nm). For oer = backrests, see OEM 2 recommendations a +o FY 9 Lubricate lower bearings Upper beang NOTE: Upper bearings prelubed at factory. No lubrication required curing instalation Front View 8 219941 Rev. 0WARNING: After compieting any service procedure, always test the sidesnifter ‘through five complete cycles. First test vith no load, then test with a ioad to make sure the attachment operates correctly Defore returning i to the sob, Daily Check items shown each day, Report problems to your supervisor. See Service Maral for mamtenance and repair proceautes. 100-Hour Every time the fit tuck is serviced or every 100 hours of ‘muck operation, whichever comes first. complete the following maintenance procedures: + Check for loose or missing bolts, warn or amaged hoses, hydraulic leaks, and Camaged or missing fork stops. ‘+ Inspect clearance between sideshifter ewer hooks and truck lower camiage bar (Refer to Step 4, installation) Tighten tower hook capscrews to 120 f.-Ibs (165 Nm) 500-Hour ‘After each 500 hours of truck operation, in addition to the 00-hour maintenance, perform the following procedures: + Tighten backrest capscrews (Cascade) to 145 ft-lbs. (195 Nm), + Apply general-purpose Ithium-based chassis grease 10 Sidestiter upper ana lower bearings. ARTS Product Identification — This Section shows replacement parts for F-Series Sideshifters. The procuct mocel number ‘and serial number are stamped on the back surface of the LH vertical bar (driver's view). and must be provided when ordering replacement parts. The cylinder/anchor bracket ‘assembly part number is stamped on the front surface RH fend of the anchor bracket (driver's view). ‘Stamped mode! number, ‘serial number, specifications. NSPECTION & MAINTENANCE Hydraulic Cylinder, Upper and Hoses Jower hook engagement Forks Fasteners 1000-Hour ‘After each 1000 hours of truck operation in addition tothe 1100 and S00-hour maintenance, perform the folowing procedures: + Inspect upper and lower bearings for wear. If any Dearing is worn to less than 3/32 in. (2.5 mm) thickness, replace the entire bearing set. See Service Manual for replacement procedure. + Inspect forks for wear (Use Cascade fork bar wear {gauge 209560 anc fork wear calipers 686093) WARNING: For the safety of yourself anc ‘others, DO NOT instail the parts shown in this Manual unless you have thoroughty reviewed the eppropriate Service Manual A ‘Sticker showing patent numbers, Phone numbers for servic <= vim Stamped cylinder | i ‘assembly part number | (opposite side). i a ah ‘soos Back (Driver's) View 219941 Rev. 010 ‘Optional Pallet Guard {;® ‘Quick Disconnect, Lower Hooks (equipped) Fron View ‘55F ner] ary] PART no, DESORPTION incr [arr [Parr no. | DESCRIPTION Ty [e360 | Taper Beane, composi 7 [ 2] omeaa [PaO [ow [ess | Urner Beang, onze pimra) [| | eartes | capscten MEE TT w | cyinder Assen 1 Pe | e7ssis | Gude S| Fass toner oan CoB ie12 | 7990 | aol Pin Fa[ 4 [555057 nut SENG. GS fair [1 | panes | Pate iad Sa[ ca] eiso4 | Nat jie_[-2 [essa | capscren. MiB FECT aaerae toe eae fete [2 | eseses | Lockvastor Se[ a | eev2es | washer. 895 3 eoiers | Fring 20 ICES Sr[ce | essrat | apse, se NOXTS, GS 2 aoraoe [ing 30-165 ST[ce resist | Capseen 6x5. GE 2 [esrze? | rang 30 JICS6 oY 20 [72 [sess rring-20 Jc 26 S| 2 | BaeeE Sey Daa Po eotst | ring st CBS TOT [2194007 ork Sop Kt TRESS 2 eriwo [ring 80 ace Seal IEE TECe | server ow Resta Sen Bo [pean | ring TR Fone Seat AGEL Tee [asia [G9 Loner ook CL 4 [-aaete2—[ Lower ook Senies Ki © 1 Frame noes replac & Inciagea'n Service Kt Se prc: cog pars beataown Y Quanity as rea ‘eudedin Palet Guar Kx 220688 ger complete Sesnt Assemby Reference: SK-6349 219941 Rev. 0S5F REF] GTY] PARTNO. | __ DESCRIPTION [1 flocse.soKe| Cymnaer Assemay fez[2 | se2132 | Roa Seat 4 jes | sees | ona 1d nee jee 2 | Ro wiper Seal oe S [2 | 21ea2e | RetinerSeal comer =m __| Roaision ssembi 7 [=| a | Cynder Set 7ise65 | fod Seal sevice Ke Front View sso © ctadea in Service Ki 219868, i Notsonesabia oraer new Cyindor Assembly. © Refero compeie part numoer samped on anchor Bracke. r sonal umber Stamped on ame. Reference’ $ 10032 Backrest SSF Backrest Height 3éin. | agin. | 60in. (21.5.em) | (122 em) |(152.5 em) REF [GTY| PARTNO. | PART NO. | PART NO. DESCRIPTION TL searea | aae710 | searmt | Saewest— Sin (87 omy Wa TO esarre [680773 [684774] Bacirest= 57 i. (94 cm) Wieth [| e8a775 [684776 |_ 664777 | Bacirest= 47 n_(104 em) Wath [| asa77e [684779 | 564760 | Bocwest = 48 n.(126.5 om) With 3 [| ese7et | “ssa7e2 | eea7ea | Bacnrest= 61 in. (155 om) Wath 26 200173, ‘Capscrew. M62 x 35 at 654586 Looevasher MIE Reterence:5-5370 219941 Rev. 0 "ARTS Recommended Spare Parts 55F [__unms service PART NUMBER DESCRIPTION i | et | 250 ‘BASE UNIT AND MOUNTING 218360 Upper Beaing fay vel | eo preset Lower Beanng 6s | 2 | a ones Loner Hook o | 2] 4 = Capscrew of] «| a ' Nt o | it | a oste2s Washer of ils ‘CYUNDER 10029:x0m Cylinder Assembly o | o : 28868 Shiner Senice Kx 1] 2 ‘ It See specific parts page for pan number. Publications 55F PART NO. DESCRIPTION 7iabei | Uae Warial Operation saloon Pans) 720526 Senace Manus 7978 | Too Caiiog 37964 | Ure Ince Oroer Foor Contacting Cascade Customers —Cascace produc iterature, service literature, pans and videos are available trough authorized lift ruck dealers. To find the dealer nearest you, contact: Cascade Corporation U.S. Headquarters 2201 NE 201st Fairview, OR 97024-9718 Tel: 800-CASCADE (227-2233) 503-669-6300 FAX: 888-329-8207 Lift Truck Dealers — To order parts, service literature or videos: © Cascade Corporation 1998 Cascade Parts Sales. 2501 Sheridan Ave. Springfield, OH 45805 Tel: 888-CASCADE (227-2233) FAX: 888-329-0234 7.98 Part Number 219941== Service Manual 35D/40D and 55D/60D High-Visibility WORLDMAST ~ Full Free Lift 2-Stage Mast Manual Number 689225 cascade’ Cannons Ragan Trade! Cacase CaponContents Page INTRODUCTION. Section 1 1 introgucton 1 Special Definitions: 4 ‘Too! Requirements 1 INSTALLATION INSTRUCTIONS, Section 2 2 Truck System Requirements 2 ‘Mounting Bracket Installation 2 Mast instalation | 4 Inspection ang Adjustments 5 (Chain inspection and Tension 5 Free Lit Chain Adjustment 5 ‘Upright Rail Lubncation 5 ‘Syiincer Bleeding 6 Mast Skewing 6 tternal Installation Zz PERIODIC MAINTENANCE, Section 3 8 Daily Inspection 8 +100 Hour inspection 8 500 Hour ion 8 ‘TROUBLESHOOTING, Section 4 3 SERVICE, Section 5 70 ‘Mast Removal 10 inders al p ‘Main Lift Cylinder Description at Free Lit Cylinder Description 2 Gytinder Operation, 3 Main Lift Cynder Flemoval-Mast on Floor 5 Free Lift Cylinder Removai-Mast on Floor 16 Free Lift Cylinder RemovalMast on Truck 7 Main Lift Cyinder Service Free Litt Cylinder Service Piston Removal 3 Bleed | S18) Valve Cartridge Service | | Removal Mast on Truck ‘Carriage Removal-Mast on Floor 23 Carriage inspection 24 Mast Uprights, 25 Dpright Description 25 Upright Operation 28 Upright Disassembly zr Upright Inspection 27 Upright Reassembly 28 Mast Skewing 23 Chains 30 ‘and Tension ‘Chain Setch Free Lift Chain Adjustment Free Lit Chain Service |sen 1 Introduction 11 Introduction ‘This manual provides the instalation instructions, periocke ‘maintenance, troubleshooting and service procedures for the Cascade D-Series WORLDMAST™, roller masts, In any communication about the mast, refer to the mast Serial number stamped on the namepiate. I the name- plate is missing, these numbers are also stamped on the left-hand side upper cheekplate, See Figure 1. WARNING: Do not instal a WORLDMAST™ A tna suck with a capany grea han be ‘tuck rated capacities shown below. “TRUCK CAPACITY AT 24 in. (610 mm) LOAD CENTER 35D 40D SSD 60D '3500 bs. 4000 bs. S5001bs. 6000 Ibs. (1585 kg) (1812 kg) (2491 kg) (2718 kg) Modifications and additions which affect eapaciy or safe ‘operation shall not be performed without prior written. ‘approval from Cascade per ANSI BS6.1. 12 Special Definitions ‘A statement preceded by 4X WARNING is information ‘that should be acted upon to prevent bodlly Injury. A WARNING is always inside a nuded box. CAUTION ‘A statement preceded by CAUTION is information that ‘should be acted upon to prevent machine damage. IMPORTANT ‘A statement preceded by IMPORTANT is information that significance. ‘ossesses special NOTE ‘A statement preceded by NOTE is information that is handy ‘to know and may make your job easier. 1s Tool Requirements Listed below are the minimum tools needed to work on a WORLDMAST™, METRIC 17, 19, 24 mm Open End or Socket Wrench INCH ‘3/4, 13/6, 7/8, 15/16, 1.0, 1-1/16 in. Open End or ‘Socket Wrench ‘Vin. Allen Wrench Snap ing Piers Giaw Type Spanner Wrench Strap Wrench Torque Wrench 2b. Dead Blow Hammer RQODR Rav 0 Sumoes Bera! Numbers = LEFT-HAND SIDE OF ouTeR Upricnt CHANNEL, Example: 55D-MD~001-00025-M Figure 1. Serial Number Locationsam 2 INStallation Instructions 21 Truck System Requirements To achieve the maximum iting capacity of the mast, the indicated in the char below. This chart also indicates the howe and fing Szeto use between ‘control ‘and mast valve. Vatve inet Port 3idin, SAE O-ing IMPORTANT: Cascacio Masts are compatible with SAE 10W Figure 2. Valve inet Port. ‘base oi per Mi. Spec. MIL-O-5606 or MIL-O-2104 petroleum onl. Use of synthetic or aqueous base hycrauic oil is not recommended. I fre resistant hydrauc oil must be used, contact Cascade, 22 Mounting Bracket Installation @ Ititie necessary to install mounting brackets and cross- members ft your it tuck, consult with the nearestseam 2 INStallation Instructions 22 Mounting Bracket Installation (Continued) WARNING: Mounting bracket and crossmem- bber welding must be performed by a certified welder familiar with this type of fabrication. @ Disassemble the outer channel from the mast prior to welding. Refer to Section 5.5-3 for disassembly proce- dures. © Clean all surfaces to be welded. Remove paint, oil, gfease and other contaminants. @ Locate the mounting brackets and crossmembers on the mast rails. Ciamp in piace with °C: clamps. Protect - the mast ral inner surfaces from weld spiatter with fiberglass cloth, © Preheat the weld area to 100" F (38° C) before welding, Do not weld in a draty area. @ WELD METHOD A - Attach the ground wire to the outer Weld using FAW (Fux Core Arc Weld) AWS E7OT-5 1/16 in. (1.5 mm) diameter wire with 100% COz shielding gas. Use the location and filet size shown holding a close are. Do not oscillate or use a wash bead pattem. Let the welds slow cool WELD METHOD B - Attach the ground wire othe outer Upright. Weld using E-7018 law hydrogen 5/32 in. (4 * mm) electrodes. Use reverse polarity or a AC welding machine set at 145-225 amps. Do not use electrodes ‘to moisture without first re-drying them at 200° F (75° C) for 2 hours. Use the locaton and filet ‘Sze shown holding a close ere. Do not escilate or use a wash bead pattern. Let the weids slow cool WARNING: Weld areas that willbe vertical ‘seams when the mast is standing upright only DO NOT WELD ANY HORIZONTAL SEAMS. ‘SEE FIGURE 4, @ Weld in the tat position oniy. Weld each bracket in wo ‘passes. See Figure 4. Run ihe frst wed from the ‘oto ofthe bracket to midpoint. Run the second weld from the tp of the bracket to midpoint and overlap the first weld to elmnate arc eraters. © Remove slag and inspect the wold. The following elects are not allowed: undercut, overlap, sess tracks and porosity. Clean the weld area and repaint © The measurement showm in Figure 5 should be taken fier welding and cooling the mast. This cimension ‘must be maintained fo the uprights to operate propery @ Reassemble the mast. Refer to Section 5.5-5. 689225 Rev. 0 WARNING 0 NOT WELD THESE AREAS, HORIZONTAL WELDS WiLL REDUCE THe STRUCTURAL STRENGTH OF THE CHANNEL, WARNING |i WELD ON VERTICAL SEAMS ONLY, Wilds are rypiea! for st mount. Figure 4, Mounting Brackets, Top View [SD . 2055" 400 7 (22mm) $50, 2331in, + 03 in, {882.2mm1_—i Bev ‘Mwesssre Tasige fo Inaie oF Oster Uorgnt Se Two! ‘Teena Bottom. outer Uprignt Figure 5. Ornensional inspection.sem 2 Installation Instructions 23 Mast Installation @ Raise anc biock the front end of the truck 1 ft (25 om) per ‘ANSI BSS.1 or drive the tuck over a service pit. @ install the bearings to the lower axie mounts. © Ludscate the bearing surtaces of the lower axle and tit, cylinder mounting brackets wih chassis grease. © Litt the mastusing an overhead hoist with chain hooks ‘attached to the cheekpiate liting holes. Position the mast lower axle mounts on the tuck abe. Install the rrount caps and canscrews. Tighten the capscrews to the tuck manufacture’s torque specifications. IMPORTANT: Prior to connecting the tit cinders to the mast, make sure the cylinders “bottom” evenly. Adjust the tit ‘finders to prevent the mast from “racking during tting, Fler to your tuck service manual for procedures. © Connect the lift ruck hose to the mast vaive. @ Connect the tit cylinders tothe mast anchor brackets. Tighten the pin capscrews to the tuck manufacturers toraue specifications. NOTE: Use as few ftings as possible and always use 45* fitings instead of 90° fitings. Keep the hose lengths to a rrintrum. Avoid sharp bends or pinch porns when rouing 689225 Rev. 0secon 2 INStallation Instructions 24 Inspection and Adjustments FEU SME UMATIRIS 241 Chain Inspection and Tension ‘The hoist chains have been factory lubricated using heat and orignss ana ase pressure to force te brant thoroughly ino te chai inks. a Avoid removal or contamination of this factory applied Flusn lubricant. Do not wash, sand blast, etch, steam clean, or Carriage 2 in, paint the chains for initial mast installation. _l Below Uorers ALA ‘The chains must be adjusted with equal tension to ensure proper load distibution and mast operation. To determine Figure 7. Upright and Cariage Postion. ‘equal tension, extend the unloaded mast to put the chains Lnder tension. Press the center of a strand of chain with your thumb, then press at te same piace on the other chain of the pair. Each chain in a pair should have equal "give", If they {0 not have equal tension, perform the hoist chain adjust- ments described below. 242 Free Lift Chain Adjustment ~The free tt chains should be acjusted so that when the Unloaded masts fuly lowered, the camiage is positoned as shown in Figure 7 @ Locate the threaded chain anchors on the front side of the inner upright crossmember on each side ofthe cylinder. @ Adjust one chain to achieve the correct cariage position ‘when fuly lowered, as shown in Figure 7 and 8, © Adjust the other chain to achieve equal chain tension. Tighten the nuts together to a torque of 50-70 tbs. (68- 95Nm). @ Raise and lower the mast several times to confirm the adjustments. Upriane Bowe 243 Upright Rail Lubrication Lubricate the full length of each upright rail with chassis lube ‘ot Kendall SR-12K (Cascae Part No. 599474) as showm in, °. Lore at Lube Pho. sooere ‘LUBRICATE ONLY WHERE INDICATED BY THE HEAVY LINE FOR THE FULL. LENGTH OF EACH UPRIGHT. Figure 8. Rai Lubrication. 689225 Rev. 0seam 2 INStallation Instructions 244 Cylinder Bleeding WARNING: The cyiinders must be bled 10 remove ai. Air in tre cyinders will compress on| the first extension which could rupture the ‘yinders causing serious bodly injury and Property damage. When new or after repait, the cylinders may have air tapped in them that must be removed. To bleed air do the following : @ Without a load extend the tree lift cyinder and continue tp extend the main lit cyinders to 90% of full stroke. Retract all cyinders completely. Repeat three times. © Batend the cylinders without a load at 50% full engine ‘speed then build full system pressure at the end of the main fit cyinder svoke. Electric trucks - limit the ‘control valve moverient to achieve the 50% speed. React all cylinders. Repeat four times. © Cycle the mast with a half load (50% mast rated capacity) through full cylinder extension several times. ‘The cylinders should extend smoothly. Repeat the steps if cyinder extension is not smooth. 245 Mast Skewing Check for mast skewing as described in Section 5.56.sen 2 INStallation Instructions 25 Internal Reeving Installation @ Install the ftings to the carriage bracket. @ Install the front hose guide bracket to the back side of the inner upright crossmember. Tighten the cap- Screws to a torque of 48-52 ft-lbs. (65-70 Nm), © nota the rear hose guide bracket to the outer ‘upright by inserting the round bar atthe end of the bracket ito the hole in the upper erossmember. @ Axach the lower end of the bracket to the inside of the outer upright crossmember leaving a.75 in (19 smn) to 1.75. (44,5 men) gap between the tap of the bracket and the upper crossmember. The a bracket should be parallel withthe upright. Tighten tas os ‘the capscrew to a torque of 48-52 ft-lbs. (65-70 Nm), | © Remove the existing capscrew and guard from one | ‘ide of the cyinder crosshead. Insta the hase | sheave and guard wih the hardware supplies \ Tighten the capscrew to a torque of 48-52 ft-lbs. From Howe + | Qe. Gurae races | Insta the hoses tothe carriage fitings with the white line facing ourward. @ Feed the hoses between the crosshead guard and sheave. Raise the carriage just above ‘reel. Route the hoses under the tab on the front hose guide bracket. install the hose clamp. ull on the hoses to remove slack. Tighten the capscrew to a torque (of 25-30 ft-tbs. (35-40 Nm), ‘Completely lower the camiage. © Route the hoses to the rear guide ‘bracket. The loop in the hoses sshouid be 4 in. (101 mm) 1 in. (25 mm) below the bottom of the rearbracket. © Install the hose clamp at the top of the rear guide bracket. Make sure the loop is the same for both hoses. Tighten the capscrew toa torque of 25-30 ft-lbs. (35-40 Nm) ® Install the bulkhead fitings to the bracket with the securing nuts located on the top side. Install the hose ends to the fitings. @ Move the lowering control valve ‘and bracket to the back side of the ‘center crossmember. Tighten the ‘capscrews tp a torque of 25-30 ft.- tbs. (35-40 Nm). Check and adjust hose clearances. @® Raise and iower the mast several times to make sure the hoses are ‘racking correct in the guide ‘brackets. Use the white line on the ‘hoses 10 detect hose twisting Adjusting the hose ends with a 2tight amount of twist may improve soe tracking in the guides. Sy Figure 10, intemal Reaving instalation, 689225 Rev. 0sae 3 Periodic Maintenance 31 Periodic Maintenance For proper operation and an extended service life, your WORLDMAST™ should be inspected and serviced requiarly ‘as part of your normal ift ruck maintenance schedule accord- ing tothe following outines and ANSI BS6.1 procedures. ‘The recommended intervals are for masts operating under rrormal conitions. if the mast is operating in severe conditions ‘or corrosive atmospheres, the inspections should be per- formed more frequently. ‘WARNING: Never work on the mast with aload ‘on the forks or attachment, inthe raised positon without supports or while anyone is near te lift ‘tuck control handles per ANSI BS6.1 31 Daily Inspection Perform the folowing atthe beginning of each work shit: 1. Extnd the cariage a few inches off the ground and make ‘sure the chains are under equal tension. Refer to Section 568 and 5.64 for chain adjustment 2 Extend the mast to its fl height to make sure the mast rails and camiage exend freely witout binding. 3. Wile the mastis extended, inspect he upright ras for (Proper lubrication. Refer to Section 5.5-5 step @ for rail Eiricaton. 4. Make sure te intemal reeving hoses (# equipped) ravel evenly in the hose guides. Adjust the hose ends if re- quired. Tighten the fitings making sure they do not twist. 31-2 100 Hour Inspection ‘Attar each 100 hours of itt ruck operation, and in adftion to the daily inspection: 1. Inspect and lubricate the fulllength of the chains with SAE ‘40 wt. oil or Bowman Heavy Load Red Grease (Cascade ppartno. 200867). CAUTION: The chains must be coated with a fim of lubricant, atalltimes. 31-3 500 Hour Inspection ‘Aft each 500 hours of ff truck operation, and in adltion to the Daily and 100 Hour Inspection: 1. Each pair of load rollers on the uprights and carriage ‘should be shimmed so that a total side to side clearance ‘to greater than 1/16 in. (1.5 mm) occurs at the tightest [point throughout the travel ofthe member. Pry between the upright and load roller so that the oppasite load roller ‘ght against the upright. Measure the clearance for the pai of rollers atthe X0X shown. See Figure 11. ‘© H.acdiional shims are required, refer to Section 5.5-5 {for upright rollers or Section 5.42 for carriage rollers. 2 Check the chains for wear end stretch, Refer to Section 56-1 for complete chain inspection. 8 689225 Rev. 0sen 4 Troubleshooting ‘The following table lsts problems that may be encountered ‘on your WORLDMAST®, the probable causes and the rec ‘ommended corrective acton that should be taken to restore the mast to normal operating conditen. PROBLEM PROBABLE CAUSE SOLUTION Gyiinders dont it load onwontmove- + Emory 8) Pruggediinlet hose. 8) Unplug hose or replace By suffcrento 1) Check the ruck hyerauls stem Tor correct o level in tank, elective pump or puro dive, leaks in the lines or ‘Ssconnectad contval valve linkage. Repair orreplace as necessary ©) Beri or jammed plnger ©)_Repair or replace as necessary “A. WARNING: Exreme care should be used when working on a unitwhen the cariage (win or without load isthe raised positon. * Loaded a) Plugged piston check valve. a) Unplug check vaive or replace. 'b)_Truck relief valve setng iow. ’b)_Raise rusk relief sting 1 specifed evel. ©) _Overcapacity. ¢) Reduce load to specified capacity. ‘@) Mechanical bind dueto bent plunger 6) Remove mechanical bind by of bad rollers. replacing/freeing plunger and rollers. A. WARNING: Exreme care should be used when working on a unit when the cariage {wth or without a load) sin the raised pastion Binders arf a) Enema eakn pressure ine. '@) Tighten or replace as necessary. 'b) Truck vane delecive-cycle m Rill B) Repair replace buck valve 7 height vent. A ©) External leaks at retainer. ©) Replace all cylinder seais. @)__ Piston check valve leaking @)_Replace check valve Spongy or jerey action 13) Sticky or defective tuckrelel valve. a) Remove and check tw muck reielvave. contaminated oll caused the matfunction, rain and flush the system, change the fiter ‘and refill with fresh oi. (A. WARNING: Extreme care should be used when working on a unit when the camage {with or without load)is in the raised positon. 'b) Bent or damaged cylinder plunger. ') Disassemble, check and repair cyinder asses | (A. WARNING: Exveme care should be used when working on a unit when the camage {with or without a load) is in the raised positon. ©) Load rollers not properly adjusted or -_-¢)-_ Adjust or repair as necessary. (A WARNING: Extreme care should be used when working on a unit when the camage (with or without a load) i in the raised positon. ! ¢) _Mast channels imp: lubricated. Lubricate mast. (with or without a load) is in the raised position. @) _Lowbattery charge. ©) Charge battery. 4) Low pump volume. f)_ Install accumulator. 9) _Lowoil level. 9) _Filloi reservoir. fh) Insufficient hydraulic tank capacty or fh) Install larger tank or baffles. baffles. ‘Oner ‘Contact Cascade Corporation. 689225 Rev. 0scan 5 Service 5A Mast Removal © Raise and block the front end of the tuck 1 ft (25m) or drive the tuck over a service pit. @ Disconnect the lt ruck supply hose trom the mast valve. Plug the hose end and cap the valve fitting, WARNING: Do not stand on or near the mast wile suspended by the hoist. © Attach overhead hoist chain hooks to the cheekpiate lifing holes. Take up slack in the chain. © Disconnect the tit cylinders from the mast anchor ‘brackets. For reassembly, tighten the pin cansorews 10 the truck manufacurers torque spectications. © Disconnect the mast lower mounts. For reassembly, tighten the canscrews to the tuck manufactures orque specifications. © Litaway the mast @ Formast installation, refer to Section 2.1. WARNING: Do not stand the mast upright unless itis chained to a support. Figure 12, Mast Removal BRODER Rev 0sein 9 Service s2 Cylinders 521 Main Lift Cylinder Description The main lt cylinders are single stage displacement type cylinders. They consist of a shell and a telescoping plunger/piston assembly. During extension the ol pressure is acting against the plunger outer ameter due to the intemal porting through the piston. The piston seals do not affect cyinder extension. The truck hoist control valve holds tne cylinders in place once extension has stopped. ‘The shellis internally threaded at the top end to hold the fetainer. The retainer seals provide a high-pressure hy- i Installation | { | O Hritis necessary to instal mounting brackets and cross- || (P| members to ft your lift tuck, consult wth the nearest Nita Cascade Service Department listed on the back caver. B+ You must supoly dimensions A though F shown in se Figure 3. Failure to install the correct brackets and cross- oes members can result In mast stuctura falure, Boal iniuy oe I ‘and loss of warranty. WARNING: Failure to install the correct brackels and crossmembers can result in mast structural failure, Bodly injury and loss of warranty. ‘Sie View Figure 6. Determining Mounting Bracket Locaton 2 687250 Rev. 1sen 2 Installation Instructions 22 Mounting Bracket Installation (Continued) WARNING: Mounting bracket and crossmem- ber welding must be performed by a cerified ‘older familiar with this type of fabrication. @ Disassemble the outer channel from the mast prior to welding. Reler to Secton 5 53 for eisassembly proce- sures © Cican al surfaces to be welded. Remove paint, oil, grease and other contaminen's @ Locate the mounting brackets and crossmembers on the mast rals. Clamp in place with °C" clamps. Protect the mast ral inner surfaces from weld splatter with fiberglass cloth © Preheat the weld area to 100° F (38° C) before welding. Do not weld in adray area, @ WELD METHOD A - Attach the ground wire to the outer upright. Weld using FCAW (Flux Core Arc Weld) AWS E7OF-5 1/16 in. (1.5 em) diameter wire with 100% COz shielding gas. Use the location and filet size shown holding a clase aro. Do not escllate or use a wash Dead pattern. Let the welds slow cod WELD METHOD B - Attach the ground wire to the outer Upright, Weld using E-7018 low hydrogen 5/32 in. (4 mm) electrodes. Use reverse polarity or a AC welding machine set at 145-225 amps. Do not use electrodes exposed to molsture without first re-drying them at 200° F (75° C) for 2 hours. Use the location and filet size shown holding a close arc. Do not oscillate or use ‘a wash bead pattern. Let the welds slow cool ‘seams when the mast is standing upright only. DO NOT WELD ANY HORIZONTAL SEAMS. ‘SEE FIGURE 4, ( WARNING: Weld areas that will be vertical DO NOT WELD THESE AREAS, RORIZONTAL WELDS WiLL REDUCE THE STRUCTURAL glam Stouna WARNING STRENGTH OF THE CHANNEL, WARNING Baegenvermens SEAMSONLY 28 (6mm) ® we Soont 0) @ Weldin te fat positon only. Weld each bracket in two passes. See Figure 4. Run the frst weld trom the Bottom ofthe bracket to midpoint. Run the second weld from the top ofthe bracket to midpoint and overap the frst weld to oiminate ave craters @ Remove slag and inspect the weld. The following Gefects are not alowed: undercut, overiap, sess cracks and porosity, Clean the weld area and repaint © Tho measurement shown in Figure 5 shoul be taken ater welding and cooling the mast. This dimension rust be maintained forthe upighs to operate propery. @ Reassemble the mast. Refer to Section 5.5-5. 687250 Rev. 1 ures Moning Bracke's Outer Upriane Ina fo Inaie Top View lo) co 350 _ 20.56 in 400 * (822mm! 850 _23.31 in. + 03, 50D ~ (582.2!) =|:Bevm) gh Suter pres Be Tao Places Jap ane Bottom, Figure 5 Dimensional hspsem 2 INStallation Instructions 23 Mast Installation © Raise and biock the frontend of the tuck ¢ (89 em) per ANSIB56.1 or drve the tuck ovar a sontce ph @ instal the bearings othe lower axle mounts © Lubricate he bearing surfaces of he lower axloand sit cinder mouniing brakes wih chassis grease © Litto mast using an overhead hoist wih chain hooks attached tothe cheekplate ting holes. Postion the mast iowor axie mourts on fe truck ele. Install the mount cape and capecrens. Tighten the capscrews tothe ruck manufacturers toraue specticatons IMPORTANT: Priorto connecting the tit cylinders tthe mast, snake sure tho eyiinders “bottom” every. Adjust the tit yinclers to prevent the mast rom "racking? sing sing Fotor to your tuck service manval for procedures © Connect the it ruck hase tothe mas: valve © Connect te tit oyinders to the mast anchor brackets. Tighton the pn eapscrews to the ruck manulacturer’s torque specications NOTE: Use as fw ftings as possible and always use 45° ftings instead of 90"fitngs, Koop the hose longins toa ranmum, Avoid sharp bends or pinch poins whe routing the nose. contact Cascade it Seditional tense are Figure 6. Mast nsiatation 687250 Rev. 1sein 2 INStallation Instructions 24 24-1 24-2 24-3 Inspection and Adjustments Chain Inspection and Tension ‘The hoist chains have been factory lubricated using heat and ’ressure 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, or paint the chains for initial mast installation, ‘The 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 ofa 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". If they {G0 not have equal tension, perform the hoist chain adjust ments described below. Main Lift Chain Adjustment The main lft chains should be adjusted so that when the Unioaded mast is fully lowered, the uprights and carriage are positioned as shown in Figure 7. © fAcjust one chain to achiove the correct upright postion ‘when fly lowered, as shown in Figure 7 and 6 © Acivs the oer chain to achieve equal cain tension Tigton the nus together to a torque of 50-70 fs. (62-95 Nr), © Raise and iower the mast several times to confm the adstments Free Lift Chain Adjustment The free lit chains should be adjusted so that when the unloaded mast is fuly lowered, the carriage is positioned as shown in Figure 7. @ Locate the threaded chain anchors on the front side of the inner upright crossmeminer on each side of the cylinder. @ Adjust one chain to achieve the correct carriage position when fully lowered, as shown in Figure 7 and 9 © Adjust the other chain to achieve equal chain tension. Tighten the nus together to a torque of 50-70 tbs. (68-95 Nm), © Raise and lower the mast several times to confirm the adjustments 687250 Rev. 1 CUSHION TIRE SrnUndectewence J J ecxice\\f PEUMSIRES, 1 Figure 7. Upright ard Garage Postion ml Main Ut Chain &} ar Figure 8. Man Lit Chains Cylinder Free Lit Figure 9. Free Lit Cham,seam 2 Installation Instructions 2.44 24-5 24-6 24-7 Free Lift Cylinder Supply Hose Tracking Adjustment Make sure the cylinder supply hose is not twisted and travels evenly in the hose guide. Check the hose to be sure itis not souffng. Adjust the hose by loosening the hose end ‘connection atthe valve and twist the Nose. Tighten the hose ‘end while holding the hose in place. See Figure 10. Tension con the hose can be adjusted by using a diferent set of bracket holes, Use the hotes that place a small amount of tension on the hose. Upright Rail Lubrication Lubricate the full length of each upright rail with chassis lube or Kendall SR-12x (Cascade Part No. 599474) as shown in Figure ‘1 1 a hy Upright Rall Lube PartNo, 599874 | a Cylinder Bleeding ) WARNING: The cylinders must be bied to remove air. Air inthe cylinders wil compress on the first extension which could rupture the oyinders causing serious bodlly injury and propery damage. When new or after repair, the cylinders may have air rapped inthem that must be rermoved. To bleed arr do the following © Without a toad extend the free lit eylinder and continue toextend the main lft cylinders to 90% of full stoke. Retract all cyinders completely. Repeat three times. @ Extend the cylinders without a toad at 50% full engine ‘speed then build full system pressure atthe end of the main lit eyinder stroke. Electric tucks - limit tne contro valve movement to achieve the 60% speed. Retract all cylinders, Repeat four times © Cycle the mast with a half load (50% mast rated ‘capacity) through ful cylinder extension several times. The cylinders should extend smooth. Repeat the steps if cylinder extension is not smooth, Mast Skewing Check for mast skewing as desoribed in Section 5.5-6, Figure 10. Hose Tracking Adjusimont (oae Upright Channels SE 4 Y || Yj Cae) LUBRICATE ONLY WHERE INDICATED. BY THE HEAVY LINE FOR THE FULL LENGTH OF EACH UPRIGHT. Figure 11, Rail Lubrication SSS 687250 Rev. 1ea» 2 Installation Instructions 2s Internal Reeving Installation © instal the fitings to the carriage bracket @ Install the hoses to the carriage fitings. Leave the fittings loose, © Install tne hose sheave, shaft and guard tothe crosshead chain sheave shaft. Route the hoses over the crosshead sheave. Tighten the capscrew to a torque of 48:52 f.- lbs. (65-70 Nm). © Raise the carriage approximately 8 ft, (240.cm). Route the hoses on the front side of all crossmembers down- ward under the tab on the front side ofthe cylinder suppor, Feed the hoses backward under the crossmem- ber around the casting guide upward under the back side tab, ‘© Pull on the hose ends to remove hose slack @ install the existing capscrew from the main lft chain shaft Install the hoses and sheave to the shaft. Tighten the canscrew to a torque of 65 ft-lbs. (88 Nm). Make sure tha sheave rotates freely. @ Feed the hoses through the access hole in the cross- member. Atach hoses to the bracket fitings. Leave the fitings loose on the bracket. © Pulldown on the hoses to remove slack. Attach the bracket to the crossmember. Tighten the capscrew to a torque of 38 ft-bs, (51 Nm). © Raise and lower the mast several times to ‘make sure the hoses are tacking correctly. Use the write line on the hose to detect twisting. Adjust the hose ends if required. Tighten titings making sure they do not a ‘wt FRONT VIEW | pack view Figure 12, Intomal Reeving instalation 687250 Rev. 1sean @ Periodic Maintenance 34 34-1 34-2 31-3 Periodic Maintenance For proper operation and an extended service life, your WORLDMAST™ should be inspected and serviced regularly as par of your normal ift tuck maintenance schedule accord: ing to the following outines and ANSI BSB. procedures ‘The recommended intervals are for masts operating under normal conditions. Ifthe mast is operating in severe conditions Cor corrosive atmospheres, the insnectons should be px formed mare frequently A Daily Inspection Perorm the following tthe beginning of each work sit 1, Extend the carage afew inches off the ground and make sure the chai are under equal tension Pero Section Se0and 56-4 for chan aqusiment 2. Extend the mast tots ful height to mako sure the mast ais land cariago extond rely wehout binding WARNING: Nevor work on the mast with aload ‘on the forks or attachment, in the raised position without supports or while anyone is near the lt tuck control handles per ANSI BSE. 1 3. While the mastis extended, inspect the upright rails for proper lubrication. Refer to Section 5.5-5 step @ for ra lubrcation, 4, Make sure the internal reeving hoses (f equipped) travel evenly in tha hose guides. Adjust the hose ends i re- ‘quired, Tighten the fitings making sure they do not twist. 100 Hour Inspection ‘Afar each 100 hour fit tuck operation and in adton to the daiy inepection 1. Inspect and lubricate the ful length of the chains with SAE 40 wt. oll or Bowman Heavy Load Red Grease. CAUTION: The chains must be coated with afm of lubricant atall times, 500 Hour Inspection ‘Attar each 500 haurs of It truck operation, and in adaiton to the Dally and 100 Hour Inspection 4. Each pair of load rollers on the uprights and carriage should be shimmed go that a total side to side clearance no greater than 1/16 in (1.5 mm) occurs at the tightest point throughout the travel of the member. Pry between the upright and load roller so that the opposite load roller is ight against the upright. Measure the clearance for the pair of rallers at the XXX shown, See Figure 13. ‘If additonal chims are requized, refer to Section 55-5 {or upright rollers or Section §.4°2 for carriage roles. 2. Check the chains for wear and stretch. Reter to Section 5.6-1 for complete chain inspection Figure 13, load Roller Clearances 687250 Rev. 1sen 4 Troubleshooting ‘The fllowing table lists problems that may be encountered on your WORLDMAST®, the probabie causes and the re ‘ommended corrective action that should be taken to restore the mast io norma operating condition PROBLEM PROBABLE CAUSE ‘SOLUTION Cylinders don’ it ioad ‘oPwont move + Empty @) Plugged inlet hose 8) _Unplug hose or replace, b) Insufficient oi b) Check the truck hydraulic system correct oj level in tank, defective pump or ump dive, leaks inthe lines or disconnected control valve inkage. Repair orreplace asnecessary ©) Repair or replace as necessary. ‘¢) Bent or jammed plunger. (A WARNING: Extreme care should be used when working on a unit when the carriage {hit or tn aloac anne rlsea poston + Loaded Pugged pston check vee a) “Unplug cteckvave on )_Truck elf valve seting ow )”"Rase ruck elet seting to spec €) Over capaci €) Reduce load te speci capaci “@) Mechanica’ ind due to bert unger @)Rornove mechanical bind by orbad les, replacinghreaing punger and rotors “A. WARNING: Exreme care should be used when working on a unit whon the carriage (with oF without a load) is in the raised position. Ojndes a @_Erernal akin pressive ine By _Tgiiov or eplae as TRO B) Truck va celecive-cyce oh —B) ”Repar or replace tuck valve fe oven ©) bxtena leaks atvetane. @)_ Replace al oyinder al @)_Pston check valve faking. @)Popiace check valve, Sporgy ory ao a) Sic or Gefecive rack ehel vane. a) Remove and chock Wek iat vave. F Contaminated ol caused the atuncton, Gran ond fash the ystom,evange te fr sruretiwith rash of JA WARNING: Extreme care should be used when working on a unit when the carriage: ___| bwin orthotic) sin te sed postion ®) Bentor damaged cyinderplurger. __b) Dsassorble, chock and vena ovindor eerth (A. WARNING: Extreme care should be used when working on a unit when the carriage winor witout a load) sin the rased poston @ Load olor not propery edusiod or 6) Adjust or ep es necessary ote “A. WARNING: Exrere cave shoud be used when wordng ova uni when ie caage (with oF without a load) is in the raised position. @) Masi channels rorooery ubrcted —@)Lubrea mast 4A. WARNING: Extreme care should be used when working on a unit when the carriage {arn oraithout toad) ein te ased posto ©) Low batery charge. ©) _Chargebatery 7)__Low pam volume, — 1) neil accumulator “a)Lowaiievel : @) Fillo reservor 1) Tnsuficient hydra tark capacy o” Ital larger ark or bales baton ) Oe: Contact Cascade Corporaion 687250 Rev. 1 8sem 5 Service 54 10 Mast Removal @ Raise and biock the front end of the truck 1 ft, (30 cm) or ive the truck over a service pt. @ Disconnect the lit truck supply hose from the mast valve, Plug the hose end and cap the valve fing, WARNING: Do not stand on or near the mast while suspended by the hoist. © Attach overhead hoist chain hooks to the cheekplate ittng holes. Take up slack in the chain. © Disconnact he tit cyindrs from the mast anchor brackets. For reassembly, tighten te pin capscrews to the tuck manutacturer’s torque spectieatons. @ Disconnect the mast lower mounts, For reassembly, tighten the capserews to he ruck manufacturer's erave spectical ons. © Litaway ne mast, @ For mastinstalaion, reer to Section 2.1 WARNING: Do not ctand the mast upright Unless its chained to a support. Figure 14, Mast Removal 687250 Rev. 1sen 5 Service s2 Cylinders 52-1 2000 PSI Main Lift Cylinder Description The main tit cylinders are single stage piston type cylin- dors, They consist of a shell and a telescoping plunger! piston assembly. During extension oll pressure is actng against the full piston area. The truck hoist control valve holds the cylinder in place once extension has stopped ‘The shel! is internally threaded at the top end to hold the retainer. The retainer seals provide a high-pressure hydraulic seal against the plunger. The retainer also lirits the upward stroke of the plunger. A piston is attached to the bottom end of the plunger. The piston seal provides a high-pressure hydraulic seal against the shell, A check vaive is located in the bottom of the piston. The check valve allows residual ol between the ‘shell and plunger to escape when the cylinder is extending ‘A hydraulic tuse/cushion vaive is located in the cylinder por. In case of a hose failure between the lowering control valve and cylinders, the fuse limits the lowering speed of the cylinder. The valve also cushions the piston when the ceylinder nears the fully lowered position, 687250 Rev. 1 Retainer Bieee sre —of Plunger) Bowmoly PAY Cashion valve Figure 15 2000 PSI Cinder "1cen 5 Service 5.22 12 2600 PSI Main Lift Cylinder Description ‘The main it cylinders are single stage displacement tyoe cyinders. They consist of a shell and a tetescoping plungeripision assembly, During extension the oil pressure is acting against the plunger outer diameter due to the intarnal porting through the piston. The piston seals do not affect oylinder extension. The tuck hoist control valve holds the cylinders in place once extension has stopped. The shells internally threaded at the top end to hold the retainer, The retainer seals provide a high-pressure hy: draulic seal against the plunger. The retainer also limits the Upward stroke of the plunger. A piston is attached to the bottom end of the plunger. The piston seal provides a high-pressure hydraulic seal against the shell that engages the cushion vaive when the cylinder is fuly lowered, ‘A hydraulic tuse/cushion valve is located in the cylinder por In case of a hose failure between the lowering control vaive and cylinders, the fuse limits te lowering speed of the cylinder. The vaive also cushions the piston when the cylinder nears the Tully lowered position Plunger! Piston ‘aerembiy —f Hydraulic Fuse! Guehion Valve Figure 16 £2600 PSI Cynder 687250 Rev. 1wan 5 Service 523 Free Lift Cylinder Description ‘The 2000 and 2600 psi free Itt cylinders are single stage piston type cyinders. They consist of a shell and a plunger! piston assembly. During extension the oil pressure is acting Against the full piston area, The truck hoist control valve holds the cylinder in place once extension has stopped. The shellis internally threaded at the top end to hold the tainer. The retainer seals provide a high-pressure hydra seal against the plunger. The retainer also limits the upwar stroke of the plunger. A piston is attached to the bottom end of the plunger. The piston seal provides a high-pressure hydraulic seal against the shall. A check valve is located in the bottom of the pis: ton. The check valve allows residual ol botween the shell and plunger to escane when the cylinder is extending, Reiner —Le ‘A hydraulic fuse/eushion valve is located in the cylinder port, In case of a hose failure between the lowering control valve land cylinder, the fuse limits the lowering speed of the cylin Plunger ‘neck valve (ire flowin Hvaroule Fuse 687250 Rev. 1 13sem 5 Service 5.24 Cylinder Operation 14 Cylinders Raising 1. When the truck heist contro’ valve is actuated, oll enters the lowering control valve through the iniet port and flows unrestricied trrough the lowering control car widge, 2 Oi flows tothe cylinder inlet ports. Due to the larger bore diameter ofthe free lift cylinder compared to both rmain lft cylinders, the free it cylinder wil raise com pletely before the main lit cylinders raise, 3. Oi flows through the free ltt cylinder hydraulic tuse/ Cushion valve fo the bottom of the piston. Lifting force is created against the botiom of the piston causing the plungar to raise, Ol in the area between the plunger and shells allowed to escape through the check valve in the piston as the plunger raises to the end of ts stroke, 4. 2000 PSI Piston Type Main Lift Cylinders — 01! flows through the hydraulic fuse/cushion vaive to the botiom of the piston. Lifting force is created against the bottom of the piston causing the plunger to rase. Olin the area between the plunger and shell is alowed to ‘escape through the check vaive in the piston as the plunger raises, 2600 PSI Displacement Type Main Lift Cylinders - Oil flows through the hydraulic fuse/cushion valve to the piston. The piston is internally ported to allow oil flow 10 the area between the plunger and shell. Lifting force is Created that aots on the diameter of the plunger causing the plunger to raise 5, When oil flow from the truck hoist control valve is discontinued, the cylinders are held in position by the closed center spool of the truck valve. Cylinders Lowering When the truck hoist control valve is actuated, the rain lift then free it cyinder piungers lower, forcing oll out, through the hydraulic fuse/cushion vaives. NOTE: The restriction setting of each hydraulic fuse is lower (lows more ol fiow) than the setting of the lowering control valve, The hydraulic fuses restrict ow only in the instance of a lowering control valve or hose failure 2. Oil flows to the lowering control valve where itis re- stricted at a controled speed determined by the load being handled. 3, As the main it cylinder pistons lower over the spear in the bottom of the shell, a high pressure area is devel ‘oped between the piston and shell which engages the cushion valve to restric flow. This slows the piston! plunger just prior to bottoming providing @ smooth transition tothe free lift cylinder lowering, 687250 Rev. 1son 5 Service Main Lift Cylinder Main Lift Cylinder Free Lift Cylinder set | Plunger ‘Not used in Main Lift 2600 pa cylinders | Hyeraulie Fuse elation Vaive : H ==} = = ae ¢ Int Poet Figute 18. Cylinder Operation 687250 Rev. 1sewn D Service 5.25 Main Lift Cylinder Removal— 16 Mast on Floor © Remove the mast rom the ruck as described in Section 5.1 @ ay the mast down on wooden blocks as shown, Block Under the outer upright so the inner upright wil be ree ‘move. The cariage mustbe postioned between the blocks and free to move. Disconnect the cylinder supaly hoses from the cylinder inlet pore. Remave the special long tiings from the Gyinder ports and install pig fitings. NOTE: Each fiting holds a compressed spring in place. FRernove the snap ring fastening the cylinder rods to the intermediate upright Pallthe inner and intormediate upright outward 2 ft (60 cm). Litthe cyinger rom the base mount and angle inward to remove trough the gap at the top ofthe uorighs Note the numberof shims (i equipped) on each eyindor red For eassambly, reverse the above procedures except as olows: ® @©eooeoood remove trapped air prior to returning the mast WARNING: Main it cylinders must be bled 10 A to operation. Refer to Section 52-11 Figure 19. Cylinder Removal 687250 Rev. 1sain 5 Service 5.26 Free Lift Cylinder Removal — Mast on Floor @ Remove the mast from the truck as described in Section 5.1 @ Lay tho mast down as shown © Fol the cariage toward the center ofthe eylinder to slacken the chains and internal reeving hoses (i equipped) © Disconnect the hose from the eylinder 48° fiting. Cap the fiting and plug the hose, © Femove the chain guards fom the crosshoad. For reassembly, ighten the capscrews to a torque of 48-52 ft-lbs. (65-70 Nm). © Remove the snap ring fastening the crosshead tothe cylinder rod @ Pul the crosshead with chains and hoses (if equipped) of the oyinder rod, @ Aemove the cyinder sap © Remove the cylinder from the mast. ® For reassembly, reverse the above procedures Figure 20. Cylinder Removal 687250 Rev. 1 17cen D SErvice 5. 18 -7 Free Lift Cylinder Removal — Mast on Truck © Compietely lower the carriage. Remove forks or altachment f equipped. Make sure the free it cylinder is completely retracted. Attach an overhead hoist to the top carriage bar. by a block while removing the cylinder 10 avoid possible inury. ) WARNING: The carraige must be supported @ Raise the carriage to the center of the cylinder to slacken the chains and internal reeving hoses (it equipped). Block the carriage in place using a 4X 4X 24in, (10 X 10 X €0 cm) wood block between the lower carriage bar and the floor. Remove the cylinder strap. Remove the chain guards from the crosshead. For reassembly, tighten the capscrews to a torque of 48-52, fi-tbs. (65-70 Nm). Remove the snap ring fastening the crosshead to the cylinder od Pull the crosshead with chains and hoses if equipped) off the cylinder rod and lay over the upper carriage bar. Pry the cylindor up out of the support casting to gain ‘access to the cylinder hose fiting. Remove the hose from the 45° fing. Cap the fiting and plug the hose. 2 926 oo Remove the eylinder from the mast from the top. oo For reassembly, reverse the above procedures, Figure 2 yinder Removal 687250 Rev. 1coun 5 Service 5.28 Main Lift Cylinder Service © Remove the cylinder from the mast as described in Seton 5.25. @ Use a claw type spanner wrench (Cascade part no. {678598) 1 omove th rotaner, Soe Figure 22 Remove the plungeripiston assembly from tho shel Remove the Hycraulc Fuse owering Cushion compo: @ eo Inspect all components for nicks or burrs. Minor nicks cor burrs can be removed with 400 grit emery cloth, NOTE: Minor nicks are those that wil not bypass oil When under pressure. I they cannot be removed with emery cloth, replace the part. If the piston requires re- placing, refer to Section 5.2-10. © Replace the retainer and piston seals, back-up rings (O-rings and bearing. Lubricate the now seals with petroleum jelly prior to installation. Note the correct Seal directions. The cyinder wil not operate correctly ifthe seals are installed backwards, @ 2000 PSI CYLINDERS - When replacing the piston Check valve O-ring, make sure the check vaive is reinstalled with the arrow pointed in the correct. direction, © insta the punger retainer onto plunger. instal he plungerfison assorby into tre eying shel Tighten fe retanor oe ora vas feted below Ung he clew spanner wrench anda svep wrench Figure 22. Claw Type Spanner Wrench, 35D/40D ~ 95-125 ft-lbs, (129-169 Nm) 'SSDI60D — 225.250 ft-lbs. (305-340 Nr) oT ‘Siam ————] 2 V chelPvave ° Lowering Cushion 2000 PSI 2600 PSI Figute 23, Cylnder Service 687250 Rev. 1coum 5 SErvice 529 Free Lift Cylinder Service 20 o e 98 eo 6 Remove the cylinder from the mast as described in Section 5.2.6 oF 52-7. Use a claw type spanner wrench (Cascade part no. 1678598) to remove the retainer. See Figure 24 Remove the plunger/piston assembly from the shel. Remove the Hydraulic Fuse/Lowering Cushion compo- Inspect all components for nicks or burrs. Minor nicks. or burrs can be removed with 400 grit emery cloth. NOTE: Minor nicks are those that will not bypass oi! ‘when under pressure. If they cannot be removed with emery cloth, replace the part. Ifthe piston requires replacing, afer to Section 5:2-10. Replace the retainer and piston seals, back-up rings, (O-nngs and bearing. Lubricate the new seais with petroleum jelly prior to installation, Note the correct seal directions. The cylinder wll not operate correctly ifthe seals ere installed backwards. When replacing the piston check valve O-ring, make sure the check valve is reinstalled with the arrow pointed in the correct direction Install the plunger retainer on the plunger. Install he plunger/piston assembly into the cylinder shell. Pour 412 Cup (120 mi) hydraulic oil inta the eylinder cavity between the shell and rod. Tighten the retainer to a torque of 275-300 ft-lbs. (370-405 Nm) using the claw spanner wrench and a strap wrench. Figure oe Pionger Figure 25. Oyinder Service Cerin Carson 687250 Rev. 1Sect i 5 Service 5.210 Piston Removal 5.2-11 5.3 5.31 © Remove the plungerpiston assersby tom tho cylinder shel as desorbed in Section 52-8 0 529, @ Use a srap wrench (Cascade part no. 678649) and £00 git emery cloth to secure the plunger whie turnrig the Baton wih apn type spanner wrench (Cascade part fo. 679017) Turn the piston until the snap wite end is visible through thohole. Use a scrowdrver to start the wre end out tno hola Tur the piston to feed the wie out Pall the piston from the plunger For reassembly, reverse the above procedures except as olows oo ‘Install a new snap wire when installing tne piston, Cylinder Bleeding WARNING: The eviinders must be bled to A Tomove ar Arintne eyinders wil compress on the fret extension which could rupture the Sylindors causing serious Body jury and property damage Aer repair the cyinders may have air rapped in them that must be removed. To bleed air do the falowng © Without a toad excend the feo lit cylinder and con- tne to extend the rain It cylinders to 90% o stroke. Retract all cyinders completely. Repeat three times, Extend the cylinders without a load at 50% full engine speed then duild to full system pressure at the end of the main lft cylinder stroke. Electric trucks «limit the control valve movernent to achieve the 50% speed Retract all cyinders. Repest four times, Cycle the mast with a half load (50% mast rated capacity) through full ylinder extension several times. The cylinders should extend smoothly. Repeat the stops if cyinder extension is not smooth Valve Valve Cartridge Service o e 8 Completely lower the mast, Remove the truck supply hose from the valve car- ttidge. See Figure 27. Plug the hose. Remove the valve cartridge from the valve. Note the stamped part no, on the cartridge for ordering a replacement. A @ For reassembly, reverse the above procedures. WARNING: Replacing the valve cartridge with a different part no. carindge may cause the mast to malfunction. 687250 Rev. 1 Figure 26, Pislon Removal Figure 27. Valve Canridge Sonice. 24