Installation Instructions

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1 c Installation Instructions Sequential Loop -Position Electronic Pressure Regulator Kits This manual provides instructions for Cascade Electronic Pressure Regulator and Indicator System. The kits provide selectable clamp force for the attachment through a driver operated push button sequence switch with indication of the force selected by colored lights on an optional light bar or light tower. The system is standard with four settings (three adjustable and truck relief). Cascade recommends using a Low Pressure Tank Line Kit for a dedicated return connection to the truck tank. Light Bar (Optional) Push Button Switch Kits without Light Tower/ Light Bar Voltage Part No. V V Kits with Light Tower Voltage Part No. V V Kits with Light Bar Voltage Part No. V V Light Tower (Optional) Sequence Controller Low Pressure Tank Line Kit Part No cascade corporation Cab Light Bar -Position Regulator Valve AC55.eps For Technical Support... To Order Parts... Call: Fax: Call: Fax: Internet: Internet: Write: Cascade Corporation, PO Box 087, Portland, OR 979 Write: Cascade Corporation, 50 Sheridan Ave., Springfield, OH 5505

2 Installation Disconnect the cable from the positive battery terminal. Disconnect cable from positive battery terminal. Locate and install the regulator valve assembly on the truck cowl or under the floorboard using /8 in. capscrews. Watch for clearance when the mast is tilted back if mounting on the cowl. The regulator valve has adjustment screws that need easy access for final adjustment. Install a return to tank line to the T port on the side of the valve to connect with the truck tank line. Cascade Low Pressure Return Line Adapter Kits are listed below..75 in. (9 mm) ID Tank Hose Part No in. (5 mm) ID Tank Hose Part No in. ( mm) ID Tank Hose Part No in. (8 mm) ID Tank Hose Part No Install tee fitting AC00.eps Install regulator valve assembly 5Install hose to P port Install a No. 8 tee fitting to the P port on the side of the regulator valve. 5 Install a No. 8 hose from the truck auxiliary valve CLAMP port to the P port tee fitting on the side of the regulator valve. 6 Install a No. 8 hose from the valve P port tee fitting to the supply circuit for the attachment CLAMP port. 7 Install a No. 8 hose from the truck clamp auxiliary valve OPEN port to the supply circuit for the attachment Open port. Install return to tank line AC09.eps 6 Install hose to attachment Clamp port 7 Install open circuit hose 6 T Attachment Valve C O 7 5 P Hoist Control Valve Clamp Control Valve Hydraulic Pump Relief Valve Tank AC090.eps

3 8 Locate and mount the Cab Light Bar on the truck dashboard or overhead guard with the velcro provided. Position for best peripheral viewing due to brightness of lights. 9 Install the Push Button Switch to the clamp control lever. Remove the control knob. Position switch on the handle in a location for comfortable thumb or index finger operation. Place the double sided tape under the switch to secure the switch in place. Using a heat gun, heat tubing to secure the switch to the handle. NOTE: Remove tubing around button, as desired. Reinstall the knob. Install cable ties as needed for the wires. 0 Locate and mount the Push Button Controller on the truck using the provided velcro. Watch for clearance when the mast is tilted back if mounting on the cowl. Connect the Sequence Controller to the Push Button Switch. Light Tower Option Locate and mount the optional Light Tower at the rear of the truck. A simple bracket can be fabricated to mount the Light Tower on the back of the overhead guard. The light tower cable can be routed out the bottom of the stand or out the side of the light assembly using the grommet supplied. See the wire and terminal connections shown. Light Bar Option Locate and mount the optional Light Bar on the back of the overhead guard. Mount Light Tower OR Mount Light Bar AC00.eps Tape Shrink Tube Cable routed out bottom or side of stand. Grommet supplied for side exit. 9 Control Handle and Knob Install Push Button Switch Remove tubing around button, as desired. Light Tower Wire Terminal Wire Terminal Wire Terminal Wire Terminal Green/Yellow (Ground) Terminal C C 5 in. for typical hand 8 Mount Cab Light Bar 0 Mount Sequence Controller 9 Mount Push Button Switch AC9.eps

4 CAUTION: Consult the Lift OEM for proper + power source connection. Connect the cable ends. V s Connect the fused positive wire to a V switched power source. Connect the ground wire. V-8V s Connect the fused positive wire from the cable harness to the voltage converter supplied. Connect the voltage converter to the voltage filter. Connect the voltage filter to a switched power source. Connect the ground wire. NOTE: When installing on electric trucks with regenerative breaking, voltage filter must be installed. Failure to install voltage filter can cause damage to electrical components. Check the cable routing for pinch points and clearance. Use wire ties as needed. Reconnect the positive battery cable to the battery. T P Regulator Valve Light Tower Connect Cable Ends Cab Light Bar OR Push Button Switch Light Bar Fuse Sequence Controller + -8V Voltage V Filter + + Switched Switched Voltage Converter Fuse Block Fuse Block Battery (V-8V) Battery (V) IC s Use chassis ground. Electric s Use battery ground. AC58.eps

5 , Adjust Relief Cartridges Push Button Switch Relief Adjustment To set the valve relief cartridges, install a 5000 psi AC56.eps (5 bar) pressure gauge (Cascade Part No. 6658) in the valve P port. A clamp force indicator can also be used to adjust the relief cartridge settings. Refer to Clamp Force Indicator Operator Guide for Carton Clamps or 750 for Paper Roll Clamps. IMPORTANT: All three valve relief cartridges are preset to 00 psi. Relief pressure for each cartridge must be adjusted for your application. T Press the Push Button Switch until the light indicates green. The solenoid coil also has a small indicator light. P Loosen the jam nut on the No. relief cartridge. Adjust the relief cartridge (/6-in. Allen hex wrench) inward (CW) to raise pressure or outward (CCW) to lower the pressure. Clamp a load and check the pressure. Readjust as required. Tighten the jam nut. Press the Push Button Switch until the light tower indicates Amber. Repeat steps and to adjust No. relief cartridge. Light Bar 5 Press the Push Button Switch until the light tower indicates Red. Repeat steps and to adjust No. relief cartridge. 6 When the light tower indicates clear, the relief valve has no effect. Pressure to the attachment is determined by the truck system relief pressure. Switch Position Relief Cartridge Light Tower Light Bar Pressure Green Green Lowest Amber Amber Higher Red Red Next Higher None Clear Clear Highest NOTE: To program controller to skip Position ( Relief), contact Cascade Corporation Engineering Department. 5 Switch Position Light Tower Switch Position

6 Electronic Pressure Regulator Control & Indicator Kits With Light Tower! 9 * ) 5 & % # 8 ^ $ $ ^ fl 6 7 ( fi 0 % # Fuse AC6.eps Battery 6

7 Electronic Pressure Regulator Control & Indicator Kits With Light Tower REF QTY PART NO. DESCRIPTION REF QTY PART NO. DESCRIPTION Pressure Regulator V Washer, M Pressure Regulator -8V Seal Kit 79 Converter & Filter Kit Solenoid Coil V 8889 Relief Valve Assembly 0 Relief Cartridge Sequence Controller 66 Seal Kit Plug Fuse, ATM type 7.5 Amp Solenoid Cable Harness Solenoid Cartridge Fitting, Bulb-Red Solenoid Cable 600 Bulb-Amber Wire Harness 600 Bulb-Green Cab Light Bar Bulb-Clear Conduit, 5 mm ID x 000 mm Light Tower with Cable Power Harness Cable 6069 Conduit, 9 mm x 75 mm Nut, M Push Button Switch Bulb, Square D type DLBLJ Lockwasher, M Washer, M5 x Capscrew, M x Capscrew M5 x Nut, M Velcro Washer, M Capscrew, M5 x Lockwasher, M Lockwasher, M Capscrew, M8 x Voltage Converter, -8V V Nut, M Voltage Filter Includes items through. Includes items through 8. Includes items 7 & 8. Quantities as required. 7

8 Electronic Pressure Regulator Control & Indicator Kits With Light Bar * ) 5 fl 6 ( & 7 ªº Bulbs (GE 9) qw % # 9 8 ^ $ i %! $ ^ # r e u fi 0 Fuse Block t AC6.eps Battery 8

9 Electronic Pressure Regulator Control & Indicator Kits With Light Bar REF QTY PART NO. DESCRIPTION REF QTY PART NO. DESCRIPTION Pressure Regulator V Fuse, ATM type 7.5 Amp Pressure Regulator -8V Solenoid Cartridge 79 Converter & Filter Kit 608 Bulb-Red 8889 Relief Valve Assembly 600 Bulb-Amber Sequence Controller 600 Bulb-Green Plug Bulb-Clear Solenoid Cable Harness Velcro Fitting, Light Bar Assembly Solenoid Cable Capscrew, M6 x Wire Harness 06 Lockwasher, M Cab Light Bar Aluminum Bar Conduit, 5 mm ID x 000 mm Capscrew, M8 x Power Harness Nut, M Conduit, 9 mm x 75 mm Red Lamp Assembly Push Button Switch Red Lens Lockwasher, M Amber Lamp Assembly Capscrew, M x Amber Lens Nut, M Green Lamp Assembly Washer, M Green Lens Lockwasher, M Clear Lamp Assembly Capscrew, M8 x Clear Lens Nut, M Washer, M Washer, M Capscrew, M5 x Seal Kit Lockwasher, M Solenoid Coil V Nut, M5 0 Relief Cartridge Voltage Converter, -8V V 66 Seal Kit Voltage Filter Includes items through. Includes items through 8. Includes items 8 through Includes items 7 & 8. Quantities as required. 9

10 Electronic Pressure Regulator Control & Indicator Kits Without Light Tower/ Light Bar! 9 * ) 5 & ( % # 8 ^ $ $ ^ 6 fl 7 fi 0 % Fuse Block AC60.eps Battery 0

11 Electronic Pressure Regulator Control & Indicator Kits Without Light Tower/ Light Bar REF QTY PART NO. DESCRIPTION REF QTY PART NO. DESCRIPTION Pressure Regulator V Capscrew, M8 x Pressure Regulator -8V Nut, M8 79 Converter & Filter Kit Washer, M Relief Valve Assembly Seal Kit Sequence Controller Solenoid Coil V Plug 0 Relief Cartridge Solenoid Cable Harness 66 Seal Kit Fitting, Fuse, ATM type 7.5 Amp Solenoid Cable Solenoid Cartridge Wire Harness 608 Bulb-Red Cab Light Bar 600 Bulb-Amber Conduit, 5 mm ID x 000 mm 600 Bulb-Green Power Harness Bulb-Clear 6069 Conduit, 9 mm x 75 mm Velcro Push Button Switch Washer, M Lockwasher, M Capscrew, M5 x Capscrew, M x Lockwasher, M Nut, M 7680 Nut, M Washer, M Voltage Converter, -8V V Lockwasher, M Voltage Filter Includes items through 8. Includes items through. Includes items &. Quantities as required.

12 Do you have questions you need answered right now? Call your nearest Cascade Service Department. Visit us online at AMERICAS Cascade Corporation Parts Sales 50 Sheridan Ave. Springfield, OH 5505 Tel: 888-CASCADE (7-) Fax: Cascade Canada Inc Timberlea Blvd. Mississauga, Ontario Canada LW-M6 Tel: Fax: Cascade do Brasil Rua João Guerra, Macuco, Santos - SP Brasil 05-0 Tel: Fax: EUROPE-AFRICA Cascade Italia S.R.L. European Headquarters Via Dell Artigianato 7050 Vago di Lavagno (VR) Italy Tel: Fax: Cascade (Africa) Pty. Ltd. PO Box 65, Isando A Steel Road Sparton, Kempton Park South Africa Tel: Fax: ASIA-PACIFIC Cascade Japan Ltd. -, -Chome, Kukuchi Nishimachi Amagasaki, Hyogo Japan, Tel: Fax: Cascade Australia Pty. Ltd. 5 Ipswich Road Rocklea, QLD 07 Australia Tel: Fax: Cascade Korea B 9L Namdong Ind. Complex, 69-8 Gojan-Dong Namdong-Ku Inchon, Korea Tel: Fax: Cascade New Zealand 5 Ra Ora Drive East Tamaki, Auckland New Zealand Tel: Fax: Cascade-Xiamen No. 668 Yangguang Rd. Xinyang Industrial Zone Haicang, Xiamen City Fujian Province P.R. China 606 Tel: Fax: Sunstream Industries Pte. Ltd. 8 Tuas South Street 5 Singapore Tel: Fax: Cascade India Material Handling Private Limited No, Global Trade Centre / Rambaugh Colony Lal Bahadur Shastri Road, Navi Peth, Pune 00 (Maharashtra) India Phone: Fax: c Cascade Corporation Part No

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