Installation Instructions

Transcription

1 c Installation Instructions Electronic Pressure Regulator Kits with Rotary This manual provides installation and operator instructions for Cascade s Electronic Pressure Regulator with Rotary kits. The kits allow the driver to select three preset pressures plus truck system pressure to control clamp force. The switch can be set to block the truck system pressure for three active pressure settings. A cab mounted light bar is provided to indicate current setting. Some kits include an optional indicator Light Tower or Light Bar. Cascade recommends using a Low Pressure Tank Line Kit for a dedicated return connection to the truck tank. Voltage V -8V Electronic Pressure Regulator Kits Part No Kits with Light Tower Part No Kits with Light Bar Part No NOTE: Kits are UL Classified (File # AU) for safety in Electric Battery (UL 8) and IC Engine (UL 8) Indust. type E, ES, G, GS,G/LP/ GS/LPS, LP, LPS, D and DS. Light Bar (Optional) Light Tower (Optional) Selector Low Pressure Tank Line Kit Part No. 87-R Cab Light Bar Regulator Valve (-Position) AC.eps cascade corporation For Technical Support... To Order Parts... Cascade Corp. File No. AU Call: Fax: Call: Fax: Internet: Internet: Write: Cascade Corporation, PO Box 087, Portland, OR 979 Write: Cascade Corporation, 0 Sheridan Ave., Springfield, OH 0

2 Installation Disconnect the cable from the negative battery terminal or as directed by OEM truck manual. Locate and install the regulator valve assembly on the truck cowl or under the floorboard using M8 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 Kit 8078 includes fittings and hose to adapt to these tank lines: 0.7 in. (9 mm) ID Tank Hose.00 in. ( mm) ID Tank Hose. in. ( mm) ID Tank Hose Install a No. 8 tee fitting to the P port on the side of the regulator valve. Install a No. 8 hose from the truck clamp auxiliary valve CLAMP port to the P port tee fitting on the side of the regulator valve. 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 Install return to tank line tee fitting AC09.eps Remove GA0.eps Install Install cable from negative battery terminal. regulator valve assembly hose to attachment Clamp port Install hose to P port 7Install open circuit hose T Attachment Valve C O 7 P Hoist Control Valve Clamp Control Valve Hydraulic Pump Relief Valve Tank AC090.eps

3 NOTE: UL Classified Kits require installation by qualified personnel only without major disturbance, cutting, splicing or soldering of factory installed wiring. 8 Locate and mount the Cab Light Bar on the truck dashboard or overhead guard with the provided velcro or M capscrews and hardware. Position for best peripheral viewing due to brightness of lights. 9 Locate and mount the Selector in a location convenient to the truck operator with the fasteners provided. 0 Light Tower Option Locate and mount the optional Light Tower at the rear of the truck or where desired. A simple bracket can be fabricated to mount the Light Tower. Light Bar Option Locate and mount the optional Light Bar on the back of the overhead guard or where desired. 0 Mount Light Tower Mount Light Bar OR 8 Mount Cab Light Bar User Supplied Bracket 9 Mount Selector AC9.eps

4 CAUTION: Consult the Lift OEM for proper + power source connection. Connect the extension cable(s), if required, as shown. Connect the cable ends to the components, as shown. V s Connect the fused positive wire to a V switched power source. Connect the ground wire. V-8V s Mount voltage converter to truck. Connect the fused positive wire from the converter to a V-8V switched power source. Connect the ground wire. Check the cable routing for pinch points and clearance. Use wire ties as needed. Connect battery cable(s) to their proper terminal(s). WARNING: For UL Classified Kits, to reduce the risk of fire, replace only with same type and rating for fuse. Light Tower Regulator Valve T P Connect Cable Ends Optional Light Tower/Bar Extension Cable Optional Extension Cable OR Light Bar Selector -8V V Fuse, A Fuse Block Fuse, A ed Voltage Converter ed Fuse Block Battery (V-8V) Battery IC s Use chassis ground. Electric s Use battery ground. (V) AC07.eps

5 OPERATION WARNING: All operators must read and understand this section before use. This accessory is intended to be used by a trained operator. Operators must have a thorough knowledge ad understanding of the safe operation of this equipment and this accessory. Before operation, daily inspect switch, valve and wiring. Perform and operation test in a safe place to verify proper function. It is the Vehicle OEM's responsibility to access the effect of this Cascade Corp. equipment on the vehicle specifications, performance and operation. WARNING: Residual risk exists to personnel in the work area. Never operate in harms range of pedestrians or bystanders. Operate only in compliance to facility, state and federal standards. For this accessory: a) The Weighted Emission Sound Pressure Level (LpA) does not exceed 70 db(a). b) The Value of Whole Body Vibration does not exceed 0, m/s. c) The Value of Hand-Arm Vibration does not exceed, m/s.

6 , Adjust Relief Cartridges Selector AC9.eps Relief Adjustment To set the valve relief cartridges, install a 000 psi ( bar) pressure gauge (Cascade Part No. 8) 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 080 for Carton Clamps or 70 for Paper Roll Clamps. T IMPORTANT: All three valve relief cartridges are preset to 00 psi. Relief pressure for each cartridge must be adjusted for your application. Shift the selector switch to position. See the light display chart below. The solenoid coil also has a small indicator light. Loosen the jam nut on the No. relief cartridge. Adjust the relief cartridge (/ 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. Shift the selector switch to position. Repeat steps and for the other relief positions. With the selector switch in the th position, the relief valve has no effect. Pressure to the attachment is determined by the truck system relief pressure. Position Relief Cartridge Light Tower Light Bar Pressure Green Green Low Amber Amber Low-Medium Red Red High-Medium None Clear Clear High Position P Light Tower Light Bar Position

7 8 Modifying for Three Active Settings The system is standard with four settings active (three adjustable and truck relief). The switch box can be easily modified to three active settings, blocking out the truck relief position. Remove the cover from the switch box. Remove the screw from the No. position on the switch and install it in No. position. Reinstall the cover making sure the seal is properly seated. Remove cover Making sure the seal is properly seated. AC.eps 7 AC.eps Install screw in No. position

8 Electronic Pressure Regulator Kits ) ( * % fl & ^ $ 7 8 V-8V fi 0! V AC08.eps # 7

9 Electronic Pressure Regulator Kits REF QTY V Kits PART NO. PART NO. PART NO. DESCRIPTION Electronic Pressure Regulator Kits 887 Light Tower 89 Light Bar Power Cable Fuse, A See Light Tower page for parts breakdown. See Light Bar page for parts breakdown. REF QTY -8V Kits PART NO. PART NO. PART NO. DESCRIPTION Electronic Pressure Regulator Kits Convertor Kit, UL 887 Light Tower 89 Light Bar Voltage Convertor Convertor Wire Harness Fuse, A Power Extension Cable, 8 in. (00 cm) See Light Tower page for parts breakdown. See Light Bar page for parts breakdown. Included in Convertor Kit 888 Common Parts REF QTY PART NO. DESCRIPTION 9 0 Control Box Capscrew, M x 70 8 Washer 8899 Lockwasher 77 Nut Wire Harness 8889 Relief Valve Assembly 097 Solenoid Cable Harness Solenoid Cable Cab Light Bar 9 09 Velcro 0 09 Conduit, 9 mm x 7 mm 0797 Conduit, mm x 000 mm 7900 Capscrew, M x 0 Washer 0 Lockwasher 778 Nut 88 Light Tower/Bar Extension Cable, in. (0 cm) 808 Light Tower/Bar Extension Cable, 7 in. (8 cm) 09 Light Tower/Bar Extension Cable, 8 in. (00 cm) 7 Fuse, Vdc See Relief Valve Assembly page for parts breakdown. See Cab Light Bar page for parts breakdown. Included in Convertor Kit 888. Not included in Electronic Pressure Regulator Kits 8 Reference: 8 (R), 87 (R), 88 (R), 8 (R), 80 (R), 8 (R)

10 Light Tower Group AC8.eps REF QTY PART NO. DESCRIPTION 887 Light Tower Group 887 Light Tower Assembly 8898 Capscrew, M x Cap 7878 Capscrew, M x 0007 Washer, M 890 Lockwasher, M 780 Nut, M Globe Clear Globe Red Globe Yellow Globe Green 880 LED cluster Clear 88 LED cluster Red 887 LED Cluster Yellow 888 LED Cluster Green Includes items,, 7. 9

11 Light Bar Assembly 7 0! 9 8 AC8.eps REF QTY PART NO. DESCRIPTION 89 Light Bar Assembly 778 Nut, M 0 Lockwasher, M 0 Washer, M 78 Capscrew, M x Capscrew, M x Washer, M Nut, M 8 89 Light Assembly - Clear Light Assembly - Red 0 89 Light Assembly - Amber 890 Light Assembly - Green 0

12 Cab Light Bar Assembly 7 8 REF QTY PART NO. DESCRIPTION 098 Cab Light Bar Assembly 77 Nut, M 8899 Lockwasher, M 8 Washer, M 780 Capscrew, M x 0998 Bulb - White 08 Bulb - Red Bulb - Amber 8 00 Bulb - Green Includes items 8. NOTE: Items are a part of main kits. AC08.eps Relief Valve Assembly 9 0 REF QTY PART NO. DESCRIPTION 8889 Relief Valve Assembly 8888 Valve Body 080 Plug 0 Relief Cartridge Seal Kit 077 Fitting 0089 Solenoid Cartridge Solenoid Coil V Seal Kit Capscrew, M8 x Washer, M8 89 Lockwasher, M8 77 Nut, M8 Includes items,, and 7. NOTE: Items,, 9 are a part of main kits. AC87.eps Cascade Corporation Part No. 87-R