Installation Instructions
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1 c Installation Instructions 55K & 100K Fork Positioner Installation Kits for Toyota Masts This document provides installation instructions for Cascade Installation Kits. Each kit provides hoses and a manifold or tubes to connect the hydraulic system on a K-Series Fork Positioner to the reeving supply hoses on a Toyota lift truck carriage. Installation Kit (3-Stage FFL FSV Masts through 7/31/05) 1 Install the manifold block to the carriage hose terminal bracket. Install the manifold with the 90 fittings facing forward. Install the capscrews and lockwashers from the back side. 2 Connect the mast reeving hoses to the manifold fittings. 3 Connect the hoses to the manifold fittings and fork positioner supply fittings. 1 3 FP0798.eps Part No R8 cascade corporation For Technical Support... To Order Parts... Call: Fax: Call: Fax: Internet: Internet: Write: Cascade Corporation, PO Box 20187, Portland, OR Write: Cascade Corporation, 2501 Sheridan Ave., Springfield, OH
2 Installation Kit (3-Stage FFL FSV Masts after 8/1/05) 1 Install the tube weldment to the carriage hose terminal bracket. 2 Connect the mast reeving hoses to the tube fittings. 3 Install reducer fittings to the tube ends. 4 Connect the hoses to the reducer fittings and fork positioner supply fittings. 1 2 FP0884.eps 3 4 2
3 Installation Kit (Quad Masts) 1 Connect the tube weldment fittings to the RH (viewed from driver seat) mast reeving hoses using straight connectors. 2 Connect the reducer fittings to the tube weldment fittings. 3 Connect the hoses to the reducer fittings. Connect the other hose ends to the fork positioner supply fittings. 1 FP0925.eps 2 3 3
4 Installation Kit (2-Stage FFL FV Masts) 1 Install the tube weldments to the carriage hose terminal bracket. 2 Connect the mast reeving hoses to the tube fittings. 3 Install reducer fittings to the tube ends. 4 Connect the hoses to the reducer fittings and fork positioner supply fittings. 5 Connect hoses to the sideshifter supply fittings. 2 5 FP0234.eps
5 Installation Kit (BFD45U, FSV Masts) 1 Install a 90 fitting and reducer fitting to the left hand inner supply tube end. 2 Install a reducer fitting to the left hand outer supply tube end. 3 Install 90 fittings to the sideshift cylinder ports. 4 Connect the hose with 90 end (530 mm) to the left hand outer supply reducer fitting (viewed from driver seat) and fork positioner supply fitting. 5 Connect a hose (584 mm) to the left hand inner supply reducer fitting (viewed from driver seat) and fork positioner supply fitting. 6 Connect a hose (520 mm) to the right hand outer supply fitting (viewed from driver seat) and right hand sideshift cylinder fitting. 7 Connect a hose (400 mm) to the right hand inner supply fitting (viewed from driver seat) and left hand sideshift cylinder fitting. 8 Install a cable tie to reduce hose movement FP2206.eps
6 Installation Kit (BFD45U, FSV Masts) 1 Install reducer fittings to the left hand mast supply fittings. 2 Install the tube to the left hand fork positioner supply fitting. 3 Connect a hose (460 mm) to the right hand fork positioner supply fitting and the left hand outer mast supply fitting. 4 Connect a hose (460 mm) to the left hand fork positioner supply tube and the left hand inner mast supply fitting. 5 Connect a hose (299 mm) to the right hand sideshift cylinder fitting and right hand outer mast supply fitting. 6 Connect a hose (506 mm) to the left hand sideshift cylinder fitting and right hand inner mast supply fitting. 7 Install a cable tie to reduce hose movement FP2203.eps
7 Installation Kit (100K V Masts) 1 Connect the tube weldment fittings to the LH (viewed from driver seat) mast reeving fittings. 2 Connect the hoses to the tube weldment fittings and fork positioner supply fittings. 3 Connect the sideshifter hoses to the RH (viewed from driver seat) mast reeving fittings and cylinder fittings. 3 FP1558.eps
8 Installation Kit (100K FSV Masts) 1 Connect the sideshift tube weldment to the LH (viewed from driver seat) mast reeving fittings. 2 Connect the fork position tube weldment to the RH (viewed from driver seat) mast reeving fittings. 3 Install reducer fittings to the fork positioner tube ends. 4 Connect the sideshift hoses to the LH (viewed from driver seat) tube weldment fittings and sideshift cylinder fittings. 5 Connect the fork position hoses to the RH tube weldment fittings and fork positioner supply fittings. 6 Install a cable tie to reduce hose movement. 4 6 FP1784.eps
9 Installation Kit (100K FSV Masts) 1 Install bracket using capscrews and lockwashers. Tighten capscrews to 25 ft.-lbs. (35 Nm). 2 Install the No. 6 bulkhead fittings to the bracket. 3 Install valves (SSL label up), fittings and tubes to the sideshift cylinder ports. 4 Connect the hoses to the valve fittings and fork positioner supply fittings. 5 Connect the tubes to the bulkhead fittings and carriage hose terminal fittings. 6 Install the hoses, fittings and No. 6 tubes to bulkhead fittings. 7 Install the hoses, fittings and No. 8 tubes to the junction block. Install cable ties to hoses as needed. 2 1 SSL label up Connect inner hose to SSR port (see top of valve). FP1708.eps Back View
10 Parts List Installation Kit (3-Stage FFL FSV Masts through 7/31/05) 45 6 FP0793.eps REF QTY PART NO. DESCRIPTION Hose Installation Kit Hose Manifold Fitting, Lockwasher, M Capscrew, M8 x Adapter Fitting Included in Manifold Assembly
11 Parts List Installation Kit (3-Stage FFL FSV Masts after 8/1/05) FP0885.eps REF QTY PART NO. DESCRIPTION Hose Installation Kit Hose Tube Weldment Reducer Fitting,
12 Parts List Installation Kit (Quad Mast) FP0926.eps REF QTY PART NO. DESCRIPTION Hose Installation Kit Tube Weldment Fitting, Hose 12
13 Parts List Installation Kit (2-Stage FFL FV Masts) 6 47 FP0235.eps REF QTY PART NO. DESCRIPTION Hose Installation Kit Tube Weldment Fork Positioner Fitting, Tube Weldment Sideshift Capscrew, M8 x Hose Hose Lockwasher, M8 13
14 Parts List Installation Kit (BFD45U, FSV Masts with A450 Piping) FP2205.eps REF QTY PART NO. DESCRIPTION Hose Installation Kit Fitting, Hose Hose Hose Hose Cable Tie Fitting, Fitting,
15 Parts List Installation Kit (BFD45U, FSV Masts with A450 Piping) FP2204.eps REF QTY PART NO. DESCRIPTION Hose Installation Kit Fitting, Hose Hose Hose Cable Tie Tube 15
16 Parts List Installation Kit (100K V Mast) 2 3 FP1559.eps REF QTY PART NO. DESCRIPTION Hose Installation Kit Tube Weldment Hose Hose Hose 16
17 Parts List Installation Kit (100K FSV Mast) 5 7 FP1785.eps REF QTY PART NO. DESCRIPTION Hose Installation Kit Nut, Tube Weldment Tube Weldment Reducer Fitting, Hose Hose Cable Tie 17
18 Parts List Installation Kit (100K FSV Mast) $ ) 5 *( FP1709.eps Back View ^ # & REF QTY PART NO. DESCRIPTION Hose Installation Kit Fitting, Fitting, Tube Fitting, Tube Fitting, Fitting, Tube Fitting, Bracket Tube Tube Fitting, Hose, 435 mm Hose, 505 mm Hose, 625 mm Hose, 515 mm Washer, M Capscrew, M10 x Hose, 453 mm Valve Cable Tie Cascade Corporation Part No R8
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