Installation Instructions

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1 c Installation Instructions Electronic Rotational Control Group This manual provides installation instructions for Cascade Electronic Rotational Control (ERC) Kits. Rotational Control provides accurate stops during rotation to position the attachment arms at true vertical or bilge position to reduce product damage of misclamped loads. An electrical supply circuit using a cable reel (Cascade Power Supply recommended) is required to provide an electrical connection between the Electrical Rotational Control on the attachment and the truck electrical system. A normally closed pushbutton switch mounted on the truck ROTATE control lever is pressed to override the stop positions for continuous rotation. Major components are shown. NOTE: Kits are UL Classified (File # AU3546) for safety in Electric Battery (UL 583) and IC Engine (UL 558) Indust. Truck type E, ES, G, GS,G/LP/ GS/LPS, LP, LPS, D and DS. NOTE: UL Classified Kits require installation by qualified personnel only without major disturbance, cutting, splicing or soldering of factory installed wiring. NOTE: Some kits described in this document are not UL Classified. Power Supply Group Solenoid Valves Deceleration and Stop Limit Switches (NO) Cable Junction Box Override Switch (NC) Stops Rotation stops at both vertical positions and at the bilge position. Pressing the override switch allows continuous rotation. Carriage Cable Junction Power Cable AC031.eps RC0718.eps cascadew corporation For Technical Support... To Order Parts... Cascade Corp. File No. AU3546 Call: Fax: Call: Fax: Internet: Internet: Write: Cascade Corporation, PO Box 0187, Portland, OR 9794 Write: Cascade Corporation, 501 Sheridan Ave., Springfield, OH 45505

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3 Cable, Switch Installation 1 Connect the power cable from the electronic rotational control (ERC) enclosure on the back of the attachment to the power supply cable end at the truck carriage. Install pushbutton switch on ROTATE control lever. NOTE: The installation shows connection to Cascade Power Supply/Communication Kit 8719 or which includes components for over-the-mast electrical supply from the power cable to the carriage cable connection. Refer to Installation Manual Tilt Control Knob Switch Mounted on Knob Face Flatten Surface Forward Heat Shrink Tubing Remove tubing around button 1Carriage Power Cable Terminal Connector Paper Roll Clamp Cable Reel Power Supply Override Pushbutton Switch, if equipped (Normally Closed) ROTATE Control Knob + Truck Power Switch Mounted on Knob Bracket Bracket Heat Shrink Tubing Power Cable Carriage AC017.eps AC0181.eps Operation and Adjustment 1 Test the installation before putting the truck in service. When rotating, attachment travel should stop at the vertical and bilge handling positions. Wait 3 seconds to rotate after stopping OR press the rotate override button to continue rotating. If rotation stops at the vertical or bilge position, continue with step. If rotation stops momentarily and then continues at the vertical or bilge positions: A Reduce the hydraulic input pressure for the rotate function. OR B Adjust bother counterbalance cartridges CCW in 1/ turn increments until rotation stop at the vertical and bilge position. If rotation does not stop at the vertical or bilge positions: A Inspection the wiring installation. Look for loose connection or pinches cables. B The limit switch end rollers are not fully engaging the deceleration ramp and stop capscrew (if equipped) at the vertical or bilge position. Adjust the limit switch actuators to engage the ramp and stop capscrew (if equipped). The ramp and stop (if equipped) can also be adjusted for precision of the stop position. The stop capscrew height is also adjustable (if equipped). To continue rotation, wait 3 seconds after stopping or the rotate override button must be pressed to continue rotation. To rotate without stopping, press the override button. Stop Capscrew (if equipped) AC031.eps Rotation stops at both vertical position and at the bilge position. Pressing the override switch allows continuous rotation. Wait 3 seconds or press override button to continue rotating. Deceleration Ramp Limit Switches (Normally Open) AC1800.eps

4 Rotational Control Electrical Hookup STOP Limit Switch (Normally Open) DECEL Limit Switch (Normally-Open) DECEL Solenoid Rotator Drive Valve Block STOP Solenoid NOTE: UL Classified Kits require installation by qualified personnel only without major disturbance, cutting, splicing for soldering of factory installed wiring. NOTES: 1 All cables -conductor with Deutsch-type connectors. Recommendations: Electrical Power Relay preferred as a minimum for rotational control Power Bus/Relay preferred for multiple accessories 3 For relay or power bus installation, refer to the following: Relay Installation Instructions Power Bus Installation Instructions Cable Junction Box NOTE: Factory-adjusted time delay relay inside. If necessary, see service manual to change setting. Mast WARNING: For UL Classified kits, to reduce the risk of fire, replace only with same type and rating of fuse. STOP Sol STOP Sw DECEL Sol DECEL Sw Power Coil Cord Power Supply/ Communications Groups ROTATE Control Knob Override Pushbutton, if equipped. (Normally Closed) Carriage Fuse + + Power Bus/Relay (1V output only) + OR Unswitched Switched Switched Truck Fuse Block Key Truck Fuse Block Key Truck Battery 1V Truck Battery AC018.eps IC Trucks Use chassis ground. Electric Trucks Use battery ground. 3

5 Retrofit Installation Rotational control is also available as a field installation kit for attachment that have predrilled faceplates and baseplate. 1 Locate the eight holes that need to be tapped with the 6 mm tap provided. Six holes are location in the faceplate and two hole are located in the baseplate. Drill out the holes using the 5.3 mm drill bit provided. Tap the holes using the 6 mm tap. Locate the two holes in the baseplate that need to be tapped with the 8 mm tap provided. Drill out the hole using the 7.3 mm drill bit provided. Tap the holes using the 8 mm tap. 8 mm tap in places mm tap in 8 places 1 AC063.eps O-Rings 3 Disconnect hydraulic hoses to the drive group. Tag the hoses for reassembly. 4 Remove the four capscrews fastening the check valve to the drive group. Keep track of the two O-rings between the check valve and drive motor. AC064.eps 4

6 5 Install the new solenoid valve to the drive group. Place the two O-rings between the solenoid valve and drive motor. Install the four capscrews and tighten to 0 ft.-lbs. 5Install solenoid valve O-rings 6 Install the limit switches and brackets to the baseplate. Tighten the baseplate bracket capscrews to 14 ft.-lbs. 7 Install the stop ramps to the faceplate. Tighten the stop capscrews to 3 ft.-bs. Shim as required. AC065.eps Shim 7Stop Ramp 6Install limit switches and brackets Limit Switch Shim 7Stop Ramps Previous design, for reference only AC1791.eps 5

7 8 Install the cable junction box to baseplate. Tighten the capscrews to 14 ft.-lbs. 8 Install junction box on a 45F in the location 8 Install junction box on a 60F through 150F in the location AC179.eps 9 Install the cables. Use the adhesive blocks and wire ties to secure the wiring. 10 Adjust the limit switch engagement with the stops as described in Operation and Adjustment on page. 9 Install cables 10 Adjust stops AC1793.eps 6

8 Rotational Control Assembly (Single Drive) 9 & fl ^ 8 1 fi 0! # 7 % $ ) # 3 4 ( * # AC005.eps 7

9 Rotational Control Assembly REF QTY 1V 4V 36V 48V Rotational Control Wire Harness DESCRIPTION Fuse, 5 Amp, 1V, UL Classified Fuse, Amp, 4 48V, UL Classified Fuse, ATC Solenoid/Cable Assembly Solenoid/Cable Assembly Relay Enclosure Assembly Use with non UL Classified kits (older versions) Common Components REF QTY DESCRIPTION Valve Assembly without Coils Capscrew, 5/16 NC x.00 GR Switch Mounting Plate Capscrew, M5 x u Plate, Stop 11 3 u Block, Deceleration Shim,.030 in Capscrew, M6 x u Capscrew, M6 x u Nut, M Switch/ Cable Assembly Switch/ Cable Assembly Power Cable Extension Cable Assembly Cable Tie Anchor Cable Tie Anchor Cable Tie Switch Assembly Shrink Tubing, 5 mm dia Shrink Tubing, 75 mm dia Switch Mounting Bracket Capscrew, M8 x Washer Lockwasher Casting, ERC Ramp Adhesive Tape (not shown) Thread Cutting Tap, M6 (not shown) Thread Cutting Tap. M8 (not shown) Twist Drill, 5.3 mm (not shown) Twist Drill, 7.3 mm (not shown) u For reference only. Reference: Retrofit Group & , Common Components Group , &

10 Rotational Control Assembly (Single Drive) fi 0! ( 8 * 1 # 3 % 4 6 $ 7 & ^ 5 % 9 ) % $ AC7.eps 9

11 Rotational Control Assembly (NOT UL CLASSIFIED) REF QTY NON UL NON UL NON UL NON UL NON UL 1V 1V 1V 4V 4V Rotational Control Wire Harness DESCRIPTION Fuse, 5 Amp, 1V, UL Classified Fuse, Amp, 4 48V, UL Classified Fuse, ATC Solenoid/Cable Assembly Solenoid/Cable Assembly Relay Enclosure Assembly Valve Assembly without Coils Capscrew, 5/16 NC x.00 GR Switch Mounting Plate Extension Cable Assembly Power Supply Refer to Installation Instructions 8179 for parts. Use with non UL Classified kits (older versions) Common Components REF QTY DESCRIPTION Capscrew, M5 x u Plate, Stop 13 3 u Block, Deceleration Shim,.030 in Capscrew, M6 x u Capscrew, M6 x u Nut, M Switch/ Cable Assembly Switch/ Cable Assembly Power Cable Extension Cable Assembly Cable Tie Anchor Cable Tie Anchor Cable Tie Switch Assembly Shrink Tubing. 5 mm dia Shrink Tubing, 75 mm dia Switch Mounting Bracket Capscrew, M8 x Washer Lockwasher Casting, ERC Ramp Reference: Common Components Group , , &

12 Rotational Control Assembly (0H-33H Single Drive) ! 1 ) % 3 * ( 5 AC040.eps & ^ # $ % 11

13 Rotational Control Assembly (NOT UL CLASSIFIED) REF QTY NON UL NON UL NON UL NON UL 1V 4V 36V 48V Rotational Control Wire Harness DESCRIPTION Fuse, 5 Amp, 1V, UL Classified Fuse, Amp, 4 48V, UL Classified Fuse, ATC Solenoid/Cable Assembly Solenoid/Cable Assembly Relay Enclosure Assembly Use with non UL Classified kits (older versions) Common Components REF QTY DESCRIPTION Capscrew, M5 x Switch/ Cable Assembly Switch/ Cable Assembly Switch Mounting Bracket Capscrew, M8 x Switch Mounting Plate Cable Tie Anchor Cable Tie Anchor Cable Tie Capscrew, M6 x Power Cable Extension Cable Assembly Shim,.030 in Casting, ERC Ramp Washer Lockwasher Switch Assembly Shrink Tubing. 5 mm dia Shrink Tubing, 75 mm dia. Reference: Common Components Group , &

14 Rotational Control Assembly 1 fl 9 & ^ fi % $ 0! # [ ) 5 # ( * # 13

15 Rotational Control Assembly (Dual Drive) REF QTY 1V 1V 4V 36V 48V Rotational Control Wire Harness DESCRIPTION Fuse, 5 Amp, 1V, UL Classified Fuse, Amp, 4 48V, UL Classified Fuse, ATC Solenoid/Cable Assembly Solenoid/Cable Assembly Relay Enclosure Assembly Valve Assembly Capscrew Use with non UL Classified kits (older versions) Common Components REF QTY DESCRIPTION Switch Mounting Plate Capscrew 10 3 u Plate, Stop 11 3 u Block, Deceleration Shim,.030 in Capscrew 14 3 u Capscrew, M6 x u Nut, M Switch/Cable Assembly Switch/Cable Assembly Power Cable Extension Cable Assembly Cable Tie Anchor Cable Tie Anchor Cable Tie Switch Assembly Shrink Tubing. 5 mm dia Shrink Tubing, 75 mm dia Switch Mounting Bracket Flange Screw Tube Washer Lockwasher Casting, ERC Ramp Thread Cutting Tap, M6 (not shown) Thread Cutting Tap. M8 (not shown) Twist Drill, 5.3 mm (not shown) Twist Drill, 7.3 mm (not shown) u For reference only. Reference: Retrofit Group & , Common Components Group , &

16 Solenoid Valve AC088.ai 6! 9 REF QTY DESCRIPTION Valve Assembly without Coils Valve Body Orifice Solenoid Valve Valve Solenoid Valve Fitting, Fitting, Fitting, Orifice Service Kit Service Kit Service Kit 15 Cascade Corporation Part Number 874-R5

Installation Instructions

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