c Installation Instructions Light Kits for Three-Position Pressure Relief Valve 0 This manual provides installation instructions for, or Kits used with -Position Pressure Relief Valve 0. The switch box installation allows for relief selections. The light assemblies use V bulbs. A voltage converter and filter are used for -8V applications. AC97.eps The switch box contains a cam that activates the microswitch based on lever position. When a microswitch is switched ON, a colored light illuminates to show which relief cartridge is selected. Voltage Kit Kit Kit V 05 7 805-8V 05 79 805 Light Tower 5 Cover Includes Voltage Converter & Filter Kit 79 Remove the original stops on the valve and discard. The switch box may be installed in either 80 position as required for clearance or cable routing, as shown below. The switch box mounting holes must line up with the two tapped holes near marks and. Install the kit stops and capscrews to securely fasten the switch box to the valve. Drive the cam onto the shaft with a rubber mallet. The cam may be installed in either 80 position depending on switch box mounting and valve mounting positions. NOTE: Cam slots and microswitch arms face each other when activated. The cam can be pryed off and rotated 80, if needed. 5 Install the cover by sliding on and tapping into place. Box Mounting Positions Capscrews Original Stops, Capscrews (Discard) (Relief selections stamped on Valve) X Cam Box Microswitches Kit Stops Three-Position Pressure Relief Valve AC00.eps AC007.eps AC005.eps cascade corporation Part No. 79-R For Technical Support... To Order Parts... Call: -800-7- Fax: -888-9-807 Call: -888-7- Fax: -888-9-0 Internet: www.cascorp.com Internet: www.cascorp.com Write: Cascade Corporation, PO Box 087, Portland, OR 979 Write: Cascade Corporation, 50 Sheridan Ave., Springfield, OH 5505
Locate and mount the 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. Locate and mount the light bar on the back of the overhead guard. Connect the cable extension and route the cable from the light bar to join the switch box cable. Cable routed out bottom or side of stand. Grommet supplied for side exit. 5 Locate and mount the cab light. Position for best peripheral viewing. Connect the cable extension and route the cable from the cab light to join the switch box cable. C White Wire Terminal Red Wire Terminal Black Wire Terminal Green/Yellow (Ground) Terminal C Connection Diagram Truck Fuse Block Rotary Box Fuse-A (V Applications, User supplied) Box Cable Voltage Filter (-8V Applications) Fuse-A Voltage Converter -Position Pressure Relief Valve 7 AC9.eps 8 Voltage Converter (-8V Applications) Power Supply Wiring
CAUTION: Consult the Lift Truck OEM for proper + power source connection. 7 Connect the cables together using the diagrams and schematics, shown below. The green wires are connected to the power supply wiring. 8 Connect the power supply wiring (user supplied) to the truck fuse block. Eighteen gauge (8 AWG) power supply wiring is recommended. V Trucks Install a Amp inline fuse in the + power supply wire. Connect the fused positive wire to a switched power terminal on the truck fuse block. NOTE: When installing on electric trucks with regenerative breaking, voltage filter 095 must be installed. Failure to install the voltage filter can cause damage to electrical components. V-8V Trucks Connect the voltage filter to the voltage converter. Connect the positive wire to a switched power terminal on the truck fuse block. Important: For -8V application, Voltage Converter 059 must be wired into the circuit. The voltage converter has its own Amp input fuse. Check the cable routing for pinch points and clearance. Use wire ties as needed. Electrical Schematic V User Supplied To Truck Fuse Block (ed Circuit) Amp Fuse Green Red Box White Black AC9.eps Electrical Schematic V-8V To Truck Fuse Block (ed Circuit) Voltage Filter Amp Fuse Orange Red Voltage Converter Green Red Box White Black AC9.eps Black
Relief Adjustment To set the valve relief cartridges, install a 5000 psi (5 bar) pressure gauge (Cascade Part No. 58) and fitting to the valve G port. A clamp force indicator can also be used to adjust the relief cartridge settings. Refer to Clamp Force Indicator Operator Guide 0580 for Carton Clamps or 750 for Paper Roll Clamps. -Position Sample Settings Position X - Not Available Position - 00 psi Position - 00 psi Position - 800 psi IMPORTANT: Cartridges are preset to 000 psi. Relief pressure for each cartridge must be adjusted for your application. Four stop positions are not available when a switch box is mounted on the valve. Shift the valve lever index pointer to position stamped on the valve body. See the light display chart below. Red Green Amber T Adjust Relief, Cartridges P G AC95.eps 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 No. relief position. 5 Shift the selector switch to position. Repeat steps and for the No. relief position. Relief Light Position Cartridge Color Green Amber Red Position Position Position CAUTION: Do not remove the rotating spool from the valve body. Permanent damage will occur due to the spring loaded detents and will void the warranty. Replace valve as a complete assembly.
-Position Light Kits Parts List! # 5 9 8 0 @ 7 $ % AC5.eps Fuse, Amp REF QTY Volt -8 Volt DESCRIPTION 05 05 -Position Light Kit - 795 795 Assembly 05 05 Assembly 79 Voltage Converter & Filter Kit 795 795 Cover 7955 7955 Cam 795 795 Box 7957 7957 Stop 5 87 87 Capscrew.5 x.00 in. 08 08 Capscrew, No.-0 x.5 in. 7 070 070 8 80 80 Nut, No.-0 9 07 07 Grommet 0 0 0 Cable Assembly 07 07 0 0 Cable 05708 0708 Bulb, Square D type DLBLJ 095 Voltage Filter 5 059 Voltage Converter, -8V V Includes items through 0. Includes items through. Includes items and5. 5
-Position Light Kits 5 fl 9 8 # & @ $% ) ^ Bulbs (GE 9)! fi *( 0 7 Fuse, Amp AC09.eps
-Position Light Kits Parts List REF QTY Volt -8 Volt DESCRIPTION 7 79 -Position Light Kit - 795 795 Assembly 79 79 Assembly 79 Voltage Converter & Filter Kit 795 795 Cover 7955 7955 Cam 795 795 Box 7957 7957 Stop 5 87 87 Capscrew,.5 x.00 in. 08 08 Capscrew, No.-0 x.5 in. 7 070 070 8 80 80 Nut, No.-0 9 07 07 Grommet 0 0 0 Cable Assembly 79 79 Aluminum Bar 0995 0995 Cable Assembly 0995 0995 Cable Assembly 078 078 Red Lamp Assembly 5 798 798 Red Lens 0780 0780 Amber Lamp Assembly 7 7950 7950 Amber Lens 8 0789 0789 Green Lamp Assembly 9 795 795 Green Lens 0 05 05 Rubber Spacer 0587 0587 Capscrew, M x 0 mm 85 85 Nut, M 0 0 O-Ring 0 0 Lockwasher, M 5 79 79 Capscrew, M x 0 mm 5 0597 0597 Connector, Female 7 5 059 059 Connector, Male 8 095 Voltage Filter 9 059 Voltage Filter, 5-8V V Includes items through 0. Includes items through 7. Includes items 8 and 9. 7
5 -Position Light Kits Parts List! 9 8 % @ 7 0 ^ $ & # AC9.eps Fuse, Amp REF QTY Volt -8 Volt DESCRIPTION 805 805 -Position Light Kit - 795 795 Assembly 79 Voltage Converter & Filter Kit 795 795 Cover 7955 7955 Cam 795 795 Box 7957 7957 Stop 5 87 87 Capscrew.5 x.00 in. 08 08 Capscrew, #-0 x.5 in. 7 070 070 8 80 80 Nut, #-0 9 07 07 Grommet 0 0 0 Cable Assembly 8055 8055 08 08 Bulb, Red 00 00 Bulb, Amber 00 00 Bulb, Green 0995 0995 Cable 5 0597 0597 Connector, Female 5 5 059 059 Connector, Male 095 Voltage Filter 7 059 Voltage Converter, -8V V Includes items through 0. Includes items and7. 8
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Do you have questions you need answered right now? Call your nearest Cascade Parts Department. Visit us online at www.cascorp.com AMERICAS Cascade Corporation U.S. Headquarters 0 NE 0st Fairview, OR 970-978 Tel: 800-CASCADE (7-) Fax: 888-9-807 Cascade Canada Inc. 5570 Timberlea Blvd. Mississauga, Ontario Canada LW-M Tel: 905-9-7777 Fax: 905-9-7785 Cascade do Brasil Rua João Guerra, Macuco, Santos - SP Brasil 05-0 Tel: 55--05-8800 Fax: 55--05-8899 EUROPE-AFRICA Cascade Italia S.R.L. European Headquarters Via Dell Artigianato 700 Vago di Lavagno (VR) Italy Tel: 9-05-8989 Fax: 9-05-89890 Cascade (Africa) Pty. Ltd. PO Box 5, Isando 00 0A Steel Road Sparton, Kempton Park South Africa Tel: 7--975-90 Fax: 7--9-7 ASIA-PACIFIC Cascade Japan Ltd. -, -Chome, Kukuchi Nishimachi Amagasaki, Hyogo Japan, -0978 Tel: 8--0-977 Fax: 8--0-9777 Cascade Australia Pty. Ltd. 5 Ipswich Road Rocklea, QLD 07 Australia Tel: -800-7- Fax: + 7 7-7 Cascade Korea B 9L Namdong Ind. Complex, 9-8 Gojan-Dong Namdong-Ku Inchon, Korea Tel: +8--8-05 Fax: +8--8-055 Cascade New Zealand 5 Ra Ora Drive East Tamaki, Auckland New Zealand Tel: +-9-7-9 Fax: +-9-7-97 Cascade-Xiamen No. 8 Yangguang Rd. Xinyang Industrial Zone Haicang, Xiamen City Fujian Province P.R. China 0 Tel: 8-59-5-500 Fax: 8-59-5-57 Sunstream Industries Pte. Ltd. 8 Tuas South Street 5 Singapore 779 Tel: +5-795-7555 Fax: +5-8-8 Cascade India Material Handling Private Limited No, Global Trade Centre / Rambaugh Colony Lal Bahadur Shastri Road, Navi Peth, Pune 00 (Maharashtra) India Phone: +9 00 590 Fax: +9 00 088 c Cascade Corporation 00 0-00 Part Number 79-R5