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 6080557-8V 6080565 Kits with Light Tower Voltage Part No. V 60760-8V 6080558 Kits with Light Bar Voltage Part No. V 6080890-8V 6080889 Light Tower (Optional) Sequence Controller Low Pressure Tank Line Kit Part No. 6080555 cascade corporation Cab Light Bar -Position Regulator Valve AC55.eps 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
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. 06.00 in. (5 mm) ID Tank Hose Part No. 75.5 in. ( mm) ID Tank Hose Part No. 066.50 in. (8 mm) ID Tank Hose Part No. 607507 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
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
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 60695 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
, 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 60580 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
Electronic Pressure Regulator Control & Indicator Kits With Light Tower! 9 * ) 5 & % # 8 ^ $ $ ^ fl 6 7 ( fi 0 % # Fuse Block @ AC6.eps Battery 6
Electronic Pressure Regulator Control & Indicator Kits With Light Tower REF QTY PART NO. DESCRIPTION REF QTY PART NO. DESCRIPTION 6080558 Pressure Regulator V 0 78798 Washer, M8 60760 Pressure Regulator -8V 606857 Seal Kit 79 Converter & Filter Kit 60090 Solenoid Coil V 8889 Relief Valve Assembly 0 Relief Cartridge 6075986 Sequence Controller 66 Seal Kit 60580 Plug 5 60699 Fuse, ATM type 7.5 Amp 605967 Solenoid Cable Harness 6 60089 Solenoid Cartridge 5 6077 Fitting, 8-8 608 Bulb-Red 6 605985 Solenoid Cable 600 Bulb-Amber 7 7 605968 Wire Harness 600 Bulb-Green 8 605986 Cab Light Bar 60998 Bulb-Clear 9 6057697 Conduit, 5 mm ID x 000 mm 8 60598 Light Tower with Cable 0 6089 Power Harness 9 60598 Cable 6069 Conduit, 9 mm x 75 mm 0 7680 Nut, M5 6076077 Push Button Switch 6057068 Bulb, Square D type DLBLJ 685899 Lockwasher, M 60007 Washer, M5 x 5 76850 Capscrew, M x 5 76878 Capscrew M5 x 5 5 7657 Nut, M 609665 Velcro 6 6865 Washer, M 5 6058 Capscrew, M5 x 5 7 6869 Lockwasher, M8 6 685866 Lockwasher, M5 8 76850 Capscrew, M8 x 65 7 606659 Voltage Converter, -8V V 9 767 Nut, M8 8 60695 Voltage Filter Includes items through. Includes items through 8. Includes items 7 & 8. Quantities as required. 7
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 y @ AC6.eps Battery 8
Electronic Pressure Regulator Control & Indicator Kits With Light Bar REF QTY PART NO. DESCRIPTION REF QTY PART NO. DESCRIPTION 6080890 Pressure Regulator V 5 60699 Fuse, ATM type 7.5 Amp 6080889 Pressure Regulator -8V 6 60089 Solenoid Cartridge 79 Converter & Filter Kit 608 Bulb-Red 8889 Relief Valve Assembly 600 Bulb-Amber 7 6075986 Sequence Controller 600 Bulb-Green 60580 Plug 60998 Bulb-Clear 605967 Solenoid Cable Harness 8 609665 Velcro 5 6077 Fitting, 8-8 9 608087 Light Bar Assembly 6 605985 Solenoid Cable 0 7669 Capscrew, M6 x 0 7 605968 Wire Harness 06 Lockwasher, M6 8 605986 Cab Light Bar 6076676 Aluminum Bar 9 6057697 Conduit, 5 mm ID x 000 mm 8 60587 Capscrew, M8 x 0 0 6089 Power Harness 8 6865 Nut, M8 6069 Conduit, 9 mm x 75 mm 5 60768 Red Lamp Assembly 6076077 Push Button Switch 6 798 Red Lens 685899 Lockwasher, M 7 607680 Amber Lamp Assembly 76850 Capscrew, M x 5 8 7950 Amber Lens 5 7657 Nut, M 9 607689 Green Lamp Assembly 6 6865 Washer, M 0 795 Green Lens 7 6869 Lockwasher, M8 607688 Clear Lamp Assembly 8 76850 Capscrew, M8 x 607790 Clear Lens 9 767 Nut, M8 60007 Washer, M5 0 78798 Washer, M8 6058 Capscrew, M5 x 5 606857 Seal Kit 5 685866 Lockwasher, M5 60090 Solenoid Coil V 6 7680 Nut, M5 0 Relief Cartridge 7 606659 Voltage Converter, -8V V 66 Seal Kit 8 60695 Voltage Filter Includes items through. Includes items through 8. Includes items 8 through Includes items 7 & 8. Quantities as required. 9
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
Electronic Pressure Regulator Control & Indicator Kits Without Light Tower/ Light Bar REF QTY PART NO. DESCRIPTION REF QTY PART NO. DESCRIPTION 6080557 Pressure Regulator V 8 76850 Capscrew, M8 x 65 6080565 Pressure Regulator -8V 9 767 Nut, M8 79 Converter & Filter Kit 0 78798 Washer, M8 8889 Relief Valve Assembly 606857 Seal Kit 6075986 Sequence Controller 60090 Solenoid Coil V 60580 Plug 0 Relief Cartridge 605967 Solenoid Cable Harness 66 Seal Kit 5 6077 Fitting, 8-8 5 60699 Fuse, ATM type 7.5 Amp 6 605985 Solenoid Cable 6 60089 Solenoid Cartridge 7 605968 Wire Harness 608 Bulb-Red 8 605986 Cab Light Bar 600 Bulb-Amber 7 9 6057697 Conduit, 5 mm ID x 000 mm 600 Bulb-Green 0 6089 Power Harness 60998 Bulb-Clear 6069 Conduit, 9 mm x 75 mm 8 609665 Velcro 6076077 Push Button Switch 9 60007 Washer, M5 685899 Lockwasher, M 0 6058 Capscrew, M5 x 5 76850 Capscrew, M x 5 685866 Lockwasher, M5 5 7657 Nut, M 7680 Nut, M5 6 6865 Washer, M 606659 Voltage Converter, -8V V 7 6869 Lockwasher, M8 60695 Voltage Filter Includes items through 8. Includes items through. Includes items &. Quantities as required.
Do you have questions you need answered right now? Call your nearest Cascade Service Department. Visit us online at www.cascorp.com AMERICAS Cascade Corporation Parts Sales 50 Sheridan Ave. Springfield, OH 5505 Tel: 888-CASCADE (7-) Fax: 888-9-0 Cascade Canada Inc. 5570 Timberlea Blvd. Mississauga, Ontario Canada LW-M6 Tel: 905-69-7777 Fax: 905-69-7785 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 7050 Vago di Lavagno (VR) Italy Tel: 9-05-8989 Fax: 9-05-898960 Cascade (Africa) Pty. Ltd. PO Box 65, Isando 600 60A 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, 66-0978 Tel: 8-6-60-977 Fax: 8-6-60-9777 Cascade Australia Pty. Ltd. 5 Ipswich Road Rocklea, QLD 07 Australia Tel: -800-7- Fax: +6 7 7-7 Cascade Korea B 9L Namdong Ind. Complex, 69-8 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: +6-9-7-96 Fax: +6-9-7-97 Cascade-Xiamen No. 668 Yangguang Rd. Xinyang Industrial Zone Haicang, Xiamen City Fujian Province P.R. China 606 Tel: 86-59-65-500 Fax: 86-59-65-57 Sunstream Industries Pte. Ltd. 8 Tuas South Street 5 Singapore 67796 Tel: +65-6795-7555 Fax: +65-686-68 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 007-007 Part No. 6080555