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 6050780 (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. 6055410-R8 cascade corporation For Technical Support... To Order Parts... Call: 1-800-227-2233 Fax: 1-888-329-8207 Call: 1-888-227-2233 Fax: 1-888-329-0234 Internet: www.cascorp.com Internet: www.cascorp.com Write: Cascade Corporation, PO Box 20187, Portland, OR 97294 Write: Cascade Corporation, 2501 Sheridan Ave., Springfield, OH 45505 2
Installation Kit 6058003 (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
Installation Kit 6060375 (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
Installation Kit 6063496 (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 4 1 3 4 4
Installation Kit 6178235 (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. 3 6 8 7 3 FP2206.eps 5 1 2 4 5
Installation Kit 6178348 (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. 5 3 6 FP2203.eps 7 4 2 1 6
Installation Kit 6807872 (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 2 1 2 7
Installation Kit 6809076 (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 5 3 2 3 1 5 8
Installation Kit 6816816 (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 6 3 7 Connect inner hose to SSR port (see top of valve). FP1708.eps Back View 4 5 4 9
Parts List Installation Kit 6050780 (3-Stage FFL FSV Masts through 7/31/05) 45 6 FP0793.eps 1 2 3 1 REF QTY PART NO. DESCRIPTION 6050780 Hose Installation Kit 1 2 6055409 Hose 2 1 6050755 Manifold 3 2 617917 Fitting, 4 4 2 787389 Lockwasher, M8 5 2 768525 Capscrew, M8 x 40 6 2 6043723 Adapter Fitting Included in Manifold Assembly 6050778. 10
Parts List Installation Kit 6058003 (3-Stage FFL FSV Masts after 8/1/05) FP0885.eps 1 3 2 1 REF QTY PART NO. DESCRIPTION 6058003 Hose Installation Kit 1 2 6055409 Hose 2 1 6057818 Tube Weldment 3 2 6181119 Reducer Fitting, 6-4 11
Parts List Installation Kit 6060375 (Quad Mast) FP0926.eps 2 1 3 REF QTY PART NO. DESCRIPTION 6060375 Hose Installation Kit 1 1 6060365 Tube Weldment 2 2 2670 Fitting, 6-4 3 2 6055409 Hose 12
Parts List Installation Kit 6063496 (2-Stage FFL FV Masts) 6 47 FP0235.eps 5 3 2 1 5 REF QTY PART NO. DESCRIPTION 6063496 Hose Installation Kit 1 1 6063509 Tube Weldment Fork Positioner 2 2 2670 Fitting, 8-4 3 1 6063514 Tube Weldment Sideshift 4 4 787372 Capscrew, M8 x 20 5 2 6055409 Hose 6 2 6063564 Hose 7 4 787389 Lockwasher, M8 13
Parts List Installation Kit 6178235 (BFD45U, FSV Masts with A450 Piping) 8 36 2 8 FP2205.eps 5 1 7 1 4 REF QTY PART NO. DESCRIPTION 6178235 Hose Installation Kit 1 2 6181119 Fitting, 6-4 2 1 6178330 Hose 3 1 6178331 Hose 4 1 6178338 Hose 5 1 6178339 Hose 6 4 200343 Cable Tie 7 1 2680 Fitting, 6-6 8 2 601676 Fitting, 6-6 14
Parts List Installation Kit 6178348 (BFD45U, FSV Masts with A450 Piping) 2 5 4 FP2204.eps 3 6 1 REF QTY PART NO. DESCRIPTION 6178348 Hose Installation Kit 1 2 6181119 Fitting, 6-4 2 1 6178694 Hose 3 2 6178696 Hose 4 1 6178695 Hose 5 4 200343 Cable Tie 6 1 6808359 Tube 15
Parts List Installation Kit 6807872 (100K V Mast) 2 3 FP1559.eps 4 1 4 REF QTY PART NO. DESCRIPTION 6807872 Hose Installation Kit 1 1 6807862 Tube Weldment 2 1 6807878 Hose 3 1 6807882 Hose 4 2 6807885 Hose 16
Parts List Installation Kit 6809076 (100K FSV Mast) 5 7 FP1785.eps 6 143 4 5 6 REF QTY PART NO. DESCRIPTION 6809076 Hose Installation Kit 1 2 2617 Nut, 6 2 1 6809074 Tube Weldment 3 1 6809079 Tube Weldment 4 2 2669 Reducer Fitting, 6-4 5 2 6809090 Hose 6 2 6054406 Hose 7 2 200343 Cable Tie 17
Parts List Installation Kit 6816816 (100K FSV Mast) 7 0 8 9 $41 23 6 ) 5 *( FP1709.eps Back View %! @ ^ # & REF QTY PART NO. DESCRIPTION 6816816 Hose Installation Kit 1 2 201671 Fitting, 6-6 2 4 220569 Fitting, 4-6 3 2 6095232 Tube 4 4 604511 Fitting, 6-6 5 2 6816915 Tube 6 2 2348 Fitting, 8-8 7 2 2375 Fitting, 6-6 8 2 205824 Tube 9 2 2347 Fitting, 6-6 10 1 6816916 Bracket 11 1 6816952 Tube 12 1 6816954 Tube 13 2 617917 Fitting, 4-4 14 1 6816993 Hose, 435 mm 15 1 6816994 Hose, 505 mm 16 2 6054406 Hose, 625 mm 17 1 6817097 Hose, 515 mm 18 2 787383 Washer, M10 19 2 683820 Capscrew, M10 x 16 20 1 6817094 Hose, 453 mm 21 2 6820111 Valve 22 2 200343 Cable Tie Cascade Corporation 2015 5-2015 18 Part No. 6055410-R8