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: 1-800-7-33 Fax: 1-888-39-807 Call: 1-888-7-33 Fax: 1-888-39-034 Internet: www.cascorp.com Internet: www.cascorp.com Write: Cascade Corporation, PO Box 0187, Portland, OR 9794 Write: Cascade Corporation, 501 Sheridan Ave., Springfield, OH 45505
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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 6001137 which includes components for over-the-mast electrical supply from the power cable to the carriage cable connection. Refer to Installation Manual 8179. 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
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 600670 Power Bus Installation Instructions 6019876 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
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 4 3 6 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
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
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
Rotational Control Assembly (Single Drive) 9 & fl ^ 8 1 fi 0! # 6 @ 7 % $ ) # 3 4 5 @ ( * # AC005.eps 7
Rotational Control Assembly REF QTY 1V 4V 36V 48V 8705 8706 8707 8708 Rotational Control 1 1 6001647 6811810 6811810 6811810 Wire Harness DESCRIPTION 1 6806708 Fuse, 5 Amp, 1V, UL Classified 1 6806701 6806701 6806701 Fuse, Amp, 4 48V, UL Classified 1 19414 19414 19414 19414 Fuse, ATC-10 3 1 6003161 600316 6003163 6003164 Solenoid/Cable Assembly 4 1 6003169 6003170 6003171 600317 Solenoid/Cable Assembly 5 1 7888 7890 789 7894 Relay Enclosure Assembly Use with non UL Classified kits (older versions) Common Components REF QTY DESCRIPTION 6 1 6001035 Valve Assembly without Coils 7 4 607060 Capscrew, 5/16 NC x.00 GR8 8 1 00 Switch Mounting Plate 9 768784 Capscrew, M5 x 35 10 3 u Plate, Stop 11 3 u Block, Deceleration 1 3 60098 Shim,.030 in. 13 8 761170 Capscrew, M6 x 0 14 3 u Capscrew, M6 x 0 15 3 u Nut, M6 16 1 04 Switch/ Cable Assembly 17 1 56 Switch/ Cable Assembly 18 1 03 Power Cable 19 870 Extension Cable Assembly 0 600501 Cable Tie Anchor 1 7 600451 Cable Tie Anchor 9 600479 Cable Tie 3 1 6048 Switch Assembly 4 1 6001641 Shrink Tubing, 5 mm dia. 5 1 606934 Shrink Tubing, 75 mm dia. 6 1 01 Switch Mounting Bracket 7 600668 Capscrew, M8 x 0 8 1 0346 Washer 9 1 0633 Lockwasher 30 3 6047884 Casting, ERC Ramp 6014987 Adhesive Tape (not shown) 6009181 Thread Cutting Tap, M6 (not shown) 600918 Thread Cutting Tap. M8 (not shown) 6009185 Twist Drill, 5.3 mm (not shown) 6009186 Twist Drill, 7.3 mm (not shown) u For reference only. Reference: Retrofit Group 6009183 & 6813750, Common Components Group 6001010, 600101 & 6811471. 8
Rotational Control Assembly (Single Drive) fi 0! ( 8 * 1 fl @ # 3 % 4 6 $ 7 & ^ 5 % 9 ) % $ AC7.eps 9
Rotational Control Assembly (NOT UL CLASSIFIED) REF QTY NON UL NON UL NON UL NON UL NON UL 1V 1V 1V 4V 4V 600381 6004494 617385 606331 618497 Rotational Control 1 1 6001647 6001647 6001647 6811810 6811810 Wire Harness DESCRIPTION 1 6806708 6806708 6806708 6806708 6806708 Fuse, 5 Amp, 1V, UL Classified 1 6806701 6806701 Fuse, Amp, 4 48V, UL Classified 1 19414 19414 19414 19414 19414 Fuse, ATC-10 3 1 6003161 6003161 6003161 600316 600316 Solenoid/Cable Assembly 4 1 6003169 6003169 6003169 6003170 6003170 Solenoid/Cable Assembly 5 1 7888 7888 7888 7890 7890 Relay Enclosure Assembly 6 1 6001035 6001035 Valve Assembly without Coils 7 4 600668 600668 Capscrew, 5/16 NC x.00 GR8 8 1 01 6004413 01 01 01 Switch Mounting Plate 9 1 871 Extension Cable Assembly 10 1 609816 Power Supply Refer to Installation Instructions 8179 for parts. Use with non UL Classified kits (older versions) Common Components REF QTY DESCRIPTION 11 768784 Capscrew, M5 x 35 1 3 u Plate, Stop 13 3 u Block, Deceleration 14 3 60098 Shim,.030 in. 15 8 761170 Capscrew, M6 x 0 16 3 u Capscrew, M6 x 0 17 3 u Nut, M6 18 1 04 Switch/ Cable Assembly 19 1 56 Switch/ Cable Assembly 0 1 03 Power Cable 1 870 Extension Cable Assembly 600501 Cable Tie Anchor 3 7 600451 Cable Tie Anchor 4 9 600479 Cable Tie 5 1 6048 Switch Assembly 6 1 6001641 Shrink Tubing. 5 mm dia. 7 1 606934 Shrink Tubing, 75 mm dia. 8 1 00 Switch Mounting Bracket 9 600668 Capscrew, M8 x 0 30 1 0346 Washer 31 1 0633 Lockwasher 3 1 6047884 Casting, ERC Ramp Reference: Common Components Group 6001010, 600101, 6004493 & 6811471. 10
Rotational Control Assembly (0H-33H Single Drive) 6 9 7 0 8! 1 ) % 3 4 @ * ( 5 AC040.eps & ^ # $ % 11
Rotational Control Assembly (NOT UL CLASSIFIED) REF QTY NON UL NON UL NON UL NON UL 1V 4V 36V 48V 6810401 681040 6810403 6810404 Rotational Control 1 1 6001647 6811810 6811810 6811810 Wire Harness DESCRIPTION 1 6806708 Fuse, 5 Amp, 1V, UL Classified 1 6806701 6806701 6806701 Fuse, Amp, 4 48V, UL Classified 1 19414 19414 19414 19414 Fuse, ATC-10 3 1 6003161 600316 6003163 6003164 Solenoid/Cable Assembly 4 1 6003169 6003170 6003171 600317 Solenoid/Cable Assembly 5 1 7888 7890 789 7894 Relay Enclosure Assembly Use with non UL Classified kits (older versions) Common Components REF QTY DESCRIPTION 6 768784 Capscrew, M5 x 35 7 1 56 Switch/ Cable Assembly 8 1 04 Switch/ Cable Assembly 9 1 01 Switch Mounting Bracket 10 600668 Capscrew, M8 x 0 11 1 00 Switch Mounting Plate 1 600501 Cable Tie Anchor 13 7 600451 Cable Tie Anchor 14 9 600479 Cable Tie 15 8 761170 Capscrew, M6 x 0 16 1 03 Power Cable 17 870 Extension Cable Assembly 18 3 60098 Shim,.030 in. 19 1 6047884 Casting, ERC Ramp 0 1 0346 Washer 1 1 0633 Lockwasher 1 6048 Switch Assembly 3 1 6001641 Shrink Tubing. 5 mm dia. 4 1 606934 Shrink Tubing, 75 mm dia. Reference: Common Components Group 6001010, 600101 & 6811471. 1
Rotational Control Assembly 1 fl 9 & ^ fi 8 @ % $ 0! # [ 3 4 6 7 ) 5 # ( * # AC041.eps @ 13
Rotational Control Assembly (Dual Drive) REF QTY 1V 1V 4V 36V 48V 8711 606741 871 8713 8714 Rotational Control 1 1 6001647 6001647 6811810 6811810 6811810 Wire Harness DESCRIPTION 1 6806708 6806708 Fuse, 5 Amp, 1V, UL Classified 1 6806701 6806701 6806701 Fuse, Amp, 4 48V, UL Classified 1 19414 19414 19414 19414 19414 Fuse, ATC-10 3 1 6003161 6003161 600316 6003163 6003164 Solenoid/Cable Assembly 4 1 6003169 6003169 6003170 6003171 600317 Solenoid/Cable Assembly 5 1 7888 7888 7890 789 7894 Relay Enclosure Assembly 6 1 6000991 6000991 6000991 6000991 Valve Assembly 7 4 607065 607060 607060 607060 Capscrew Use with non UL Classified kits (older versions) Common Components REF QTY DESCRIPTION 8 1 00 Switch Mounting Plate 9 768784 Capscrew 10 3 u Plate, Stop 11 3 u Block, Deceleration 1 3 60098 Shim,.030 in. 13 8 761170 Capscrew 14 3 u Capscrew, M6 x 0 15 3 u Nut, M6 16 1 04 Switch/Cable Assembly 17 1 56 Switch/Cable Assembly 18 1 03 Power Cable 19 1 870 Extension Cable Assembly 0 600501 Cable Tie Anchor 1 7 600451 Cable Tie Anchor 9 600479 Cable Tie 3 1 6048 Switch Assembly 4 1 6001641 Shrink Tubing. 5 mm dia. 5 1 606934 Shrink Tubing, 75 mm dia. 6 1 01 Switch Mounting Bracket 7 600668 Flange Screw 8 4451 Tube 9 6 0346 Washer 30 6 0633 Lockwasher 31 3 6047884 Casting, ERC Ramp 6009181 Thread Cutting Tap, M6 (not shown) 600918 Thread Cutting Tap. M8 (not shown) 6009185 Twist Drill, 5.3 mm (not shown) 6009186 Twist Drill, 7.3 mm (not shown) u For reference only. Reference: Retrofit Group 601473 & 6813751, Common Components Group 6001010, 600101 & 6811471. 14
Solenoid Valve 0 4 5 7 @ 1 3 8 AC088.ai 6! 9 REF QTY DESCRIPTION 6001035 Valve Assembly without Coils 1 1 0565 Valve Body 4 0641 Orifice 3 1 067 Solenoid Valve 4 6003173 Valve 5 1 17 Solenoid Valve 6 663694 Fitting, 3 7 3 601377 Fitting, 8 8 3 604510 Fitting, 6 9 3 8698 Orifice 10 667516 Service Kit 11 1 1049 Service Kit 1 1 6031791 Service Kit 15 Cascade Corporation 01 08-01 Part Number 874-R5