Cascade 55K User manual

Installation
Instructions
c
cascadeW
corporation
For Technical Support . . . To Order Parts . . .
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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
K-Series Fork Positioner
Solenoid Control Kits
This sheet provides installation instructions and replacement
parts list for Cascade Solenoid Control Kits. The kits provide
two function operation using a single function hydraulic supply
and solenoid actuation to select the sideshift or fork position
functions. A Cable Reel and internal hose reeving or 6-N-1
Cable-Hose Reel is required to supply hydraulics and electric
signal to the solenoid.
FP0955.eps
Sideshifter Fork Positioner
Solenoid
Valve
NOTE: Kits are UL Classified (File No. 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: To be UL Classified, these
kits must be used with a Cascade
UL Classified Power Supply.
Cascade Corp.
File No. AU3546

2
FP0783.eps
3Install the solenoid valve to the bracket. Tighten the
capscrews to a torque of 4 ft.-lbs. (5 Nm).
FP0958.eps
1
4
Component Installation
1Mount the guard to the sideshifter lower carriage bar.
Tighten the capscrews to a torque of 25 ft.-lbs. (35 Nm).
FP0959.eps
2Install the hoses to the valve fittings with the hose length
orientation shown. Tighten the hose ends with the natural
bend of the hoses upward. Install the diode to the solenoid
coil.
4Install the bracket to the guard. Tighten the capscrews to
a torque of 25 ft.-lbs. (35 Nm). 3
4

3
6Install the kit hoses. Route the hoses to prevent wear and
pinch points.
7Install supply hoses from the mast internal reeving fittings
to the sideshift cylinder supply fittings. Route the hoses to
prevent wear and pinch points.
FP0957.eps
FP0960.eps
5
6
7Mast reeving
fittings
FP0956.eps
5Remove any existing fittings from the sideshift cylinder
ports. Install the new supply manifold and fittings to the
sideshift cylinder ports. Do not remove the flow restrictor
washers from the cylinder ports.
Remove
existing
fittings

4
AC1212.eps
Control Handle Switch–
Use Control Knob Kit 6823292 (12V) OR 6823293 (24V-48V)
OR
Low Profile Switch Kit 6818564 (12V) OR 6818622 (24V-48V)
Fuse
Unswitched
Truck
Fuse Block
Truck
Battery
8 Connect wires from the control handle switch and solenoid
valve terminals to the truck electrical system. The fuse
must be connected to an unswitched positive terminal. The
solenoid must be able to energize with the truck key in the
off position.
Operation
• Sideshift left and right several times.
• Engage the fork position function by pressing the solenoid
button. Open and close the forks several times.
• Check for operation in accordance with ANSI standards
shown below.
• Check for leaks at the fittings, valve and cylinders.
FP0870.eps
GA0010.eps
Hoist Up
Hoist Down Tilt Forward
Tilt Back
A
A
A
B
B
B
SIDESHIFT and
SOLENOID ACTIVATED
FORK POSITIONING
ASideshift Left – Forks Out (press button)
BSideshift Right – Forks In (press button)
A
B
Solenoid
Valve
Diode
WARNING: To reduce risk of fire, replace only
with the same type and ratings of fuse. The
fused power cable is polarity sensitive. The
positive wire must be connected to a positive
power source.
NOTE: UL Classified Kits require installation by qualified
personnel only without major disturbance, cutting, splicing or
soldering of factory installed wiring.

5
FP0961.eps
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55K Solenoid Control Kit
REF QTY PART NO. DESCRIPTION REF QTY PART NO. DESCRIPTION
6064496 55K Solenoid Control Kit–12V 10 1 6050411 Manifold ●
6064505 55K Solenoid Control Kit–24V 11 2 6050405 Hose, 22.0 in. (560 mm)
6064506 55K Solenoid Control Kit–36V 12 1 6050725 Hose, 15.75 in. (400 mm)
6064507 55K Solenoid Control Kit–48V 13 1 6050052 Hose, 20.0 in. (510 mm)
1 1 6052246 Guard 14 5 617915 Fitting, 4-4 ● ■
2 1 767611 Capscrew, M10 x 40 15 1 617917 Fitting, 4-4 ●
3 4 787373 Capscrew, M8 x 25 16 1 6008166 Solenoid Cartridge ■
4 1 6054448 Mounting Bar
17
1 6860494 Solenoid Coil–12V ■
5
1 6064490 Solenoid Valve Assembly–12V 1 6860576 Solenoid Coil–24V ■
1 6064502 Solenoid Valve Assembly–24V 1 6859258 Solenoid Coil–36V ■
1 6064503 Solenoid Valve Assembly–36V 1 6860663 Solenoid Coil–48V ■
1 6064504 Solenoid Valve Assembly–48V 18 1 6126457 Service Kit
6 2 768785 Capscrew 19 1 6052237 Valve Body ■
7 1 768991 Roll Pin, 5 x 10 mm ■20 2 665595 Decal
8 1 201671 Fitting ●21 1 669432 Diode
9 1 6050638 Fitting
●Included in Manifold Assembly 6050615
■Included in Solenoid Valve Assembly, Item 5

6
REF QTY PART NO. DESCRIPTION REF QTY PART NO. DESCRIPTION
6068058 65K Solenoid Control Kit–12V 10 1 6050411 Manifold ●
6068209 65K Solenoid Control Kit–24V 11 2 6064656 Hose, 24.0 in. (610 mm)
6068210 65K Solenoid Control Kit–36V 12 1 6050052 Hose, 20.0 in. (510 mm)
6068211 65K Solenoid Control Kit–48V 13 1 6064643 Hose, 27.0 in. (685 mm)
1 1 6052246 Guard 14 5 617915 Fitting, 4-4 ● ■
2 1 767611 Capscrew, M10 x 40 15 1 617917 Fitting, 4-4 ●
3 4 787373 Capscrew, M8 x 25 16 1 6008166 Solenoid Cartridge ■
4 1 6054448 Mounting Bar
17
1 6860494 Solenoid Coil–12V ■
5
1 6064490 Solenoid Valve Assembly–12V 1 6860576 Solenoid Coil–24V ■
1 6064502 Solenoid Valve Assembly–24V 1 6859258 Solenoid Coil–36V ■
1 6064503 Solenoid Valve Assembly–36V 1 6860663 Solenoid Coil–48V ■
1 6064504 Solenoid Valve Assembly–48V 18 1 6126457 Service Kit
6 2 768785 Capscrew 19 1 6052237 Valve Body ■
7 1 768991 Roll Pin, 5 x 10 mm ■20 2 665595 Decal
8 1 201671 Fitting ●21 1 669432 Diode
9 1 6050638 Fitting
●Included in Manifold Assembly 6050615
■Included in Solenoid Valve Assembly, Item 5
FP1139.eps
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65K Solenoid Control Kit

7
FP1657.eps
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100K Solenoid Control Kit
REF QTY PART NO. DESCRIPTION REF QTY PART NO. DESCRIPTION
6074873 100K Solenoid Control Kit–12V 10 1 6050411 Manifold ●
6074945 100K Solenoid Control Kit–24V 11 1 6064643 Hose, 27.0 in. (686 mm)
6074947 100K Solenoid Control Kit–36V 12 1 6050052 Hose, 20.0 in. (510 mm)
6074948 100K Solenoid Control Kit–48V 13 2 6064656 Hose, 24.0 in. (610 mm)
1 1 6076117 Guard 14 5 617915 Fitting, 4-4 ● ■
2 1 768814 Capscrew, M10 x 60 15 1 617917 Fitting, 4-4 ●
3 4 787373 Capscrew, M8 x 25 16 1 6008166 Solenoid Cartridge ■
4 1 6076112 Mounting Bar
17
1 6860494 Solenoid Coil–12V ■
5
1 6064490 Solenoid Valve Assembly–12V 1 6860576 Solenoid Coil–24V ■
1 6064502 Solenoid Valve Assembly–24V 1 6859258 Solenoid Coil–36V ■
1 6064503 Solenoid Valve Assembly–36V 1 6860663 Solenoid Coil–48V ■
1 6064504 Solenoid Valve Assembly–48V 18 1 6126457 Service Kit
6 2 768785 Capscrew 19 1 6052237 Valve Body ■
7 1 768991 Roll Pin, 5 x 10 mm ■20 2 665595 Decal
8 1 201671 Fitting, 6-6 ●21 1 669432 Diode
9 1 6050638 Fitting, 6-4 22 1 787383 Washer, M10
●Included in Manifold Assembly 6050615
■Included in Solenoid Valve Assembly, Item 5

8
FP1718.eps
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120K, 150K & 165K Solenoid Control Kit
REF QTY PART NO. DESCRIPTION REF QTY PART NO. DESCRIPTION
6805088 Solenoid Control Kit–12V 9 1 6050638 Fitting ● ■
6805091 Solenoid Control Kit–24V 10 1 617917 Fitting, 4-4 ●
6805092 Solenoid Control Kit–36V 11 1 6805079 Hose, 34.0 in. (870 mm)
6805093 Solenoid Control Kit–48V 12 1 6050052 Hose, 20.0 in. (510 mm)
1 1 6090116 Guard 13 2 6805080 Hose, 31.0 in. (795 mm)
2 1 6054448 Mounting Bar 14 1 669432 Diode
3 6 787372 Capscrew, M8 x 25 15 1 6008166 Solenoid Cartridge ■
4
1 6064490 Solenoid Valve Assembly–12V
16
1 6860494 Solenoid Coil–12V ■
1 6064502 Solenoid Valve Assembly–24V 1 6860576 Solenoid Coil–24V ■
1 6064503 Solenoid Valve Assembly–36V 1 6859258 Solenoid Coil–36V ■
1 6064504 Solenoid Valve Assembly–48V 1 6860663 Solenoid Coil–48V ■
5 1 768991 Roll Pin, 5 x 10 mm ■17 1 6126457 Service Kit
6 2 768785 Capscrew 18 1 6052237 Valve Body ■
7 1 6050411 Manifold ●19 2 665595 Decal
8 1 201671 Fitting ●
●Included in Manifold Assembly 6050615
■Included in Solenoid Valve Assembly, Item 4

9
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© Cascade Corporation 2014 11-2014 Part Number 6064509-R3
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answered right now? Call your nearest Cascade Service Department.
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AMERICAS
Cascade Corporation
U.S. Headquarters
2201 NE 201st
Fairview, OR 97024-9718
Tel: 800-CASCADE (227-2233)
Fax: [phone]
Cascade Canada Inc.
5570 Timberlea Blvd.
Mississauga, Ontario
Canada L4W-4M6
Tel: [phone]
Fax: [phone]
Cascade do Brasil
Praça Salvador Rosa,
131/141-Jordanópolis,
São Bernardo do Campo - SP
CEP 09891-430
Tel: [phone]
Fax: [phone]
EUROPE-AFRICA
Cascade Italia S.R.L.
European Headquarters
Via Dell’Artigianato 1
37030 Vago di Lavagno (VR)
Italy
Tel: [phone]
Fax: [phone]
Cascade (Africa) Pty. Ltd.
PO Box 625, Isando 1600
60A Steel Road
Sparton, Kempton Park
South Africa
Tel: [phone]
Fax: [phone]
ASIA-PACIFIC
Cascade Japan Ltd.
2-23, 2-Chome,
Kukuchi Nishimachi
Amagasaki, Hyogo
Japan, 661-0978
Tel: [phone]
Fax: [phone]
Cascade Korea
121B 9L Namdong Ind.
Complex, 691-8 Gojan-Dong
Namdong-Ku
Inchon, Korea
Tel: [phone]
Fax: [phone]
Cascade-Xiamen
No. 668 Yangguang Rd.
Xinyang Industrial Zone
Haicang, Xiamen City
Fujian Province
P.R. China 361026
Tel: [phone]
Fax: [phone]
Cascade India Material
Handling Private Limited
No 34, Global Trade Centre
1/1 Rambaugh Colony
Lal Bahadur Shastri Road,
Navi Peth, Pune 411 030
(Maharashtra) India
Phone: [phone]
Fax: [phone]
Cascade Australia Pty. Ltd.
1445 Ipswich Road
Rocklea, QLD 4107
Australia
Tel: [phone]
Fax: [phone]
Cascade New Zealand
15 Ra Ora Drive
East Tamaki, Auckland
New Zealand
Tel: [phone]
Fax: [phone]
Sunstream Industries
Pte. Ltd.
18 Tuas South Street 5
Singapore 637796
Tel: [phone]
Fax: [phone]