6802876R1 HFC User Manual
Contents
1. 6 6088041 6088041 HFCVave _______________ O 8 1 6061953 Voltage Converter 24 48V gt 12V___ 9 1 1 6034612 6034612 Pressure TestKit M Includes items 7 4 8 Included in Switch Group 6097464 O Included in Switch Group 6097465 Truck Fuse Block 6802876 R1 ARTS P EQUALIZER amp INTENSIFY VALVES Non Solenoid Intensify Valve PART NO DESCRIPTION 6092596 Non Solenoid Intensify Valve 3 4 5 2 V Fitting 12 Fitting 8 S ri 2646 Fitting 8 Solenoid Equalizer Valve mer arv PARTNO DESCRIPTION z 6097081 Equalizer Vave LNV 3 1 611293 Fitting 12 12 6056977 Solenoid Valve AC1779 eps 6014287 Coil 12V 6 1 6093794 Fitting 12 12 6092647 Relief Valve Cartridge 6802876 R1 15 _ p Ants SENSOR SWITCH i L L AC1724 eps REF QTY PARTNO DESCRIPTION 6095969 Switch Assembly i 6802876 R1 _ p Ants HFC VALVE O Directional Valve Cartridge Relief Valve Cartridge us nel a ce a A a 1 6054498 Orifice 020 663694 Fitting 3 M Refer to Glossary for flow requirements 6802876 R1 17 _G Lossary 18 Clamp Pressure Pressure set to clamp a load Final Pressure V2 The final HFC adjusted clamp pressure applied when the load is hoisted Freelift2. Instructions 6097260 Equalizer Page 2 amp 3 6802876 R1 Intensify Valve Prior to Installation The system can be calibrated to balance the clamp force relationship of clamp capacity and truck size The truck HOIST pressure should be equal to or higher than clamp pressure to properly clamp paper Total load weight equals paper weight plus clamp weight Confirm that the truck size is compatible with the clamp capacity Available maximum hoist pressure with load weight combined maximum size load and weight of the clamp should be determined in freelift The hoist pressure determined needs to be within 10 of the clamping pressure required to clamp the heaviest load HFC Kit without switch Part No 6093682 HFC Kit with switch Part No 6097470 12 V 6097471 24V 48V NOTE Cascade recommends that component installation be done according to page number order Sensor Switch Page 6 os PA a IN ce sae l N Tea 3 i a 4 AC1896 eps 1 NSTALLATION EQUALIZER INTENSIFY VALVE AND HOSES WARNING Before removing hydraulic lines or components relieve pressure in the hydraulic system Turn truck off and open the truck auxiliary control valve s several times in both directions WARNING Follow all recommended safety practices including chaining the freelift mast to the mainlift crossmember when mast is raised 1 Insta
3. use the same process with HFC However it is recommended to use the techniques above for all loads unless absolutely necessary CAUTION Develop adequate clamp force to hold the load when feathering WARNING Truck control handle and attachment function activation shown here conforms to ASME ANSI B56 1 recommended practices Failure to follow these practices may lead to serious bodily injury or property damage End user dealer and OEMs should review any deviation from the practices for safe operation ROTATE Drivers view A Counterclockwise CCW B Clockwise CW SHORT ARM 45 degree position only C Open D Close 4 Operation for a split arm clamp with HFC is the same as a solid arm clamp except for the following e HFC should be used with the Cascade full arm travel split arm circuit Close the free arm fully when handling one roll with one split arm Full clamp force develops after free arm bottoms e When clamping a full height roll with both split arms operate the clamp as a solid arm clamp NOTE HFC allows lower clamp starting pressures so that light loads can be handled without damage along with heavier loads Slightly slower arm speed is normal If roll diameters vary widely with very low starting pressures the slower arm speed can be corrected with an optional arm overdrive system Consult Cascade 6802876 R1 E T ROUBLESHOOTING CAUTION Prior to troubleshooting verify that c
4. OP2 port of the HFC valve to the attachment revolving connection OPEN port supply circuit 7 Connect a No 6 minimum hose from the H port of the HFC valve to the HFC port of the equalizer valve 8 Inspect hoses for pinch points and secure as required Mast Cylinders Equalizer HFC Valve TRUCK al MAST Existing Lowering Control Valve Hoist Valve Hydraulic Pump 7 4 HFC Valve Q 5 qj 1 S de c KA l gt W AY 2 f y E Y a TE QA eg O Hoist Line Pressure Gauge Port A AC1768 eps Revolving 6 Connection a ATEN Zz Zz HFC Valve H OP1 CL1 T Clamp z Valve Truck Tank AC1747 eps 6802876 R1 Hoist Auxiliary NSTALLATION RETURN TO TANK amp OPTIONAL OVERDRIVE VALVE 1 Install a return to tank fitting in the tank line Lube hose ends and fitting for easy assembly For complete installation procedure refer to Installation Instructions 211744 Cascade Low Pressure Return Line Adapter Kits are as follows Single Line Dual Line Tank Hose ID Adapter Kit Adapter Kit 75 in 19 mm 214062 6049380 1 00 in 25 mm 211745 6049381 1 25 in 31 mm 214066 6049382 1 50 in 38 mm 6037507 6049383 NOTE For trucks with pressurized return to tank lines the hydraulic tank filler cap must be opened to relieve trapped pressure 2 N
5. R if needed ew f G Sensor Switch SS Fixed location SZ on mast additional bracket shown N No 8 AC1748 eps OR Moving Member bracket with spring not used 15 in ir Fixed Sensor Switch Member OR AC1749 eps Cylinder Solenoid LED 6802876 R1 E NSTALLATION DISABLING HFC SYSTEM To temporarily disable the HFC features perform the following steps 1 Turn V1 inward CW or until desired clamp pressure is reached The maximum pressure that the cartridge is capable of handling is 3000 psi 207 bar 2 Turn V4 all the way out CCW 3 OPTIONAL If the hoist capacity is affected by lifting a load turn V5 all the way out CCW 4 The truck attachment will now operate in the standard mode NOTE To enable HFC features refer to Prior To Operation section HFC VALVE AC1623 ai 6802876 R1 V5 N SOLENOID ENSIFY VALVE DS SOLENOID OPERATED EQUALIZER VALVE AC1899 eps ETUP CARTRIDGE ADJUSTMENT CARTRIDGE FUNCTION SUMMARY Starting Pressure V1 Sets starting pressure Final Pressure V2 Adjusts clamping pressure after hoisting Must be adjusted after all other cartridges are set Static Hoist Pressure V3 Closes connection from hoist line to clamp line Freelift Pressure V4 Limits maximum clamping pressure Must not be set lower than pressure needed to handle maximum roll Mainlift Pressure V5 Increases freelif
6. 7 U SER MANUAL Hydraulic Force Control No 6802876 R1 PL Cascade Cascade is a Registered Trademark of Cascade Corporation ONTENTS Page OVERVIEW 1 INSTALLATION 2 Solenoid Operated Equalizer Valve and Hoses 2 Non Solenoid Intensify Valve and Hoses 3 HFC Valve and Hoses 4 Return to Tank amp Optional Overdrive Valve 5 sensor Switch if equipped 6 Disabling HFC System 7 SETUP 8 OPERATION 10 TROUBLESHOOTING 11 PARTS 13 GLOSSARY 18 i 6802876 R1 E O VERVIEW HYDRAULIC FORCE CONTROL HFC This manual provides installation instructions prior to operation operation troubleshooting and parts for Cascade Hydraulic Force Control HFC systems If you need additional information or assistance contact Cascade Corporation Refer to the back cover What The System Does The HFC system enables Cascade Paper Roll Clamps to automatically apply clamp force proportional to weight of the load This system will reduce the chance of damage caused by excessive clamp force How The System Works An initial no slip starting pressure is applied to the load when it is first clamped As the load is lifted the HFC system increases clamp force and applies a consistent clamp force proportional to load weight The hoist system provides pressure to the HFC to increase clamp pressure as hoist pressure increases Return to Tank Page 5 HFC Valve Page 4 Optional Overdrive Valve Refer to Installation
7. Pressure V5 Pressure in the hoist line when the mast is in freelift state Mainlift Pressure V5 Pressure in the hoist line when the mast has extended above freelift Maximum Clamp Pressure V4 The maximum pressure set to clamp a load Overdrive System A system to aid with increasing arm speed and allows an attachment to have higher clamping pressure when breaking out rolls Starting Pressure V1 The minimum clamp pressure that will be applied even on light loads Static Hoist Pressure V3 The hoist pressure to achieve prior to hoisting Total Load Weight The sum of the paper roll weight and clamp weight 6802876 R1 BLANK Do you have questions you need answered right now Call your nearest Cascade Service Department Visit us online at www cascorp com En cas de questions urgentes contacter leservice d entretien Cascade le plus proche Visiter le site Web www cascorp com AMERICAS Cascade Corporation U S Headquarters 2201 NE 201st Fairview OR 97024 9718 Tel 800 CASCADE 227 2233 Fax 888 329 8207 EUROPE AFRICA Cascade Italia S R L European Headquarters Via Dell Artigianato 1 37050 Vago di Lavagno VR ltaly Tel 39 045 89891 11 Fax 39 045 8989160 ASIA PACIFIC Cascade Japan Ltd 2 23 2 Chome Kukuchi Nishimachi Amagasaki Hyogo Japan 661 0978 Tel 81 6 6420 977 1 Fax 81 6 6420 9777 Cascade Australia Pty Ltd 1445 Ipswich Road Ro
8. cklea QLD 4107 Australia Tel 1 800 227 223 Fax 61 7 3373 7333 cascade om Cm TM Cascade Corporation 2009 Zijn er vragen waarop u direct een ant woord nodig hebt Neem dan contact op met uwdichtstbijzijnde serviceafdeling van Cascade Of ga naar www cascorp com Per domande urgenti contattare l Ufficio Assistenza Cascade pi vicino Visitate il nostro sito all indirizzo WWW Cascorp com Cascade Canada Inc 5570 Timberlea Blvd Mississauga Ontario Canada L4W 4M6 Tel 905 629 7777 Fax 905 629 7785 Cascade Africa Pty Ltd PO Box 625 Isando 1600 60A Steel Road Sparton Kempton Park South Africa Tel 27 11 975 9240 Fax 27 11 394 1147 Cascade Korea 121B 9L Namdong Ind Complex 691 8 Gojan Dong Namdong Ku Inchon Korea Tel 82 32 821 2051 Fax 82 32 821 2055 Cascade New Zealand 15 Ra Ora Drive East Tamaki Auckland New Zealand Tel 64 9 273 9136 Fax 64 9 273 9137 Haben Sie Fragen fur die Sie sofort eine Antwort benotigen Wenden Sie sich anlhren nachsten Cascade Kundendienst Besuchen Sie uns online www cascorp com Tiene alguna consulta que deba ser respondida de inmediato Llame por tel fonoal servicio t cnico de Cascade m s cercano Vis tenos en www cascorp com Cascade do Brasil Rua Jo o Guerra 134 Macuco Santos SP Brasil 11015 130 Tel 55 13 2105 8800 Fax 55 13 2105 8899 Cascade Xiamen No 668 Yangguang Rd Xinyang Industrial Zone Haicang Xia
9. hoist circuit between the hoist auxiliary valve and mast lowering control valve 2 Install the hose from the hoist auxiliary valve HOIST port to the intensify valve TRUCK port 3 Install a hose that connects the MAST port of the intensify valve to the mast lowering control valve 4 Inspect hoses for pinch points and secure as required Mast Cylinders Intensify Valve Existing EES Lowering Control Valve Hoist it jee TE WH Valve pe Truck ___ Relief Valve Truck Hydraulic Pump 6802876 R1 Truck Tank AC1735 eps To Lowering Control Valve Intensify Valve 2 AC1873 eps y To Auxiliary Valve Hoist Port 1 NSTALLATION HFC VALVE AND HOSES 1 Install adapter fittings to T H CL1 CL2 OP1 and OP2 ports on the HFC valve 2 Locate and install the HFC valve on the truck cowl using 5 16 in 8 mm capscrews Watch for clearance when the mast is tilted back The HFC valve cartridges have adjustment screws that will need to be easily accessed 3 Connect a No 6 minimum hose from the truck auxiliary clamp circuit CLAMP port to the CL1 port of the HFC valve 4 Connect a No 6 minimum hose from the truck auxiliary valve clamp circuit OPEN port to the OP1 port of the HFC valve 5 Connect a No 6 minimum hose from the CL2 port of the HFC valve to the attachment revolving connection CLAMP port supply circuit 6 Connect a No 6 minimum hose from the
10. lamp is working properly and check for defective check valves and cylinder seals NOTE When adjusting cartridges turn in 1 2 turn increments Problem Solution Possible Effect Increase CW V1 May over clamp light reclamp roll Pad slips on load at start of lift If pressure in clamp cylinder does not May cause unit to lower increase after lifting during clamping decrease CCW V3 May over clamp after Decrease CCW V2 hoisting reclamp Load may not hoist truck and clamp capacity may not be compatible contact Cascade Load continues to slip after Increase CW V5 V2 has been decreased May cause pads to slip Pads crush load before Decrease CCW V1 at hoisting hoisting reclamp May cause slower arm speed during clamping Pads crush load after Increase CW V2 open hoisting and reclamp May cause load to slip If problem S AS May cause load to slip in freelift during freelift decrease CCW V5 Load slips when lift truck hits floor bumps or dock Decrease CCW V2 plate reclamp and hoist May over clamp load 6802876 R1 44 T EQUBLESHOOTING Problem Solution Possible Effect of Solution May cause mainlift and freelift to be unbalanced Hoist cylinder will not lift with a high capacity load Decrease CCW V5 May not add pressure during hoisting Hoist lowers while closing arms Hoist speed is decreased Decrease CCW V5 Clamped pressure is subs
11. ll adapter fittings to HFC TRUCK and MAST ports Equalizer Valve 1 a on the equalizer valve Install the equalizer valve in the hoist circuit between the hoist auxiliary valve and mast lowering control valve To Auxiliary Valve Hoist Port NOTE For trucks with a delivered flow volume of 18 GPM 68 L min or less install reducer fittings 2 Install the hose from the hoist auxiliary valve HOIST port to the equalizer valve TRUCK port 3 Install a hose that connects the MAST port of the equalizer valve to the mast lowering control valve 4 Inspect hoses for pinch points and secure as required 3 To Lowering Control Valve and Mast Freelift Cylinder 9 AC1897 eps Mast Cylinders LS O o Equalizer Valve Install reducer fittings if required Existing Lowering Control Valve Hoist ae NT lib SH LX Truck Tank AC1898 eps 2 6802876 R1 NSTALLATION NON SOLENOID INTENSIFY VALVE AND HOSES WARNING Before removing hydraulic lines or components relieve pressure in the hydraulic system Turn truck off and open the truck auxiliary control valve s several times in both directions WARNING Follow all recommended safety practices including chaining the freelift mast to the mainlift crossmember when mast is raised 1 Install adapter fittings to HFC TRUCK and MAST ports If IN and OUT ports are not plugged install metal plugs Install the intensify valve in the
12. men City Fujian Province P R China 361026 Tel 86 592 651 2500 Fax 86 592 651 2571 Sunstream Industries Pte Ltd 18 Tuas South Street 5 singapore 637796 Tel 65 6795 7555 Fax 65 6863 1368 11 2009 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 91 020 2432 5490 Fax 91 020 2433 0881 No 6802876 R1 PL
13. o Overdrive Valve Connect the T port on the bottom of the HFC Valve to the truck tank line fitting Overdrive Valve Connect the overdrive valve T IN port with the HFC valve T port Connect a hose from the overdrive valve T OUT port to the truck tank line fitting Refer to installation instructions 6097260 for additional information CAUTION If the overdrive valve is not directly installed to the HFC valve T port a high pressure hose must be used High pressure hose must be rated for 2300 psi 160 bar working pressure 3 Inspect hose for pinch points and secure as required Revolving Connection HFC Valve H OP1CL1 T To Equalizer 6 valve Optional Equalizer Overdrive Valve Valve Clamp Auxiliary Truck Tank AC1767 eps 6802876 R1 Return to Tank Return to Tank Fitting Single shown Hose to HFC Valve AC0226 eps HFC Valve Optional Overdrive Tank Hose Tank Hose AC1766 eps 1 Ground Switched ep Ground NSTALLATION SENSOR SWITCH IF EQUIPPED 1 Determine locations to mount the sensor switch on a fixed location on the mast and the bracket with spring wire if needed on a moving member on the mast The sensor switch will signal the mast transition from freelift to mainlift The provided mounting bracket can be used or modified to aid with mounting the sensor switch CAUTION Consult the Llft Truck OEM for proper power source connection 2 Connec
14. se the pressure by turning V5 in CW to match the desired clamp pressure NOTE For freelift mast large trucks with small Increases freelift attachments and adequate clamp pressure can not be hoisting pressure achieved with the standard valve a special equalizer valve may be required Contact Cascade for more detail 7 To adjust the Final Pressure V2 clamp a load Hoist the load Use the chart below to record the initial clamp pressure If the pressure is too high for the heaviest LENOID load turn the cartridge CW to reduce the adjusted SO O E OPERATED clamp pressure Record the adjusted clamp pressure EQUALIZER VALVE ADJUSTED ROLL INITIAL CLAMP CLAMP AC1899 eps WEIGHT PRESSURE e PRESSURE O oo IO ES OM IO ES Bo IO o ECONO ee ESOO IO O Read from long arm clamp cylinder gauge port 6802876 R1 OPERATION Auxiliary Valve Functions i Tilt Forward Hoist Down ish HH ZF aa Hoist Up Tilt Back GA0005 eps LONG ARM vertical amp horizontal positions only C Release D Clamp The HFC system works fundamentally the same as a normal lift truck system when used with a paper roll clamp Use the following techniques when clamping loads 1 Clamp arms firmly on the roll Hold for 1 second to build starting clamp pressure 2 Lift the load Clamp pressure will automatically increase according to load weight 3 If feathering is used to reduce clamp force on light loads
15. t hoisting pressure Balances freelift and mainlift hoisting pressure and make pressure available to clamping circuit IMPORTANT Check that V2 is completely turned out counterclockwise before adjustment process 1 Install the pressure gauge Cascade Pressure Test Kit 6034612 in the long arm clamp cylinder gauge port 2 Adjust the Starting Pressure V1 cartridge so that a light load is not damaged or over clamped and the heaviest load does not slip upon hoisting NOTE For attachments that are retrofitted from three position relief to HFC system and lowest pressure is known use the lowest pressure as starting pressure 3 To prevent carriage attachment from lowering during arm closing adjust the Static Hoist Pressure V3 cartridge This pressure must be less than the Starting Pressure V1 e lf the maximum weight load slips when hoisting reduce V3 by turning counterclockwise CCW e Ifthe carriage lowers when closing the arms of the clamp increase V3 by turning clockwise CW 4 To limit the maximum clamp pressure V4 fully close arms without a load and hoist to maximum lift Fully extend the mast and hold the lever for 2 seconds Lower the mast without unclamping and check the pressure If the pressure exceeds the desired maximum clamp pressure for the heaviest load turn the cartridge V4 CCW to decrease the maximum pressure RC3288 ai No Stand Zone 12 ft 4 m dia Adjusts clamping oressure after hois
16. t the harness solenoid connector to the solenoid coll 3 Connect the harness sensor switch connector to the sensor switch 4 Connect the harness cable ends to the components shown 12V Systems Connect the fused positive wire from the cable harness to a switched power source and the ground wire to a chassis ground 24V 48V Systems Connect the fused positive wire from the cable harness to a DC to DC converter positive output wire and the ground wire to the converter negative output wire Connect a 24V 48V switched power source to the converter fused positive input wire and connect the converter input ground wire to a chassis ground NOTE For troubleshooting the wire harness verify that the sensor switch solenoid and relay are working properly Check the LEDs on the sensor switch and solenoid When the mast is in freelift the LEDs will illuminate and when in mainlift the LEDs will be off Check current flow in and out of relay Solenoid 2 re S N a g Voltage Filter 24 48V systems only Pu DC to DC Converter 24V 48V systems only lll L Truck Fuse Block Truck Battery N Switch LED AC1812 eps NOTE When installing on electric trucks with regenerative breaking voltage filter 6061953 must be installed Failure to install voltage filter can cause damage to electrical components Moving member on mast spring LE Wire with p O Bracket
17. tantially higher in freelift over mainlift Increase CW V3 May have more clamp pressure in mainlift than freelift Available clamping pressure in freelift will be reduced Install switch if not 1 d inst l d mproved accuracy Decrease CCW V5 Load may slip in freelift Clamped pressure is substantially lower in Increase CW V5 freelift over mainlift May over clamp in freelift May cut off needed Over clamps when mast runs out of travel Increase CW V4 clamp pressure on heavy loads May over clamp light Light loads that require Driver may overclamp low starting pressure load if button is not Arm speed is too slow during clamping install optional arm released in time or overdrive system relief not properly set 12 6802876 R1 ARTS P HYDRAULIC FORCE CONTROL KITS LIMITED FREELIFT MAST AC 1874 eps Pressure Test Kit rer arv PARTNO DESCRIPTION 608682 HFC Kit without switch 2 1 6092598 Non Solenoid Intensify Valve Fitting 12 10 1 6034612 PressureTestKit 6802876 R1 13 14 ARTS HYDRAULIC FORCE CONTROL KITS FULL FREELIFT MAST 3 WN gt SN Y NS SY O A gt Truck AC0926 eps fi Battery Pressure Test Kit AC1901 eps Per arv PARTNO PARTNO DESCRIPTION o 60770 ck OO Po 60771 HFOKIit 24V 48V S op 217832 Converter and Filter Kit
18. ting Adjust this cartridge last FINAL PRESSURE V1 STARTING PRESSURE a Sets starting j pressure Must be higher then V3 AC1578 eps STATIC HOIST V4 MAXIMUM PRESSURE CLAMP PRESSURE Closes connection from o hoist line to clamp line Limit maximum Must be lower then V1 clamping pressure 6802876 R1 _ S ETUP CARTRIDGE ADJUSTMENT CONTINUED 5 To equalize the hoist pressure between freelift and Increases freelift mainlift clamp an average load and hoist off the ground hoisting pressure about 1 ft 30 cm freelift Record the pressure With V5 the same load at a higher position mainlift set load down in mainlift position Reclamp the load hoist the NON SOLENOID load and lower to the ground without unclamping ENSIFY VALVE Record the pressure e f pressure is within 150 psi 10 5 bar no adjustment is required e f mainlift pressure is higher than the freelift pressure increase V5 by turning CW to equalize pressure e lf freelift pressure is higher than the mainlift pressure decrease V5 by turning CCW to equalize pressure 6 For non freelift mast large trucks with small attachments clamp pressure may need to be increased If equipped the solenoid should be powered at all times by mounting the sensor switch in a location that will always switch on a ferrous object Clamp a roll and hoist Note the clamp cylinder pressure e lf the pressure is less than the desired clamp pressure increa
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