6809795R3 HFC User Manual CC
Contents
1. Solenoid Solenoid Coil Switched p Truck Batter y Truck Fuse Ground Block AC1960 eps 6809795 R2 12 T ROUBLESHOOTING CAUTION Prior to troubleshooting verify that clamp 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 load 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 hoistin g 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 blem occurs pro u 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 13 6809795 R2 o T ROUBLESHOOTING Problem Solution Possible Effect of Solution May cause mainlift and freelift to be unbalan2. mer arv PARTNO DESCRIPTION 6809000 HFCVave 6 1 220865 ShutteValve 8 1 21079 POCheckValveCarridge 9 1 60249004 SealKit 661312 Early production HFC kits used valve 6088041 All service parts are similar to Valve 6809010 19 6809795 R2 G Lossary Clamp Pressure Pressure set to clamp a load Final Pressure V2 The final HFC adjusted clamp pressure applied when the load is hoisted Freelift 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 load weight and clamp weight 6809795 R2 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 U S Headquarters 2201 NE 201st Fairview OR 97024 9718 Tel 800 CASCADE 227 2233 Fax 88
3. Page 4 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 the load Total weight equals load 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 The following is provided to assist in planning hose and fitting sizes to match the lift truck hoist line Equalizer Valve Fittings The mast and truck ports are No 12 O ring with No 12 JIC Fittings installed No 12 10 O ring reducers are supplied to adapt to smaller hoist lines HFC Kit without switch Part No 6812531 HFC Kit with switch Part No 6812477 12V 6812494 24V 48V To Mast Cylinder Reducer from 12 to 10 O ring Equalizer Valve AC2091 eps To Hoist Line Sensor Switch Page 6 NOTE Cascade recommends that component installation be done according to page number order Equalizer Valve GINS X b Page 3 a ug LL 1 AC1998 eps 6809795 R2 NSTALLATION PREPARE ATTACHMENT VALVE WARNING Before removing hydraulic Sides
4. J SER manvar Hydraulic Force Control For Carton Clamps Manual Number 6809795 R2 Cascade Cascade is a Registered Trademark of Cascade Corporation BLANK C ONTENTS OVERVIEW INSTALLATION Prepare Attachment Valve Equalizer Valve and Hoses HFC Valve and Hoses Return to Tank sensor Switch if equipped Disabling HFC System SETUP OPERATION DAILY CHECK LIST TROUBLESHOOTING PARTS GLOSSARY 6809795 R2 U t Q D NIGIGIRBICG IN IN 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 Carton 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 d e N i _ dE LEE S L o Ea PO aL N Bw Return to Tank Page 5 HFC Valve
5. the converter fused positive input wire and connect the converter input ground wire to a chassis ground NOTE For troubleshooting the wire harness refer to page 11 Solenoid Sensor 2 Switch Voltage Filter 24 48V systems only LC I Ell Switched DC to DC Converter 24V 48V systems only Truck Fuse Block Truck Battery AC1967 eps Ground 6809795 R2 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 gt Y Spring b Wire with O Bracket im if needed B lt Wz O N Sensor Switch SS l en Fixed location on mast additional bracket shown IA Ne alo AC1748 eps OR Moving Member 12 mm bracket with spring do not used BENE ZEN 1 E AS in em Fixed Sensor Switch Member OR AC1749 eps Cylinder 6 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 Pr
6. 77 6812404 HEC Kit S 6097404 6097465 SwichGrupA 6809723 6809723 6809723 VaweKtW 0 f 2170322 VolageConvrerKte 1 1 605957 6095957 WireHamess 2 1 681520 EqualzerVave NoSwitbh 3 1 681090 6810190 Equalizer Valve With Switch 5 1 6095909 6095909 SwithAssemby 6 1 6095839 6095839 Switch Mounting Bracket 8 1 601897 6017897 Fuse Samp 9 1 6006014 6006014 6006014 TestPointFitting oo pie 1 600099 Voltage Filter 7 1 fl 600459 PowrConvrer A Includes items 1 5 6 and 8 M includes items 11 15 Includes items 16 and 17 See Equalizer valve page for parts breakdown e oee HFC valve page for parts breakdown Early production HFC kits used valve 6088041 See Valve 6809010 for service parts 6809795 R2 16 17 ARTS EQUALIZER VALVE AC2113 eps 5 f uM 3 1 o 6810190 Equalizer Valve With Switch p 6014287 Col 12V 1 612497 Pug j 6809795 R2 ARTS SENSOR SWITCH D 2 TO Q S L L AC1724 eps REF QTY PART NO DESCRIPTION 6095969 Switch Assembly 6809795 R2 18 ARTS HFC VALVE O Ac2114 eps a amp
7. 8 329 8207 EUROPE AFRICA Cascade Italia S R L European Headquarters Via Dell Artigianato 1 3 030 Vago di Lavagno VR Italy 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 9771 Fax 81 6 6420 9777 Cascade Australia Pty Ltd 1445 Ipswich Road Rocklea QLD 4107 Australia Tel 1 800 227 223 Fax 61 7 3373 7333 cascade C73 Cm TM Cascade Corporation 2012 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 oparton 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 Cascade do Brasil Rua Joao 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 Xiamen 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 04 2012 Cascade India M
8. FC valve Connect a No 6 minimum hose from the CL2 port of the HFC valve to the attachment CLAMP port supply circuit Connect a No 6 minimum hose from the OP2 port of the HFC valve to the attachment OPEN port supply circuit Connect a No 6 minimum hose from the H port of the HFC valve to the HFC port of the equalizer valve Inspect hoses for pinch points and secure as required Mast Cylinders Existing Lowering Control Valve Hoist Auxiliary Valve HFC TRUCK MAST Truck Hydraulic Pump 6809795 R2 A Illi HFC Valve Hoist Line Pressure Gauge Port Valve Plug To be replaced with a solenoid cartridge for Automatic or Manual Overdrive options AC2112 eps Attachment Valve o HFC Valve Equalizer Valve H OP1 CL1 T 7544 3 Tv RAE OMT ATTI Valve Truck Tank AC1747 eps NSTALLATION RETURN TO TANK 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 6049380 1 00 in 25 mm 6049381 1 25 in 31 mm 6049382 1 50 in 38 mm 6037507 6049383 Included in adapter kit 6807816 NOTE For trucks with pressurized return to tank lines the hydraulic tank filler cap must be opened to rel
9. aterial 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 Part Number 6809795 R2
10. ced Hoist cylinder will not lift with a high capacity load Decrease CCW V5 May not add pressure during hoisting Hoist lowers while closing Increase CW V3 arms May have more clamp pressure in mainlift than freelift Available clamping pressure in freelift will be reduced Install switch if not l d installed mproved accuracy Decrease CCW V5 Load may slip in freelift Hoist speed is decreased Decrease CCW V5 Clamped pressure is substantially higher in freelift over mainlift Clamped pressure is substantially lower in freelift over mainlift May over clamp in freelift Increase CW V5 May cut off needed clamp pressure on heavy loads May over clamp light Light loads that require Driver may overclamp low starting pressure load if button is not Over clamps when mast runs out of travel Increase CW V4 Arm speed is too slow during clamping install optional arm released in time or overdrive system relief not properly set 6809795 R2 14 ARTS HYDRAULIC FORCE CONTROL KITS Z SS Truck Fuse m7 Block Truck Battery Pressure Test Kit Connector Kit a P pu zw 15 m D Series BI oe E m ds gt ey pot A 2 A O D o A Valve G Series Valve 6809795 R2 ARTS HYDRAULIC FORCE CONTROL KITS HFC HFC HFC QTY No Switch 12V 24V 48V DESCRIPTION PART NO PART NO PART NO 812531 68124
11. elift the LEDs will be on applications where the mast is extended to full e When in mainlift the LEDs will be off height on a regular basis while clamping a load Chedic tise For LED troubleshooting check the LEDs on the sensor switch and solenoid Remove relay and cables from sensor switch and e When the mast is below maximum height the solenoid coil LEDs will be off 3 Check for 12V power between relay socket terminals e When at mast full height the LEDs will be on 30 and 86 If no power check continuity e 30 and truck battery e 86 and truck battery 4 Check for continuity at all corresponding pins and terminals 5 Install cable to sensor switch fixed on a target switch LED should be illuminated Check for power at relay socket terminal 85 6 Test the relay by adding 12V power to 85 and ground to 86 With a meter check for continuity between 30 and 87 Remove power verify that there is no continuity between 30 and 87 T With the relay installed and the sensor switch fixed on a target LED illuminated check for power at the solenoid connector between 1 and 2 Solenoid connector LED should be illuminated 8 Connect cable to solenoid coil listen for a click If there is no click remove connector and check for coil resistance of 7 2 ohms at 60 F 20 C If no resistance replace coll Sensor 4 Switch Voltage Filter DC to DC Converter 24 48V 24V 48V systems only Systems only n
12. hift lines or components relieve pressure In E Fittings the hydraulic system Turn truck off and D Series 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 Orifice when mast is raised Pipe Plug CL Special 1 Open attachment arms to frame width RUE with poo 2 Disconnect the hydraulic hoses from the valve CLAMP CL OPEN OP SIDESHIFT RIGHT SSR and SIDESHIFT LEFT SSL ports 3 Remove CL port special fitting with spool or orifice pipe plug 4 Install kit pipe plug into CL port and reinstall fitting leaving spool out as needed for G Series valves D Series Valves 25 in dia NPTF plug Part No 6603 Front View G Series Valves 3125 in dia setscrew Part No 5304 5 Install kit fitting into SSR and SSL ports If equipped with No 8 hoses install adapter fittings 4 Kit Pipe Plug 4 Kit Setscrew G Series sa 2 Front View Fitting for G Series 5 Valves New Kit Fitting New Kit Kit Fitting Adapter T Eu j Adapter r E Fitting Sideshift Fa CL4640 eps CL4849 eps P or Is Fa Sideshift Ports Back View 6809795 R2 2 NSTALLATION EQUALIZER VALVE AND HOSES 1 Install adapter fittings to HFC TRUCK and MAST ports on the equalizer valve Install the equalizer valve in the hoist circuit between the hoist auxiliary
13. ieve trapped pressure 2 Connect the T port on the bottom of the HFC Valve to the truck tank line fitting 3 Inspect hose for pinch points and secure as required Return to Tank Return to Tank Fitting Single shown Hose to HFC Valve ACO226 eps Attachment Valve HFC Valve H OP1 CL1 T To Equalizer Valve To Equalizer 2 Hoist ud Clamp d Auxiliary Auxiliary Truck Tank AC2115 eps 6809795 R2 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 Lift Truck OEM for proper power source connection 2 Connect 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
14. ior To Operation section HFC VALVE AC1623 ai V5 AC2002 eps EQUALIZER VALVE Switch Valve Shown 6809795 R2 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 load Mainlift Pressure V5 Increases freelift 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 f the maxim
15. oad e Without Light Load Option If feathering is used to reduce clamp force on light loads 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 AC2185 eps 6809795 R2 10 D AILY CHECK LIST At the beginning of each shift after turning on the truck key check the following components Aa LED should be on 3 Light Load Equipped Light Load Cab Light LED should Light Load Button Light Load Valve Solenoid LED should be off AC2257 eps 11 Equalizer Valve Solenoid Proximity Switch LED should be on 1 E ho E AOD Transmitter if equipped AW LED should be on TEN um 2 AC2256 eps AOD Pad Sensor if equipped Activate by covering the sensor Observe sensor receiver LED should be off when pad sensor is covered MOD or AOD Solenoid Equipped HFC Valve MOD LED should be off AOD LED should be on O N R KO 1 AC2258 eps 6809795 R2 ROUBLESHOOTING Es WIRE HARNESS Verify the sensor switch solenoid and relay are working properly Check the LEDs on the sensor switch and Full Height Pressure Limiter Valve Kit lenoid We a o This kit prevents excessive clamp force in e When the mast is in fre
16. s higher than the freelift pressure hoisting pressure increase V5 by turning CW to equalize pressure e ffreelift pressure is higher than the mainlift pressure V5 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 load and hoist Note the clamp cylinder pressure AC2002 eps EQUALIZER VALVE Switch Valve Shown e fthe pressure is less than the desired clamp pressure increase the pressure by turning V5 in CW to match the desired clamp pressure NOTE For freelift mast large trucks with small attachments and adequate clamp pressure can not be achieved with the standard valve a special equalizer valve may be required Contact Cascade for more detail T 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 load turn the cartridge CW to reduce the adjusted clamp pressure Record the adjusted clamp pressure ADJUSTED LOAD INITIAL CLAMP CLAMP WEIGHT PRESSURE e PRESSURE e O Read from attachment valve gauge port 6809795 R2 O Auxiliary Valve Functions PERATION WARNING Truck control handle and attachment function activation shown here conforms
17. to ASME ANSI B56 1 Tilt Forward recommended practices Failure Hoist Down to follow these practices may lead AC to serious bodily injury or property damage End user dealer and OEMs ant should review any deviation from the 99099 practices for safe operation wt Todo GA0005 eps r j Hoist Up Tilt Back CLAMP SIDESHIFT A Sideshift Left The HFC system works fundamentally the same as a B Sideshift Right normal lift truck system when used with a carton clamp C Release Arms Use the following techniques when clamping loads To Lift a Unit Load 1 2 3 To Lift a Light Load 1 Layer 1 2 3 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 D Clamp Arms If equipped with Light Load Option verify cab light is off Clamp a unit load Hold for 1 2 seconds to build starting clamp pressure Lift the load Clamp pressure will automatically increase according to load weight If equipped with Light Load Option press the Light Load button On and verify cab light is on Using low to mid engine RPM clamp a light load Hold for 1 to 2 seconds to build starting clamp pressure Lift the l
18. um weight load slips when hoisting reduce V3 by turning counterclockwise CCW e f the 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 6809795 R2 nj No Stand Zone CL4644 eps Adjusts clamping oressure after hoisting Adjust this V1 STARTING cartridge last FINAL PRESSURE PRESSURE V Sets starting j pressure Must be higher then V3 AC1578 eps STATIC HOIST V4 MAXIMUM PRESSURE CLAMP PRESSURE Closes connection from hoist line to clamp line Limit maximum Must be lower then V1 clamping pressure ETUP CARTRIDGE ADJUSTMENT CONTINUED 5 To equalize the hoist pressure between freelift and mainlift clamp an average load and hoist off the ground about 1 ft 30 cm freelift Record the pressure With the same load at a higher position mainlift set load down in mainlift position Reclamp the load hoist the load and lower to the ground without unclamping Record the pressure e f pressure is within 150 psi 10 5 bar no adjustment Is required Increases freelift e If mainlift pressure i
19. valve and mast lowering control valve 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 No 12 JIC equalizer valve to the mast lowering control valve To Hoist Control Valve Port 4 Inspect hoses for pinch points and secure as required Equalizer Valve Switch Valve Shown No 12 10 O Ring Reducer No 12 10 O Ring Reducer To Mast Lowering Control Valve Freelift Cylinder No 12 JIC AC2110 eps Equalizer Mast Cylinders Existing Lowering Control Valve Hoist C So Ll ho Xe Valve Hydraulic Truck Pump Tank AC2001 eps 6809795 R2 NSTALLATION HFC VALVE AND HOSES 1 Install adapter fittings to T H CL1 CL2 OP1 and OP2 ports on the HFC valve Remove orifice plug OR from the valve Remove the orifice Reinstall orifice plug OR 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 Connect a No 6 minimum hose from the truck auxiliary clamp circuit CLAMP port to the CL 1 port of the HFC valve Connect a No 6 minimum hose from the truck auxiliary valve clamp circuit OPEN port to the OP1 port of the H
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