Clamp Open Guard - Cascade Corporation
Contents
1. 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 Installation Perform by Qualified Personnel only 1 Remove cable from positive battery terminal 1 Disconnect the cable from the positive battery terminal 2 Locate and install the solenoid valve and spacer on the truck cowl using customer supplied 25 in 6 mm fasteners Watch for clearance when the mast is tilt all the way back The valve is being installed in the clamp OPEN line from the auxiliary valve to the attachment IMPORTANT The valve must be installed in the open AC0201 eps circuit ahead of any clamp line check valve pilot lines 240 in Do not install the coil adjacent to any RF or control devices 53 mm electronics 3 Connect control valve port 1 to the supply hose going to E the attachment IMPORTANT When installing the Clamp Open Guard with Cascade s Adaptive Force Control AFC the solenoid valve must be installed between the truck auxiliary valve and the AFC valve i 4 80 in 4 Connect solenoid valve port 2 to the supply hose from the E T a 7 a 122 mm truck auxiliary valve clamp OPEN line ieee IMPORTANT Verify by visual test Installation steps 2 3 and 4 ca A 44 o r2. 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 05 2012 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 Part Number 6817283 R2
3. see truck manual 24V 48V Systems Connect the power wire from the cable harness to a DC to DC converter output wire Connect converter and voltage filter input wire to the Deutsch connect provided on the truck see truck manual Check the cable routing for pinch points and clearance Use wire ties as needed NOTE When installing a DC DC Converter on electric trucks voltage filter 6061953 must be installed Failure to install voltage filter can cause damage to electrical components 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 7 Reconnect the positive battery terminal to the battery I Deutsch Deutsch TES Connector Connect ae Input Pinot gt T to 24 V 48v To Truck Cab Light _ source Voltage Filter I l l l iIndicslo Ciguir serene E Connect i DC to DC Converter 24 48V Systems only 1 i Cable 24V 48V systems Ends LL __ __ __ only if equipped Ln annnmsnMsnM i a Connect to Converter Kit Valve A OR Deutsch Connector Connect to 12V source 5A System Switch Fuse AC2073 eps Test and Adjustment Perform by Qualified Personnel only 1 Test the installation before putting the truck in service When the truck key Is turned ON the Komatsu supplied indicator light should be off 2 Press the button and observe t
4. AC2048 eps E N OD Valve a 1 62 in a CV fa 41 mm Attachment Revolving Connection Open Clamp instal attachment meo supply hose Solenoid to Port 1 Install auxiliary valve hose to a Part 2 y lt oad AC1013 eps Hoist Clamp Valve I Valve AC0447 eps 5 Install the switch to the clamp control lever Remove the control knob Position the switch on the Install switch handle in a location for comfortable thumb or index finger 5 operation IMPORTANT Place the double sided tape under the switch to secure the switch in place Place the heat shrink tubing over the handle and switch Using a heat gun heat the tubing to secure the switch to the handle Reinstall the knob Install cable ties as needed for the wires Avoid pulling bending or pinching the switch wire 3 in 76 mm for typical hand AC0402 eps Tape NOTE UL Classified Kits require installation by qualified personnel only without major disturbance cutting splicing or soldering of factory installed wiring UE CAUTION Consult the Lift Truck OEM for proper power source connection P 6 Connect cable ends to the components as shown Hols and 12V Systems Connect the fused power cable Deutsch connector to the corresponding connector provided on the truck see truck manual 24V Systems No Connector Connect the fused power cable Deutsch connector to the corresponding connector provided on the truck
5. S ee ee 6806701 6813569 6813569 6817047 6813569 For trucks with 3 function auxiliary valve Includes item 3 For trucks with 4 function auxiliary valve Includes items 8 and 9 M Includes items 10 and 11 A Includes item 7 Common Components jary PARTNo DESCRIPTION REF 6020883 PART NO DESCRIPTION 601250 601377 Fitting 8 8 6014987 Adhesive Tape 6001641 Shrink Tube O 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 888 329 8207 EUROPE AFRICA Cascade Italia S R L European Headquarters Via Dell Artigianato 1 37030 Vago di Lavagno VR ltaly Tel 39 045 89891 11 Fax 39 045 8989 160 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 Rocklea QLD 4107 Australia Tel 1 800 227 223 Fax 61 7 3373 7333 cascade om 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 Sparton Kempton Park South Africa Tel 27 11 975 9240
6. cascade ce C TM instal lation amp Clamp Open Guard Switch Activated User Man ual Models for Komatsu This manual provides installation instructions for Cascade NOTE Kits are UL Classified File AU3546 for safety in Clamp Open Guard The kit provides an added level of Electric Battery UL 583 and IC Engine UL 558 Indust security to prevent accidental load dropping Clamp Open truck type E ES G GS G LP GS LPS LP LPS Dand Ds Guard requires a definitive action by the driver to help prevent accidental unclamping The kit is intended for use with all Cascade load bearing Clamps to conform with ANSI ITSDF B56 1 Section 7 25 7 NOTE UL Classified Kits require installation by qualified personnel only without major disturbance cutting splicing or soldering of factory installed wiring Clamp Open Guard Kits Truck Auxiliary c a Voltage Valve Part No a a ae SS SS a ee ae 12V 3 Function 6816156 ES Pa a 12V 4 Function 6813576 gt 24V 4 Function 6817050 A Q oo k lt ees 24V 48V 4 Function 6813577 SY Ke deel Clamp O i ee e NK ee a q P a C NS Y AA SRST z A LO ie 1 ee el Paper Roll Clamps af a os Layer Pickers Carton Clamps Clamps Sl CE Part No 6817283 R2 Cascadce Cascade Corp Corporation For Technical Support
7. e that the load has been lowered to its optimal position WARNING Residual risk exists to personnel in the work area operate only in compliance to facility standards Troubleshooting service only after reading this manual and by Qualified Personnel only e Check all system fuses e Verify VDC at switch connector e Check switch function N O switch e Check VDC at solenoid when switch is pressed e Check for VDC at Indicator Light when switch Is pressed Switch Sol id na lt 4 AC2074 eps Temporarily Disabling System The Clamp Open Guard can be disabled by performing the following steps e Tag equipment as not operational Do not operate when system is disabled or Known to malfunction e Disconnect the two hose ends to the normally closed solenoid valve and connect them together with a union e Remove the system power fuse in the cable harness to disable indicator light The truck and attachment will now operate without the Clamp Open Guard feature To enable the Clamp Open Guard reverse the above procedure NOTE System Fuse is located near manual switch and DC DC Converter if installed Clamp Open Guard NOTE To reduce risk of fire replace with 5A fuse only AC2075 eps 12V 12V 24V 24V 48V 3 Function 4 Function 4 Function 4 Function PART NO PART NO PART NO PART NO DESCRIPTION 6813570 6813570 6817051 6813570 solenoid Valve Assembly Ooo
8. hat the indicator light turns on 3 Hoist a load 1 in off the ground Operate the clamp open handle several times the clamp should not open Lower the load to the ground Press the button to release the load Verify that the indicator light is on while pressing the button Operation WARNING All operators must read this section Before operation inspect the switch indicator valve wiring and test operation daily Operators must have a thorough knowledge and understanding of the safe operation of the attachment with which the Clamp Open Guard is used The Clamp Open Guard provides an added level of security to prevent accidental load dropping per current ANSI standards Clamp Open Guard requires a definitive action by the driver to help prevent accidental unclamping It acts as a device to prevent accidental activation of the truck s clamp open circuit The clamp is allowed to open when the switch is activated and the indicator light on e Press the switch button then operate the truck clamp open control lever to open the clamp When the indicator light is on the clamp will open normally e f the clamp will not open when the button is pressed set the load down turn off the truck key and troubleshoot the system Follow Test and Adjustment before returning to service NOTE The system does not work like a drop stop valve that prevents carriage drop or jump when the clamp is opened The indicator light does not indicat
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