6099530 HFC User Manual
Contents
1. 6099530 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 paper roll weight and clamp weight 6099530 Do you have questions you need answered right now Call your nearest Cascade Service Department Visit us online at www cascorp com Cascade Corporation U S Headquarters 2201 NE 201st Fairview OR 97024 9718 Tel 800 CASCADE 227 2233 FAX 888 329 8207 Cascade N V Benelux Sales and Service Damsluisweg 56 PO Box 3009 1300 EI Almere The Netherlands Tel 036 5492950 FAX 036 5492974 Cascade Scandinavia AB Hammarv gen 10 PO Box 124 5 56723 Vaggeryd Sweden Tel 039 336950 FAX 039 336959 Movimenta Lda Parque Industrial Vale do Alecrim Lote 108 2950 4032. Hydraulic Force Control LINDE 25 50 Manual Number 6099530 Cascace Corporation Cascade is a Registered Trademark of Cascade Corporation ONTENTS Page OVERVIEW 1 INSTALLATION 2 Equalizer Valve and Hoses 2 HFC Valve and Hoses 3 Return to Tank amp Optional Overdrive Valve 4 Sensor Switch if equipped 5 Disabling HFC System 6 PRIOR TO OPERATION 8 OPERATION 9 TROUBLESHOOTING 10 PARTS 12 GLOSSARY 18 i 6099530 _ 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 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 Fade Sj HFC Valve Page 4 Optional Overdrive Valve Refer to Installation Instructions 6097260
3. ARTS HYDRAULIC FORCE CONTROL KIT 0926 Pressure Test Kit ACIBIS Sps REF QTY PART NO DESCRIPTION REF QTY PART NO DESCRIPTION 6095869 HFC Kit 10 1 6405015 Capscrew M8 35 1 1 6095957 Wire Harness M 11 1 6098793 Bracket A 2 1 6095796 Equalizer Valve 12 2 6405022 Capscrew 8 X 80 3 1 6088041 HFC Valve 13 2 765480 Capscrew M4 X 10A 4 1 6095969 Switch Assembly 14 2 685899 Lockwasher M4 A 5 1 6095839 Switch Mounting Bracket M 15 1 6098206 Return to Tank Kit 6 1 6097591 Fitting Hose Group 16 2 6004478 Test Point Fitting M16 X 7 16 SAE 7 1 6017897 Fuse 5 amp 17 1 6006014 Test Point Fitting M16 X 9 16 SAE 8 2 644585 Hose Clamp A 1 6034612 Pressure Test Kit 9 1 6098797 Adaptor A included in Switch Group 6097590 A Included in Mounting Group 6098792 For parts breakdown refer to Fitting Hose Group page 6099530 5 EQUALIZER VALVE 4 RETURN TO TANK KIT 6099530 REF QTY PART NO DESCRIPTION 6095796 Equalizer Valve 1 1 6095795 Valve Body 2 1 6088046 Relief Valve Cartridge 3 2 6234021 Fitting Metric L 4 1 601676 Fitting 6 6 5 1 6094473 Solenoid Valve 6 1 6014287 Coil 12V AC1818 eps REF QTY PART NO DESCRIPTION 6098206 Return to Tank Kit 1 1 6098117 Adaptor Tee 2 1 6098209 Hose 3 2 6098196 Hose Clamp 4 1 211742 Hose Clamp 5 2
4. Page 2 amp 3 6099530 Equalizer 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 NOTE Kit 6095869 is to be used on trucks with a flow volume greater than 18 GPM 68 L min NOTE Cascade recommends that component installation be done according to page number order Sensor Switch Page 6 pm N TN eps Te NSTALLATION SOLENOID OPERATED EQUALIZER VALVE AND HOSES WARNING Before removing hydraulic A 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 equalizer mounting assembly to the mast Mast cylinder Cylinder 2 Install adapter fitt
5. 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 Valve Optional Overdrive Valve To Equalizer Hoist vae Clamp Auxiliary Auxiliary Valve Valve Truck Tank AC1767 eps 1 Return to Tank Fitting Single shown HFC Valve ACO226 eps HFC Valve Optional Overdrive Valve Tank Hose Tank Hose AC1811 eps 6099530 Ground Switched Ground 6099530 NSTALLATION SENSOR SWITCH 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 AUTION Consult the Truck OEM for proper power Source connection 2 3 4 N Connect the harness solenoid connector to the solenoid Connect the harness sensor switch connector to the sensor switch Connect the harness cable ends to the com
6. V2 open hoisting and reclamp May cause load to slip If problem occurs p 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 10 6099530 T ROUBLESHOOTING 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 Hoist lowers while closing during hoisting arms clamping pressure in Hoist speed is decreased Decrease CCW V5 freelift will be reduced clamped pressure is Install switch if not substantially higher in freelift tuor malnilft installed idit d Decrease CCW V5 Load may slip in freelift Clamped pressure is i substantially lower in Increase CW V5 May over clamp in freelift over mainlift freelift Increase CW V3 May have more clamp pressure in mainlift than freelift Available May cut off needed Over clamps when mast runs out of travel Increase CW V4 clamp pressure on heavy loads M lamp light Increase CW V1 pad clamp lig 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 6099530 11 12
7. Palmela Portugal Tel 351 212387340 FAX 351 212387349 Cascade Japan Ltd 5 5 41 Torikai Kami Settsu Osaka Japan 566 Tel 81 726 53 3490 FAX 81 726 53 3497 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 C 737M Cascade Corporation 2009 Cascade Canada Inc 5570 Timberlea Blvd Mississauga Ontario Canada LAW 4M6 Tel 905 629 7777 FAX 905 629 7785 Cascade Kenhar Ltd 3 Kelbrook Road Parkhouse Ind Estate Openshaw Manchester M11 2DD England Tel 0800 243015 FAX 0161 4384055 Cascade France S A R L MHP 1D Rue De Charaintru BP 18 91360 Epinay Sur Orge France Tel 01 6454 7500 FAX 01 6454 7501 Sales Switzerland Fahrzeugbedarf 8810 Horgen Switzerland Tel 01 7279797 FAX 01 7279798 Cascade Korea 121B 9L Namdong Ind Complex 691 8 Gojan Dong Namdong Ku Inchon 405 310 Korea Tel 82 32 821 2051 FAX 82 32 821 2055 Sunstream Industries Pte Ltd No 3 Tuas Link 1 2263 Singapore Tel 65 6863 3488 FAX 65 6863 1368 Cascade GmbH Niederwippek hl 1 58579 Schalksm hle Germany Tel 02355 50900 FAX 02355 509020 Sales Scotland Macade Systems Ltd 18 Melford Road Righead Ind Estate Bellshill ML4 Scotland Tel 01698 845777 FAX 01698 845888 Cascade Hispania S A Carrer 5 Sector C Zona Franca Du
8. hoist off the ground about 1 ft 30 cm freelift Record the pressure With the same load at a higher position mainlift clamp the load hoist the load and lower to the ground without unclamping Record the pressure Increases freelift f pressure is within 150 psi 10 5 bar no adjustment hoisting pressure is required V5 e f mainlift pressure is higher than the freelift pressure increase V5 by turning CW to equalize pressure e If 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 The switch should be powered at all times Clamp a roll and hoist Note the clamp cylinder pressure e fthe pressure is less than the desired clamp pressure increase the pressure by turning V5 in CW to match the desired clamp pressure 7 To adjust the Final Pressure V2 clamp a load Hoist Adjusts clamping the load Use the chart below to record the initial clamp pressure after pressure If the pressure is too high for the heaviest hoisting Adjust this load turn the cartridge CW to reduce the adjusted cartridge last clamp pressure Record the adjusted clamp pressure FINAL PRESSURE ADJUSTED ROLL INITIAL CLAMP CLAMP WEIGHT PRESSURE PRESSURE 1 2 3 4 5 Read from long arm clamp cylinder gauge port AC1823 eps 6099530 P
9. kit hose and fitting from the OP2 port of the HFC valve to the attachment revolving connection OPEN port supply circuit Install kit hose from the H port of the HFC valve to the FC port of the equalizer valve I 9 Inspect hoses for pinch points and secure as required Mast Cylinders Equalizer Existing H OP1CL1 T Lowering Control Valve MAST TRUCK 8 5 Hoist Clamp W Auxiliary N MM Auxiliary X Valve I W Valve x HFC Valve Cylinder Hoist Line Pressure Gauge Remove 1 O and 1 fittings Port 7 Revolving Connection 6 HFC Valve 4 Truck Hyaraulic Truck Pump Tank AC1810 eps 6099530 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 Kit 6098206 NOTE For trucks with pressurized return to tank lines the hydraulic tank filler cap must be opened to relieve trapped pressure 2 No 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
10. 11740 Hose 72 in 6 211741 Fitting 8 T 601377 Fitting 8 8 8 662187 Fitting 8 6 13 5 SENSOR SWITCH L L AC1724 eps REF PART DESCRIPTION 6095969 Switch Assembly 1 1 6091430 Bracket 2 1 6092966 Switch 14 6099530 5 VALVE A01819 eps REF QTY PART NO DESCRIPTION 6088041 HFC Valve 1 1 6088042 Valve Body lt lt 2 3 601377 Fittings SF 3 1 604511 Fitting 5 9 4 1 6091000 Pressure Sequence Valve Cartridge 5 1 6090999 Pressure Sequence Valve Cartridge 6 1 220865 Shuttle Valve 7 1 609234 8 1 210379 PO Check Valve Cartridge 9 1 6024964 Seal Kit 10 1 661676 Relief Valve Cartridge 11 2 661312 Seal Kit 12 1 6086327 Directional Valve Cartridge 13 1 6098001 Relief Valve Cartridge 14 1 604510 Plug 15 1 6054498 Orifice 020 16 1 663694 Plug m Refer to Glossary for flow requirements 6099530 15 ARTS FITTING HOSE GROUP amp AC1820 eps REF QTY PART NO DESCRIPTION 6097591 Fitting Hose Group 1 2 6099256 Fitting 8 8 2 2 6098061 Hose 3 2 6095885 Fitting M10L EO 4 2 6098060 Hose 5 2 6095887 Fitting M10L EO 6 1 2680 Fitting 6 6 7 2 6097873 Hose 8 2 6095870 Fitting M18L 9 1 6234020 Fitting M18L 10 1 666817 Hose 40 in
11. ERATION O Auxiliary Valve Functions Tilt Forward Hoist Down Ww GA0005 eps Hoist Up Tilt Back 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 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 6099530 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 Driver s view 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 f
12. Install the pressure gauge Cascade Pressure Test Kit 9 6034612 in the long arm clamp cylinder gauge port E V1 STARTING PRESSURE 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 with HFC system and lowest pressure is known use the lowest pressure as starting pressure 3 To prevent carriage attachment from drifting adjust the Static Hoist Pressure V3 cartridge This pressure must be less than the Starting Pressure V1 e Ifthe maximum 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 V3 AC1815 eps pressure for the heaviest load turn the cartridge V4 STATIC CCW to decrease the maximum pressure HOIST V4 MAXIMUM PRESSURE CLAMP Closes connection from PRESSURE hoist line to clamp line Limit maximum Must be lower then V1 clamping pressure 6099530 7 ETUP CARTRIDGE ADJUSTMENT CONTINUED 5 To equalize the hoist pressure between freelift and mainlift clamp an average load and
13. anera Poligono de la Zona Franca 08040 Barcelona Spain Tel 93 264 07 30 FAX 93 264 07 31 Sales Poland Targowa 35 61 03 728 Warszawa Tel 022 619 00 49 FAX 022 619 00 49 Mobile Tel 0501 27 29 55 Cascade Australia 1445 Ipswich Road Rocklea QLD 4107 Australia Tel 1 800 227 223 FAX 617 3373 7333 Cascade do Brasil LTDA Rua Jo o Guerra 134 Macuco Santos SP Brasil 11015 130 Tel 55 13 2105 8800 Fax 55 13 2105 8899 07 2009 Cascade Finland A Petreliuksenkatu 3 01370 Vantaa Finland Tel 09 8361925 FAX 09 8361935 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 Italia S R L Via Dell Artigianato 1 37050 Vago di Lavagno VR Italy Tel 39 045 89891 11 FAX 39 045 8989160 Sales Russia Material Handling Equipment Moscow Tel 095 795 2400 FAX 095 795 2475 Email emcg emcg ru Cascade New Zealand 15 Ra Ora Drive East Tamaki Auckland New Zealand Tel 64 9 273 9136 FAX 64 9 273 9137 Part Number 6099530
14. ings to HFC TRUCK and MAST ports on the equalizer valve Equalizer Valve 3 Install the equalizer valve to the mounting assembly 4 Install kit hose from the hoist auxiliary valve HOIST port to the equalizer valve TRUCK port 5 Install the kit hose that connects from the equalizer valve MAST port to the mast lowering control valve 4 Inspect hoses for pinch points and secure as required Control Valve and Mast Freelift Cylinder 5 Equalizer AC1807 eps Valve To Auxiliary Valve Hoist Port Mast Cylinders To Lowering MAST TRUCK Existing Lowering Control Valve Y eme QUANT IL Relief Valve posa Truck Hydraulic Truck Pump Tank AC1808 eps 6099530 NSTALLATION HFC VALVE AND HOSES Install mounting assembly to the mast cylinder Install adapter fittings to T H CL2 and OP2 ports on the HFC valve Install the HFC valve to the mounting assembly A N Remove fitting from CL1 port Install kit hose and fitting from the truck auxiliary clamp circuit CLAMP port to the CL1 port of the HFC valve Remove fitting from OP1 port Install kit hose and fitting from the truck auxiliary valve clamp circuit OPEN port to the OP1 port of the HFC valve Install kit hose and fitting from the CL2 port of the HFC valve to the attachment revolving connection CLAMP port supply circuit Install
15. oid LED 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 SOLENOID OPERATED EQUALIZER VALVE AC1813 eps 6099530 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 RC3288 ai Mainlift Pressure V5 Increases freelift hoisting No Stand Zone pressure Balances freelift and mainlift hoisting pressure 12 ft 7 m dia and make pressure available to clamping circuit Adjusts clamping IMPORTANT Check that V2 is completely turned out pressure after Sets starting counterclockwise before adjustment process hoisting Adjust this Must b cartridge last 2 1
16. ponents 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 OTE For troubleshooting the wire harness verify that the sensor switch solenoid and relay are working properly C heck 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 Truck Battery N NOTE When installing on the 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 Wire with Bracket Sensor Switch Fixed location on mast additional bracket shown AC1748 eps N Moving Member 12 mm bracket with spring not shown y i Toh 15 in 4 mm Fixed Sensor Switch Member AC1749 eps Voltage Filter 24 48V systems only m 7 DC to DC Converter 24V 48V systems only Truck Fuse Block N Switch LED AC1812 eps Solen
17. ull 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 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 reclamp Pad slips on load at start May over clamp ight of lift If pressure in clamp cylinder does not increase after lifting decrease CCW V3 May cause unit to lower during clamping May over clamp after hoisting Decrease CCW V2 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
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