cascade
corporation
c
Technical
Documentation
Adaptive Force
Control (AFC)
• Introduction
• Installation
• Setup
• Operation
• Troubleshooting
• Periodic Maintenance
• Service
• Parts
cascade
corporation
Cascade is a Registered Trademark of Cascade Corporation
C ONTENTS
Adaptive Force Control (AFC)
INTRODUCTION
Overview (6095121)
INSTALLATION
AFC System Installation (6095124)
Power Supply/Communication Groups (6844330)
Hydraulic Accumulator Groups (227196)
Low Pressure Tank Line Adapter Kits (6808126)
DC to DC Converter (6009167)
Priority Flow Control Valve (6012808)
SETUP
AFC Setup Instructions (6095125)
OPERATION
Operator’s Guide – Paper Roll Clamps (210135)
Operator’s Guide – AFC Supplement (6095126)
TROUBLESHOOTING (6095127)
Hydraulic Schematic
Electrical Connection Diagram
Error Codes
Hardware
Junction Box Terminal Table
Performance
Power Tree
PERIODIC MAINTENANCE
500-Hour Maintenance (6012810)
SERVICE
AFC Valves Service (6095128)
PARTS MANUAL
Parts Manual (6095129)
APPENDIX
Glossary (6095130)
i
O VERVIEW
Accumulator
Proportional
Drop/Stop
Computer Controller Pressure
Valve
Control Valve
Load Parameter
Override
Selector:
Switch
Auto Switch
6095121-R1 1
O VERVIEW
Basic System
Controller – Mobile equipment controller that directs AFC
Options
system operation. The controller is calibrated using a Service Driver Display – A driver's display shows checked hydraulic
Pendant with a simple, menu-driven setup procedure. The pressure in the clamp cylinders, low/medium/high load
controller measures the load weight being handled using parameters selected, OK to hoist, and other AFC status
hydraulic sensors on the attachment. Based on the type of including system error(s) or that the AFC system is in override
attachment and contact pads being used, values entered into mode where the driver controls clamp pressure.
the controller are combined with default values that direct the Drop/Stop Valve – Provides protection against unwanted
AFC to apply the correct hydraulic pressure/clamp force for the Clamp movement due to slack chains and accumulator 'jump'
load weight. when load is set down and unclamped.
Proportional Pressure Control Valve – Proportions the correct Auto Switch – Automatically adjusts clamp force-to-weight
pressure to the clamp cylinders for appropriate clamp force ratio and starting pressure when handling different load sizes
required to handle a specific load weight. and types. Based on arm position and roll diameter.
Priority Flow Control Valve – Provides a constant priority flow Override Switch – Enables driver to override AFC features
required for AFC system operation. when maximum clamp pressure is required. Examples include
Transducers & Sensor Switches – Pressure transducers in trailer and railcar breakout. Driver controls clamp pressure.
the CLAMP and HOIST hydraulic circuits provide pressure AFC Datalogger – Records clamp force and other pertinent
feedback. The sensor switches on the mast provide freelift/ data during clamping operation. Clamp force data is captured
mainlift and maximum lift position feedback to the controller. and stored in a file that can be downloaded to a personal
Status Light – A two LED indicator that shows system computer or permanent storage device for analysis.
status and is mounted for driver view. Each indicator has two Scanner – Reads barcodes and sends product identification to
functions per LED: Green (ok to lift and override mode) and the AFC Datalogger to be stored.
Red (Do not lift and error).
Junction Box – Provides all required connections between Other Damage-Reduction Options
the controller, solenoid valves, limit switches, transducers and Tilt Control – Provides a precise vertical mast position,
display. Weatherproof design and labeled connectors aid enabling drivers to square the pads to the load each time.
in continuous operation and ease of system installation and Resulting full pad contact reduces the amount of clamp force
checkout. necessary, prevents load slippage, and decreases chances of
Power Supply & Communication Cable Reel – Coil cord unit edge damage to rolls or as they are set down.
provides over-the-mast connections for transducers and auto Rotational Control – Provides a precise vertical and horizontal
switch. stop during rotation so pads are square to the load when
Accumulator – An accumulator in the hoist circuit absorbs clamping a roll or tier. Prevents pads from cutting into the load
load handling shocks and reduces the clamp force required as it is picked, and reduces the chance for edge damage when
to handle a load. The accumulator provides smoother AFC setting loads down.
operation and better clamp force accuracy. Clamp Open Guard – Provides a safeguard against accidently
DC-to-DC Converter – For use on electric powered trucks to unclamping before the load is securely set down.
enable the AFC to be used with electrical power systems of any
voltage. Provides 12 VDC power to the AFC system.
2 6095121-R1
O VERVIEW
Display
(Optional)
Scanner
(Optional)
Maximum Lift
Sensor Switch
Power Supply/
AFC Override Communications
Switch Cable
(Optional)
Freelift Sensor
Datalogger Switch
(Optional)
Status Light
Priority
Flow
Control
Valve Clamp
Line
Filter Revolving
Dedicated Connection
Return to Slip Ring
Tank Line Controller
Hoist
Accumulator
Proportional
Pressure
Control Valve Hoist Pressure
Transducer
OR Carriage
Optional Hoist Cable
Drop/ Stop Junction
Valve
RC3364.eps
Cylinder
Pressure
Transducer
Auto Switch
Linear Transducer
(optional)
6095121-R1 3
O VERVIEW
Load Considerations
Paper Roll Clamps
The AFC may be set up for a wide variety of paper roll product.
See the table in Setup Instructions 6095125, Page 9, for various
load types you may be handling. After initial setup, testing
must be done with various loads you are handling to verify
optimum operation.
• Rolls must be clamped properly for the AFC features to
prevent roll damage while clamping, hoisting, traveling over
dockplates or floor bumps, and unloading. For maximum
contact pad surface friction, assure the roll is clamped
through the roll centerline, and the contact pads are parallel
to the roll. See Cascade attachment Operator's Guides for
recommended and safe handling procedures.
• The AFC system will work best when the contact pads are in
serviceable condition and are of the correct type. Pad and
contact surface choice is important if the AFC is to prevent
damage during roll handling.
• A variety of roll clamp contact pads shown below are offered
by Cascade:
RC1129.eps
4 6095121-R1
O VERVIEW
6095121-R1 5
c
Installation Adaptive Force
Instructions Control Kits
This manual provides installation instructions for Cascade Adaptive Force Control Kits. The Adaptive Force Control supplies a
preset initial clamp force and when lifted, the load is weighed and clamp force is automatically adjusted. Significant damage
reduction is achieved by not over clamping loads.
Junction Box
Light Tower
(Optional) Display
(optional) Maximum Lift
Sensor Switch
Part
er,
Numb
er:
60758
63
Devic
e
Part
Numb
er:
Freelift Sensor
60758
63
TM
Datalogger Switch
(optional)
Status
Light
AFC Override
Switch (optional)
Priority Flow
Control Valve
Clamp
Filter Revolving
Return to Line Connection
Tank Fitting Connector
Controller
AC1776.eps
Accumulator
Proportional Hoist Pressure
NOTE: UL Classified Kits require Pressure Transducer
installation by qualified personnel Control Valve OR
only without major disturbance, Optional Hoist
cutting, splicing for soldering of Drop/Stop Valve
factory installed wiring.
Carriage
IMPORTANT: Leave clearance between components to Cable Cylinder
allow for fittings, hoses and cables. Watch for clearance Connector Pressure
when fully tilting back the mast. Transducer
No. 6
NOTE: Due to different truck configurations, it may be O-Ring
possible to connect directly to the auxiliary valve as shown Port in Valve
or a hose may be needed between the main control valve
Valve
Control
and priority flow control valve.
Priority
AC0216.eps
p
WARNING: Do not start the truck until all hoses Pum No. 10
Hose to
have been installed to the Priority Flow Control proportional O-Ring Ports
Valve and Proportional Pressure Control Valve. flow valve in Valve
The truck pump and hydraulic system may (installed in
be damaged. Double check the hosing and step 10).
connections to the valve against the schematic
before starting the truck.
Installation AC0341.eps
with hose.
Valve
Control
Priority
p
Hoist Clamp Pum
Control Auxiliary
Valve Valve NOTE: 5/16 in. (8 mm)
1
capscrews may be used
if needed.
Control To Proportional
Return to 2
Priority
Valve
Priority Flow Pressure Control
Valve Tank Fitting
Control Valve Pump
Truck
Truck Relief
Hydraulic Valve
Pump Truck
Tank
AC0214.eps
Return to
tank line
Hose to
proportional
flow valve
(installed in
step 9).
AC0226.eps
2 6095124-R4
3 Hoist Drop Stop Valve (if equipped, otherwise go to step 7) –
Position the optional hoist drop stop valve on the truck cowl and
mark the mounting holes. Mount the valve using two 5/16 in.
(8 mm) capscrews. Hose to accumulator
NOTE: An alternate location is to mount the valve directly to the (installed in step 14).
mast valve.
6 No. 8
O-Ring
fitting
Solenoid
No. 1
Solenoid
No. 4
4
Connect hose from
fittings
AC1611.eps
hoist control valve.
WARNING: Mast carriage must be fully lowered or
blocked prior to removing mast cylinder hoses.
5
Hoist Drop
Accum Stop Valve
Hoist (if equipped)
Mast
Hoist Truck
4
Hoist Clamp
Control Auxiliary
Valve Valve
Control
Priority Flow To Proportional
Priority
Valve Return to
Control Valve Pressure Control
Pump Valve Tank Fitting
Truck
Truck Relief
Hydraulic Valve
Pump Truck
Tank
AC0444.eps
6095124-R4 3
7 Position the proportional pressure control valve on the
truck cowl and mark the mounting holes. Mount the valve
using two 5/16 in. (8 mm) capscrews.
8 Install fittings in ports marked CLAMP, OPEN and TANK.
NOTE: Cascade provides many of the special fittings
needed for efficient installation. Check your installation kit. 8 No. 6 O-Ring
fittings
Proportional
Flow Valve
Position 4
valve
on truck
cowl. 7
8 No. 8
O-Ring
fitting
TANK
10 Connect hose
to Priority Flow
Control Valve
Port 3.
AC1612.eps
Solenoid Valve
No. 3
9
Install low
Proportional
Relief Valve
No. 2
pressure hose
to tank return fitting.
7
Proportional Pressure
Control Valve
10 Priority Tank 9
Clamp Open
Hoist Clamp
Control Auxiliary
Valve Valve
Priority Control
Flow
Priority
Valve Return to
Control Tank Fitting
Valve Pump
Truck
Truck Relief
Hydraulic Truck
Valve Tank
Pump
AC1677.eps
4 6095124-R4
IMPORTANT: If equipped with Clamp Open Guard, the
solenoid valve must be installed between the truck auxiliary
11
valve and the AFC Proportional Control Valve valve. Connect hoses
from auxiliary
11 Connect with a tee fitting, two hoses (user supplied) valve.
from the truck auxiliary valve (clamp/open circuit) to the
proportional pressure control valve CLAMP and OPEN
ports. Install the filter in the clamp line. Open
12 Connect two hoses (user supplied) from the proportional
pressure control valve ports to the attachment CLAMP/
12
OPEN supply hoses (internal reeving or hose reel). Connect hoses
to attachment
Clamp
supply hoses.
Plug top
ports
Clamp
4 4
12
Connect hoses
Filter
AC1613.eps
Open
OR AC1614.eps
Proportional Pressure
Control Valve
Proportional
Flow Valve
Priority Tank
Clamp Open 12
11
Connect hoses
Filter
from auxiliary
11
valve. Filter
Attachment
Valve or
Revolving
Hoist Clamp Connection
Control Auxiliary
Valve Valve
Clamp Open
Guard Valve
(if equipped)
Priority Control
Priority
Flow Valve
Return to
Control Tank Fitting
Pump
Valve
Truck
Truck Relief
Hydraulic Truck
Valve Tank
Pump
AC2027.eps
6095124-R4 5
14
Hose to
HOIST line
13 Position the accumulator (precharged to 1000 psi with tee
nitrogen) on the truck cowl and mark the mounting
holes. Mount the accumulator using four 5/16 in. (8 mm) Pressure
capscrews. Transducer
Manifold
NOTE: A good alternate mounting location for the
accumulator is on the mast.
Plug OR
manifold
end
14 Pressure Transducer Manifold Equipped – Install a tee
into the hoist line. Connect a hose (user supplied) to tee.
Connect Pressure Transducer Manifold (part no. 6093619) Plug
to the hose. Plug the pressure transducer manifold hose
until the accumulator operational pressure has been end
determined during setup and calibration.
13
a hose (user supplied) from the accumulator to the hoist
14
drop stop valve ACCUM port. Plug the hose end at
the accumulator until the accumulator operational
pressure has been determined during setup and
calibration. Mount Accumulator
Hose to
(Precharged to
Hoist Drop
1000 psi with
Stop Valve
nitrogen)
To Hoist Drop
Stop Valve
AC1708.ai
13 13
14 Proportional
Flow Valve
14
Priority Tank
Attachment
Mast Cylinder Valve or
Clamp Revolving
Hoist Circuit Auxiliary Connection
Valve
Hoist
Control
Valve
Control
Priority
Valve
Priority Flow Return to
Control Valve Pump Tank Fitting
Truck
Truck Relief
Hydraulic Truck
Valve Tank
Pump
AC1679.eps
6 6095124-R4
Electronic Component Installation
NOTE: Refer to the "Wire Preparation and Installation" Section
and Junction Box Terminal Table to install cables to the
junction box. Mount all hardware first, then run cables to
1
junction box. Use labels to mark free ends. Mount
IMPORTANT: Watch for clearance when fully tilting back junction
the mast. box
AC1616.eps
4 Mount
light
tower
4 Mount the light tower (if equipped). Route the free end
cable wires to the junction box. For complete installation
OR
5
Mount
procedure, refer to Installation Instructions 6097528. light
bar
6
HIGH
LOW
7
Mount freelift Inner Upright
sensor switch Crossmember
7 Mount the freelift sensor switch that will signal the transition .5 in.
(12 mm)
from freelift to mainlift. The provided mounting bracket
can be used or modified to aid with mounting (example
shown). Refer to the dimensions shown in the example for
optimal operating distance. Use cable ties to secure the
cable leaving slack for mast tilt. Route the free cable end
to the junction box. .15 in.
(4 mm) Freelift Outer Upright
Sensor Top Crossmember
Switch
AC1618.ai
6095124-R4 7
8 Mount the maximum lift sensor switch. This switch will .3 in.
Fixed Outer
signal that the mast is within .25 in. (6 mm) of maximum Upright
(8 mm)
lift height. Refer to dimensions in the example shown
for optimal operating distance. The provided mounting Moving
bracket can be used or modified to aid with mounting. Intermediate
Use cable ties to secure the sensor switch cable leaving Upright
slack for mast tilt. Route the free end cable wires to the
8
junction box. Mount
AC1619.ai
NOTE: It may be necessary to make a final adjustment maximum
once the switches are powered. lift sensor
switch
9 Install the AFC override switch (if equipped) to the clamp
control lever. Position the switch on the handle in a Maximum
location for comfortable thumb or index finger operation. .15 in. Lift Sensor
Place the double sided tape under the switch to secure (4 mm) Switch
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. Connect the
switch cable connector to the connector cable installed
in step 8.
9 Install switch
14 Connect a wire from the Power Bus + Power Input to an 18 Connect the connector ends to PT2 and PT4 located on
unswitched power source. the Proportional Flow Valve. Route the free end cable
wires for PT2 and PT4 to the junction box.
15 Connect a wire from the Power Bus + Keyed Input to a
switched power source. 19 Connect the solenoid end to the Sol2 and Sol3 coils. Route
Sol2 and Sol3 free end cable wires to the junction box.
16 Connect ground wires from the Power Bus – Power and
Keyed Inputs to the truck chassis. 20 Connect the connector end to PT1 located on the Hoist
Drop Stop Valve (is equipped) or the Pressure Transducer
17 Connect the power wire (6090947) to the Power Bus Manifold. Route the free end cable wires for PT1 to the
output terminals. If not connected, install the power wires junction box.
to the junction box.
ELECTRIC TRUCKS – When a DC/DC converter is used, 21 Connect the solenoid end to the Sol1 and Sol4 coils to the
the cable harness negative wire must be connected to the Hoist Drop Stop Valve (if equipped). Route Sol1 and Sol4
converter NOT the truck chassis. free end cable wires to the junction box.
NOTE: If power bus is NOT used, connect the (+) and (-) 22 Connect cable 6090924 to the power supply connector or
power cables to a 12V 7.5 amp key switch circuit or relay. jumper assembly. Route the free end cable wires for PT3
Verify the connection polarity. Wire 1 is (+) and wire 2 is (-). to the junction box.
NOTE: For roll clamps with split arms, PT3 should be
installed in the pressure transmitter group.
23 ELECTRIC TRUCKS – Install the pump relay. Splice the
wires into the truck pump switch circuit. Connect the
relay connector to the cable harness.
8 6095124-R4
6 Conductor Electric Junction Box Terminal Table
23
Power Supply/ Truck
Communication Pump
Installation Junction Box Terminal/ Terminal/ Terminal/ Terminal/ Terminal/ Terminal/
Maximum Freelift
Sensor Group Switch 2 3 Step Port Cable Wire Wire Wire Wire Wire Wire
Lift Sensor
Switch Switch Relay 3 3 6090897 Display B1 / RD C1 / GN + / WH - / BK
1 4 6096063
4 1 H3 / WH H3- / BK
8
Light Tower
7 18
Electric 6092913
5 3 H3 / WH H3- / BK J3 / RD
Truck Status Light
Pump To Junction 6 2 6804099 Switch box F1- / RD F1 / BK E3 / WH
Box Port 4
6092972
7 2 F3 / BK F3+ / BN F3- / BU
Free/Main Lift
PT2 PT4 8 2 6092972 Max Lift F2 / BK F2+ / BN F2- / BU
Switch Box 6091024
(optional) 10 2 G3+ / BK G3 / WH
Proportional Override
PT3 LT1
To Junction Pressure 6079562
Box Port 2 Clamp Control Valve 11 3 B1 / BK C1 / WH
Datalogger
6
Cylinder
Slip Ring 6090962
Auto Switch 12 2 A1 / GN A2 / OG B2 / BK A3 / RD E3 / WH
(optional)
Pendant Cable
SOL2 SOL3
19
16 3 6090947 Power +/1 -/2
OR
20 18
19
1
4
6092862
Transducer PT2, PT4
6090961 SOL2
E2- / BU
H2 / BU
E2+ / OG
G2 / BN
E2 / GN E1- / BK E1+ / WH E1 / RD
22
PT1 6090959
Transducer
SOL1 20 1 D2- / BK D2+ / WH D2 / RD
Manifold Transducer PT1
Hoist Drop
Stop Valve 21 4 6090961 SOL1 G1- / BU G1 / BN
(optional) 21 4 6090961 SOL4 J1- / BU J1 / BN
6090924 Pressure Transducer Autoswitch
Junction Controller 22 1
Optional AFC
Box Mast Cable D1 / RD D1+ / WH D1- / BK E3 / GN F1 / OG F1- / BU
Override Switch
(Normally Open) 23 1 6090924 Relay ✖ J2- / BK J2 / WH
1 2 3 4
21 ✖ Share terminals with Solenoid 3
9 Service Pendant
BU
BN
Blue
Brown
RD
WH
Red
White
YE Yellow
Display
13
Fuse 5
1 Remove junction box cover.
2 Note recommended junction box port for each cable. 4
11 17
Power Bus/Relay Status Light
Loosen strain relief and pull cable through.
3 Determine the proper wire lengths, cut and strip wire ends 5
3
1 2 3 4
–+–+–+–+ -+ +- as shown.
IMPORTANT: Do not strip more than .25 in. (6 mm)
4
maximum. Junction
Unswitched
4 Place screwdriver into slot to open the wire terminal. Box Port/
14
Scanner
16
Strain Relief
Gently pivot the screwdriver away from the wire terminal.
Light Tower
Ground (optional) 5 Insert the wire into the wire terminal and remove the screw Max. .25 in.
driver from the slot. Pull wire to test for secure connection. (6 mm)
Switched
Datalogger
Status LED Truck
DC Converter
(if equipped)
15 To Junction
Box Port 1
6 When junction box wiring is complete, check for unused
holes in grommet. Insert a 1 in. (25 mm) long piece of
wire to plug the unused holes.
Fuse Block 7 Tighten strain reliefs.
IC Trucks – Key
WARNING: For UL Classified 8 Install junction box cover and tighten capscrews.
Datalogger Use chassis ground
kits, to reduce the risk of fire,
(optional) Electric Trucks –
Truck Use battery ground replace only with same type AC1640.eps
AC2022.eps
Battery and rating of fuse.
6095124-R4 9
Blank
10 6095124-R4
6 Conductor
Power Supply
24
AC1135.eps
Disabling AFC
C
L
A
M
P
6095124-R4 11
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 Cascade Canada Inc. Cascade do Brasil
U.S. Headquarters 5570 Timberlea Blvd. Praça Salvador Rosa,
2201 NE 201st Mississauga, Ontario 131/141-Jordanópolis,
Fairview, OR 97024-9718 Canada L4W-4M6 São Bernardo do Campo - SP
Tel: 800-CASCADE (227-2233) Tel: 905-629-7777 CEP 09891-430
Fax: 888-329-8207 Fax: 905-629-7785 Tel: 55-13-2105-8800
Fax: 55-13-2105-8899
EUROPE-AFRICA
Cascade Italia S.R.L. Cascade (Africa) Pty. Ltd.
European Headquarters PO Box 625, Isando 1600
Via Dell’Artigianato 1 60A Steel Road
37030 Vago di Lavagno (VR) Sparton, Kempton Park
Italy South Africa
Tel: 39-045-8989111 Tel: 27-11-975-9240
Fax: 39-045-8989160 Fax: 27-11-394-1147
ASIA-PACIFIC
Cascade Japan Ltd. Cascade Korea Cascade-Xiamen Cascade India Material
2-23, 2-Chome, 121B 9L Namdong Ind. No. 668 Yangguang Rd. Handling Private Limited
Kukuchi Nishimachi Complex, 691-8 Gojan-Dong Xinyang Industrial Zone No 34, Global Trade Centre
Amagasaki, Hyogo Namdong-Ku Haicang, Xiamen City 1/1 Rambaugh Colony
Japan, 661-0978 Inchon, Korea Fujian Province Lal Bahadur Shastri Road,
Tel: 81-6-6420-9771 Tel: +82-32-821-2051 P.R. China 361026 Navi Peth, Pune 411 030
Fax: 81-6-6420-9777 Fax: +82-32-821-2055 Tel: 86-592-651-2500 (Maharashtra) India
Fax: 86-592-651-2571 Phone: +91 020 2432 5490
Fax: +91 020 2433 0881
Cascade Australia Pty. Ltd. Cascade New Zealand Sunstream Industries
1445 Ipswich Road 15 Ra Ora Drive Pte. Ltd.
Rocklea, QLD 4107 East Tamaki, Auckland 18 Tuas South Street 5
Australia New Zealand Singapore 637796
Tel: 1-800-227-223 Tel: +64-9-273-9136 Tel: +65-6795-7555
Fax: +61 7 3373-7333 Fax: +64-9-273-9137 Fax: +65-6863-1368
c
© Cascade Corporation 2010 11-2010 Part Number 6095124-R4
All steps of these instructions must
Installation
warranty coverage.
UL Classified
Roller
Assembly
NOTE: Major
components shown.
Cable
Conduit IMPORTANT: For best performance, Power
Supply/Communication Kit must be mounted in
a clear area on side of mast as shown. Conduit
must remain straight and clear mast tilt anchors
and center crossmembers. Roller Assembly
should be as close to top of channels as possible.
Coiled
Conductor
Cable
Conduit
Carriage Anchor
Cable
Junction
Block Lower Cable
End Connector
Carriage Cable
End Connector
Push Button Switch
(Normally Open)
2
NOTE: Kits are UL Classified (File # 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.
Power Maximum
Supply Mast 1 Fork Conductors Supply
Group Height (in.) (No. @ AWG) Application Notes
6844331 166 2 @ 18 Cascade Products – Switched, 12V 2
6844332 166 2 @ 18 Cascade Products – Switched, 24-48V 3
6844333 166 2 @ 18 ERC – Unswitched
6844334 166 4 @ 26 Sensor Applications 4
6844335 166 2 @ 20 & 4 @ 26 AFC & ERC – Unswitched 5
6844336 189 2 @ 18 Cascade Products – Switched, 12V 2
6844337 189 2 @ 18 Cascade Products – Switched, 24-48V 3
6844338 189 2 @ 18 ERC – Unswitched
6844339 189 4 @ 26 Sensor Applications 4
6844340 189 2 @ 20 & 4 @ 26 AFC & ERC – Unswitched 5
6844341 218 2 @ 18 Cascade Products – Switched, 12V 2
6844342 218 2 @ 18 Cascade Products – Switched, 24-48V 3
6844343 218 2 @ 18 ERC – Unswitched
6844344 218 4 @ 26 Sensor Applications 4
6844345 218 2 @ 20 & 4 @ 26 AFC & ERC – Unswitched 5
6844346 240 2 @ 18 Cascade Products – Switched, 12V 2
6844347 240 2 @ 18 Cascade Products – Switched, 24-48V 3
6844348 240 2 @ 18 ERC – Unswitched
6844349 240 4 @ 26 Sensor Applications 4
6844350 240 2 @ 20 & 4 @ 26 AFC & ERC – Unswitched 5
6844351 320 2 @ 18 Cascade Products – Switched, 12V 2
6844352 320 2 @ 18 Cascade Products – Switched, 24-48V 3
6844353 320 2 @ 18 ERC – Unswitched
6844354 320 4 @ 26 Sensor Applications 4
6844355 320 2 @ 20 & 4 @ 26 AFC & ERC – Unswitched 5
1 Simplex, dual or triple masts only.
2 To maintain UL rating, do not exceed 5A load.
3 To maintain UL rating, do not exceed 2A load.
4 Do not use 26 AWG for high voltage or high current applications; 26 AWG rated @ .25A.
5 Do not use 26 AWG for high voltage or high current applications; 26 AWG rated @ .25A, 20 AWG rated @ 5A.
3
Power Supply/Communication Kit
Installation
1
IMPORTANT: Check that the Power Supply/Communication Kit Remove cable from
negative battery
is appropriate for the truck mast’s maximum fork height (MFH). terminal.
NOTE: If replacing an older supply/communication kit, the
new kit can be installed on the old mounting bracket for the
roller assembly. Only the front mounting hole is necessary
for installation. Install new roller assembly so that the roller
capscrew is aligned with old location of the roller hole, facing
forward. For back roller hole, install kit self-locking nut to a
shorter kit capscrew. Watch for cable
GA0436.eps interference with upper
crossmember when
1 Disconnect the cable from the negative battery terminal or carriage is raised.
as directed by OEM truck manual.
16 in.
(400 mm)
Maximum
2
(toward rear of mast) as possible, watching for clearance
problems with the upper crossmember. The cable junction
block and anchor plate must clear the roller assembly. Allow
7.5 in. (190 mm) between the carriage and roller assembly Position the
conduit port. roller assembly
back as far as
possible.
Cable junction
7.5 in. (190 mm) min. block and
clearance between carriage
3 Mark a mounting location for the roller assembly spacer and center of roller
anchor plate
block on the mast outer rail. If the spacer cannot be must clear roller
assembly conduit port. when raised.
mounted to the side of the mast, an alternate mounting
AC2482.eps
such as an L-shaped bracket attached to the back of the
mast outer rail should be used, as shown. FRONT SIDE
6
the spacer block to the mast, weld Spacer Plate
modifications to the mast rails must be Roller (if required) AC2340.eps
approved by the mast OEM. Assembly
7
Alignment Tool Raise
carriage
1/8 in. (3 mm)
8
maximum
off-center
alignment AC2483.eps
Locate carriage
cable junction
block and anchor
plate using
alignment tool
Carriage Bar
AC2484.eps
8 Center cable
terminal with roller Break off tool
Anchor Plate
9
± 1/8 in. (3 mm) end at required Tack
length weld
10
Cable
Junction
Block
Capscrew
and
Washer
Back
(Driver's)
View 2 in. (50 mm)
AC2486.eps
5
12 Locate and mark the side of mast rail for the cable
conduit lower anchor.
CAUTION: Make sure cable conduit is aligned vertically.
Do not cut or trim cable conduit.
13 Remove the cable from the roller assembly.
cable end connectors together.
Join the
12,
per manufacturer’s directions. Cable
Junction
16 Remove the roller assembly from upper spacer.
14,
17 Install the roller assembly, conduit and cable clamps.
Use the spacer plate and longer capscrews (if required)
for conduit clearance on the mast.
15
IMPORTANT: If a spacer block needs to be removed, tap
the glue joint with a chisel and it will separate. Remove
all adhesive from the mating parts, clean and reapply per
manufacturer’s directions.
Install conduit to roller assembly as follows:
A Thread the nut onto conduit, leaving 3/8 in. (10 mm) of
threads above the nut.
Spacer
B Thread conduit/nut assembly inside roller assembly. Plate (if
AC2487.eps
17 3/8 in.
C
3/16 in.
(5 mm)
(10 mm) max.
A from nut above
Thread
nut onto
conduit
AC2375.eps
18
Install
Switch
18 Control Handle Switch (if equipped) – Install push
button switch to control handle. Refer to Installation
Instructions 6822725 included with a switch, for complete
installation procedure.
19 If it is difficult to feel or operate the switch button through
the heat shrink tube, carefully cut a circle out of the tubing
around the button.
Control Handle
and Knob
AC2242.eps
6
20 Connect the power cable (if supplied) to the power supply
lower cable end connector and truck power as marked.
Watch for pinch and wear points. Install cable ties as
needed.
21 Control Handle Switch (if equipped) – Connect the
control handle switch connector to the power cable
connector. Watch for pinch and wear points. Install cable
ties as needed.
22 Connect the attachment wires to the cable adapter (if
supplied). Connect the attachment cable to the carriage
22 21
junction block cable connector. Watch for pinch and wear
points. Install cable ties as needed.
20
Power
Supply
AC2488.eps
Connect
cable ends
Carriage Junction Control
Block Cable Handle
Terminal Connector
Control
Handle Fuse
Switch (2 or 5 Amp)
(if equipped)
Key
Attachment
Power Cable
Battery
AC2494.eps
Attachment Carriage
Cable
7
Power Supply/Communication Groups
Maximum Mast Fork Height – 166 in.
@
! 0
#
$
%^ °
&
5 6
9
∙ 8 7
‹ 1
‡ )
(
*
⁄ ¤
4
fl
fi
› 3
2
AC2510.eps
8
Power Supply/Communication Groups
Maximum Mast Fork Height – 166 in.
Power Maximum
Supply Mast ➀ Fork Conductors Supply
Group Height (in.) (No. @ AWG) Application Notes
6844331 166 2@ 18 Cascade Products – Switched, 12V 2
6844332 166 2 @ 18 Cascade Products – Switched, 24V-48V 3
6844333 166 2 @ 18 ERC – Unswitched
6844334 166 4 @ 26 Sensor Applications 4
6844335 166 2 @ 20 & 4 @ 26 AFC & ERC – Unswitched 5
1 Simplex, dual or triple masts only.
2 To maintain UL rating, do not exceed 5A load.
3 To maintain UL rating, do not exceed 2A load.
4 Do not use 26 AWG for high voltage or high current applications; 26 AWG rated @ .25A.
5 Do not use 26 AWG for high voltage or high current applications; 26 AWG rated @ .25A, 20 AWG rated @ 5A.
AFC: Adaptive Force Control
ERC: Electronic Rotational Control
REF QTY PART NO. PART NO. PART NO. PART NO. PART NO. DESCRIPTION
6844331 6844332 6844333 6844334 3844335 Power Supply Group
1 1 6844356 6844356 6844356 6844361 6844366 Cable Assembly
2 1 6001647 6811810 — — — Wire Harness – Power
1 — 6806701 — — — Fuse, 2 Amp, UL Classified ◆
3
1 6806708 — — — — Fuse, 5 Amp, UL Classified ◆
4 1 6009994 6009994 — — — Switch
5 1 6846004 6846005 6846006 6846007 6846008 Power Supply Kit Decal
◆ To maintain UL Rating, replace with specified fuses.
Common Parts
REF QTY PART NO. DESCRIPTION REF QTY PART NO. DESCRIPTION
6844329 Power Supply Install Kit ● 18 1 6832205 Clamp
6 1 6818145 Sheave Assembly ■ 19 2 6026763 Spacer Plate
7 1 6820449 Conduit 20 1 6819937 Spacer Block
8 1 6838404 Nut 1 206321 Capscrew, M6 x 16
21
9 1 6819600 Back Plate 1 763169 Capscrew, M6 x 20
10 1 6818146 Bracket 22 1 206323 Washer, M6
11 2 6819200 Bearing 23 1 6844372 Junction Block
12 1 6806108 Roller 24 2 767614 Capscrew, M10 x 20
13 1 6819224 Spacer Plate 25 1 6400135 Washer, M10
14 2 786881 Nut 26 1 6846510 Hose Clamp
15 2 6819533 Capscrew, M8 x 65 27 1 6846511 Anchor Plate
2 6819534 Capscrew, M8 x 70 28 1 6027117 Alignment Tool
16
2 6026778 Capscrew, M8 x 80 29 1 6846222 UL Decal
17 2 6820902 Spacer Plate
● Includes items 17 - 29.
■ Includes items 10 - 16.
9
Power Supply/Communication Groups
Maximum Mast Fork Height – 189 in.
@
! 0
#
$
%^ °
&
5 6
9
∙ 8 7
‹ 1
‡ )
(
*
⁄ ¤
4
fl
fi
› 3
2
AC2510.eps
10
Power Supply/Communication Groups
Maximum Mast Fork Height – 189 in.
Power Maximum
Supply Mast ➀ Fork Conductors Supply
Group Height (in.) (No. @ AWG) Application Notes
6844336 189 2 @ 18 Cascade Products – Switched, 12V 2
6844337 189 2 @ 18 Cascade Products – Switched, 24V-48V 3
6844338 189 2 @ 18 ERC – Unswitched
6844339 189 4 @ 26 Sensor Applications 4
6844340 189 2 @ 20 & 4 @ 26 AFC & ERC – Unswitched 5
1 Simplex, dual or triple masts only.
2 To maintain UL rating, do not exceed 5A load.
3 To maintain UL rating, do not exceed 2A load.
4 Do not use 26 AWG for high voltage or high current applications; 26 AWG rated @ .25A.
5 Do not use 26 AWG for high voltage or high current applications; 26 AWG rated @ .25A, 20 AWG rated @ 5A.
AFC: Adaptive Force Control
ERC: Electronic Rotational Control
REF QTY PART NO. PART NO. PART NO. PART NO. PART NO. DESCRIPTION
6844336 6844337 6844338 6844339 6844340 Power Supply Group
1 1 6844357 6844357 6844357 6844362 6844367 Cable Assembly
2 1 6001647 6811810 — — — Wire Harness – Power
1 — 6806701 — — — Fuse, 2 Amp, UL Classified ◆
3
1 6806708 — — — — Fuse, 5 Amp, UL Classified ◆
4 1 6009994 6009994 — — — Switch
5 1 6846009 6846010 6846011 6846012 6846013 Power Supply Kit Decal
◆ To maintain UL Rating, replace with specified fuses.
Common Parts
REF QTY PART NO. DESCRIPTION REF QTY PART NO. DESCRIPTION
6844329 Power Supply Install Kit ● 18 1 6832205 Clamp
6 1 6818145 Sheave Assembly ■ 19 2 6026763 Spacer Plate
7 1 6820449 Conduit 20 1 6819937 Spacer Block
8 1 6838404 Nut 1 206321 Capscrew, M6 x 16
21
9 1 6819600 Back Plate 1 763169 Capscrew, M6 x 20
10 1 6818146 Bracket 22 1 206323 Washer, M6
11 2 6819200 Bearing 23 1 6844372 Junction Block
12 1 6806108 Roller 24 2 767614 Capscrew, M10 x 20
13 1 6819224 Spacer Plate 25 1 6400135 Washer, M10
14 2 786881 Nut 26 1 6846510 Hose Clamp
15 2 6819533 Capscrew, M8 x 65 27 1 6846511 Anchor Plate
2 6819534 Capscrew, M8 x 70 28 1 6027117 Alignment Tool
16
2 6026778 Capscrew, M8 x 80 29 1 6846222 UL Decal
17 2 6820902 Spacer Plate
● Includes items 17 - 29.
■ Includes items 10 - 16.
11
Power Supply/Communication Groups
Maximum Mast Fork Height – 218 in.
@
! 0
#
$
%^ °
&
5 6
9
∙ 8 7
‹ 1
‡ )
(
*
⁄ ¤
4
fl
fi
› 3
2
AC2510.eps
12
Power Supply/Communication Groups
Maximum Mast Fork Height – 218 in.
Power Maximum
Supply Mast ➀ Fork Conductors Supply
Group Height (in.) (No. @ AWG) Application Notes
6844341 218 2 @ 18 Cascade Products – Switched, 12V 2
6844342 218 2 @ 18 Cascade Products – Switched, 24V-48V 3
6844343 218 2 @ 18 ERC – Unswitched
6844344 218 4 @ 26 Sensor Applications 4
6844345 218 2 @ 20 & 4 @ 26 AFC & ERC – Unswitched 5
1 Simplex, dual or triple masts only.
2 To maintain UL rating, do not exceed 5A load.
3 To maintain UL rating, do not exceed 2A load.
4 Do not use 26 AWG for high voltage or high current applications; 26 AWG rated @ .25A.
5 Do not use 26 AWG for high voltage or high current applications; 26 AWG rated @ .25A, 20 AWG rated @ 5A.
AFC: Adaptive Force Control
ERC: Electronic Rotational Control
REF QTY PART NO. PART NO. PART NO. PART NO. PART NO. DESCRIPTION
6844341 6844342 6844343 6844344 6844345 Power Supply Group
1 1 6844358 6844358 6844358 6844363 6844368 Cable Assembly
2 1 6001647 6811810 — — — Wire Harness – Power
1 — 6806701 — — — Fuse, 2 Amp, UL Classified ◆
3
1 6806708 — — — — Fuse, 5 Amp, UL Classified ◆
4 1 6009994 6009994 — — — Switch
5 1 6846014 6846015 6846016 6846017 6846018 Power Supply Kit Decal
◆ To maintain UL Rating, replace with specified fuses.
Common Parts
REF QTY PART NO. DESCRIPTION REF QTY PART NO. DESCRIPTION
6844329 Power Supply Install Kit ● 18 1 6832205 Clamp
6 1 6818145 Sheave Assembly ■ 19 2 6026763 Spacer Plate
7 1 6820449 Conduit 20 1 6819937 Spacer Block
8 1 6838404 Nut 1 206321 Capscrew, M6 x 16
21
9 1 6819600 Back Plate 1 763169 Capscrew, M6 x 20
10 1 6818146 Bracket 22 1 206323 Washer, M6
11 2 6819200 Bearing 23 1 6844372 Junction Block
12 1 6806108 Roller 24 2 767614 Capscrew, M10 x 20
13 1 6819224 Spacer Plate 25 1 6400135 Washer, M10
14 2 786881 Nut 26 1 6846510 Hose Clamp
15 2 6819533 Capscrew, M8 x 65 27 1 6846511 Anchor Plate
2 6819534 Capscrew, M8 x 70 28 1 6027117 Alignment Tool
16
2 6026778 Capscrew, M8 x 80 29 1 6846222 UL Decal
17 2 6820902 Spacer Plate
● Includes items 17 - 29.
■ Includes items 10 - 16.
13
Power Supply/Communication Groups
Maximum Mast Fork Height – 240 in.
@
! 0
#
$
%^ °
&
5 6
9
∙ 8 7
‹ 1
‡ )
(
*
⁄ ¤
4
fl
fi
› 3
2
AC2510.eps
14
Power Supply/Communication Groups
Maximum Mast Fork Height – 240 in.
Power Maximum
Supply Mast ➀ Fork Conductors Supply
Group Height (in.) (No. @ AWG) Application Notes
6844346 240 2 @ 18 Cascade Products – Switched, 12V 2
6844347 240 2 @ 18 Cascade Products – Switched, 24V-48V 3
6844348 240 2 @ 18 ERC – Unswitched
6844349 240 4 @ 26 Sensor Applications 4
6844350 240 2 @ 20 & 4 @ 26 AFC & ERC – Unswitched 5
1 Simplex, dual or triple masts only.
2 To maintain UL rating, do not exceed 5A load.
3 To maintain UL rating, do not exceed 2A load.
4 Do not use 26 AWG for high voltage or high current applications; 26 AWG rated @ .25A.
5 Do not use 26 AWG for high voltage or high current applications; 26 AWG rated @ .25A, 20 AWG rated @ 5A.
AFC: Adaptive Force Control
ERC: Electronic Rotational Control
REF QTY PART NO. PART NO. PART NO. PART NO. PART NO. DESCRIPTION
6844346 6844347 6844348 6844349 6844350 Power Supply Group
1 1 6844359 6844359 6844359 6844364 6844369 Cable Assembly
2 1 6001647 6811810 — — — Wire Harness – Power
1 — 6806701 — — — Fuse, 2 Amp, UL Classified ◆
3
1 6806708 — — — — Fuse, 5 Amp, UL Classified ◆
4 1 6009994 6009994 — — — Switch
5 1 6846019 6846020 6846021 6846022 6846023 Power Supply Kit Decal
◆ To maintain UL Rating, replace with specified fuses.
Common Parts
REF QTY PART NO. DESCRIPTION REF QTY PART NO. DESCRIPTION
6844329 Power Supply Install Kit ● 18 1 6832205 Clamp
6 1 6818145 Sheave Assembly ■ 19 2 6026763 Spacer Plate
7 1 6820449 Conduit 20 1 6819937 Spacer Block
8 1 6838404 Nut 1 206321 Capscrew, M6 x 16
21
9 1 6819600 Back Plate 1 763169 Capscrew, M6 x 20
10 1 6818146 Bracket 22 1 206323 Washer, M6
11 2 6819200 Bearing 23 1 6844372 Junction Block
12 1 6806108 Roller 24 2 767614 Capscrew, M10 x 20
13 1 6819224 Spacer Plate 25 1 6400135 Washer, M10
14 2 786881 Nut 26 1 6846510 Hose Clamp
15 2 6819533 Capscrew, M8 x 65 27 1 6846511 Anchor Plate
2 6819534 Capscrew, M8 x 70 28 1 6027117 Alignment Tool
16
2 6026778 Capscrew, M8 x 80 29 1 6846222 UL Decal
17 2 6820902 Spacer Plate
● Includes items 17 - 29.
■ Includes items 10 - 16.
15
Power Supply/Communication Groups
Maximum Mast Fork Height – 320 in.
@
! 0
#
$
%^ °
&
5 6
9
∙ 8 7
‹ 1
‡ )
(
*
⁄ ¤
4
fl
fi
› 3
2
AC2510.eps
16
Power Supply/Communication Groups
Maximum Mast Fork Height – 320 in.
Power Maximum
Supply Mast ➀ Fork Conductors Supply
Group Height (in.) (No. @ AWG) Application Notes
6844351 320 2 @ 18 Cascade Products – Switched, 12V 2
6844352 320 2 @ 18 Cascade Products – Switched, 24V-48V 3
6844353 320 2 @ 18 ERC – Unswitched
6844354 320 4 @ 26 Sensor Applications 4
6844355 320 2 @ 20 & 4 @ 26 AFC & ERC – Unswitched 5
1 Simplex, dual or triple masts only.
2 To maintain UL rating, do not exceed 5A load.
3 To maintain UL rating, do not exceed 2A load.
4 Do not use 26 AWG for high voltage or high current applications; 26 AWG rated @ .25A.
5 Do not use 26 AWG for high voltage or high current applications; 26 AWG rated @ .25A, 20 AWG rated @ 5A.
AFC: Adaptive Force Control
ERC: Electronic Rotational Control
REF QTY PART NO. PART NO. PART NO. PART NO. PART NO. DESCRIPTION
6844351 6844352 6844353 6844354 6844355 Power Supply Group
1 1 6844360 6844360 6844360 6844365 6844370 Cable Assembly
2 1 6001647 6811810 — — — Wire Harness – Power
1 — 6806701 — — — Fuse, 2 Amp, UL Classified ◆
3
1 6806708 — — — — Fuse, 5 Amp, UL Classified ◆
4 1 6009994 6009994 — — — Switch
5 1 6846024 6846025 6846026 6846027 6846028 Power Supply Kit Decal
◆ To maintain UL Rating, replace with specified fuses.
Common Parts
REF QTY PART NO. DESCRIPTION REF QTY PART NO. DESCRIPTION
6844329 Power Supply Install Kit ● 18 1 6832205 Clamp
6 1 6818145 Sheave Assembly ■ 19 2 6026763 Spacer Plate
7 1 6820449 Conduit 20 1 6819937 Spacer Block
8 1 6838404 Nut 1 206321 Capscrew, M6 x 16
21
9 1 6819600 Back Plate 1 763169 Capscrew, M6 x 20
10 1 6818146 Bracket 22 1 206323 Washer, M6
11 2 6819200 Bearing 23 1 6844372 Junction Block
12 1 6806108 Roller 24 2 767614 Capscrew, M10 x 20
13 1 6819224 Spacer Plate 25 1 6400135 Washer, M10
14 2 786881 Nut 26 1 6846510 Hose Clamp
15 2 6819533 Capscrew, M8 x 65 27 1 6846511 Anchor Plate
2 6819534 Capscrew, M8 x 70 28 1 6027117 Alignment Tool
16
2 6026778 Capscrew, M8 x 80 29 1 6846222 UL Decal
17 2 6820902 Spacer Plate
● Includes items 17 - 29.
■ Includes items 10 - 16.
17
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 Cascade Canada Inc. Cascade do Brasil
U.S. Headquarters 5570 Timberlea Blvd. Praça Salvador Rosa,
2201 NE 201st Mississauga, Ontario 131/141-Jordanópolis,
Fairview, OR 97024-9718 Canada L4W-4M6 São Bernardo do Campo - SP
Tel: 800-CASCADE (227-2233) Tel: 905-629-7777 CEP 09891-430
Fax: 888-329-8207 Fax: 905-629-7785 Tel: 55-13-2105-8800
Fax: 55-13-2105-8899
EUROPE-AFRICA
Cascade Italia S.R.L. Cascade (Africa) Pty. Ltd.
European Headquarters PO Box 625, Isando 1600
Via Dell’Artigianato 1 60A Steel Road
37030 Vago di Lavagno (VR) Sparton, Kempton Park
Italy South Africa
Tel: 39-045-8989111 Tel: 27-11-975-9240
Fax: 39-045-8989160 Fax: 27-11-394-1147
ASIA-PACIFIC
Cascade Japan Ltd. Cascade Korea Cascade-Xiamen Cascade India Material
2-23, 2-Chome, 121B 9L Namdong Ind. No. 668 Yangguang Rd. Handling Private Limited
Kukuchi Nishimachi Complex, 691-8 Gojan-Dong Xinyang Industrial Zone No 34, Global Trade Centre
Amagasaki, Hyogo Namdong-Ku Haicang, Xiamen City 1/1 Rambaugh Colony
Japan, 661-0978 Inchon, Korea Fujian Province Lal Bahadur Shastri Road,
Tel: 81-6-6420-9771 Tel: +82-32-821-2051 P.R. China 361026 Navi Peth, Pune 411 030
Fax: 81-6-6420-9777 Fax: +82-32-821-2055 Tel: 86-592-651-2500 (Maharashtra) India
Fax: 86-592-651-2571 Phone: +91 020 2432 5490
Fax: +91 020 2433 0881
Cascade Australia Pty. Ltd. Cascade New Zealand Sunstream Industries
1445 Ipswich Road 15 Ra Ora Drive Pte. Ltd.
Rocklea, QLD 4107 East Tamaki, Auckland 18 Tuas South Street 5
Australia New Zealand Singapore 637796
Tel: 1-800-227-223 Tel: +64-9-273-9136 Tel: +65-6795-7555
Fax: +61 7 3373-7333 Fax: +64-9-273-9137 Fax: +65-6863-1368
c
© Cascade Corporation 2014 02-2014 Part Number 6844330-R1
c Load Cushion™
User Hydraulic Accumulator
Kits 227201, 227202 for
Cascade Attachments &
Guide Lift Truck Hoist Systems
This User Guide contains a general description, application
WARNING: Hydraulic accumulators may
and installation information, troubleshooting, pre-charging
contain inert gas under high pressure.
and pressure checking, service, and a parts list for Cascade
Read through entire User Guide before
Load Cushion™ Hydraulic Accumulators.
installing or servicing unit. Do not use on
hydraulic systems over 4000 psi (275 bar).
General Description
Accumulator Kits 227201 (29 cu. in.) and 227202 (58 cu. in.)
are designed to be added to the hoist or attachment
hydraulic systems on lift trucks with attachments weighing
up to 4000 lbs (1815 Kg). They provide a cushioning effect
in the hydraulic system to reduce shocks to the load and
equipment. The Accumulator is a gas-over-oil type and
requires a specific pre-charge of dry inert gas (water
pumped nitrogen recommended). No maintenance is
required, except for periodically checking the pre-charge
and checking for hydraulic leaks.
Applications
Recommended applications for Load Cushion™ Accumulators
are listed below, at the pre-charge pressures indicated: AC0192.ill
1 Forks only or no Attachment: mast hoist circuit. Cushions load and hoist system 350–400 psi (25 bar) or
during lifting, lowering, traveling. according to load.
Attachment weight's
2 Paper Roll Clamps: mast hoist circuit. (as above) pressure equivalent in
hoist main lift stage.➀
3 Sliding Arm Clamps: mast hoist circuit. (as above) (as above)
Attachment weight's
5 Adaptive Force Control (AFC): mast hoist circuit. (as above) pressure equivalent in
free lift stage as deter-
mined by controller.➁
Cushions load and pantograph
6 Push-Pull: push circuit mechanism from impacts during 2500 psi (170 bar)
load packing.
➀ Determine by connecting pressure gauge to Accumulator connection point (see schematic next page).
➁ Refer to Adaptive Force Control (AFC) Setup Instructions 6006350.
Part No. 227196 R-3
cascade姞
corporation
For Technical Support . . . To Order Parts . . .
Call: 1-800-227-2233 Call: 1-888-227-2233
OR OR
Write: Cascade Corporation, P.O. Box 20187, Portland, OR 97294 Write: Cascade Corporation, 2501 Sheridan Ave., Springfield, OH 45505
Installation Information
The Load Cushion™ Accumulator can be mounted in any
Pre-Charging or Pressure Checking
position. However, it should be mounted rigidly, and oriented NOTE: Accumulator is normally shipped with zero pre-charge,
so that the warning label is visible and the gas charging valve check the nameplate.
is easily accessible. NOTE: Accumulator is normally shipped
with zero pre-charge, check the nameplate. WARNING: Failure to read and follow these
directions can cause rapidly discharging gas
IMPORTANT: As an option, a shut-off valve is available to
and/or hydraulic fluid which can result in
facilitate hydraulic system and attachment maintenance.
death, personal injury and property damage.
1 Use the end-clamps provided in the kit and determine a Accumulator should be charged with only clean, dry inert gas
suitable mounting location on the truck cowl, mast or (water-pumped nitrogen recommended). Accumulator
attachment frame. NOTE: Before drilling holes, check that Charging Kit, Part No. 228235, is available from Cascade to
the Accumulator is protected from damage during mast tilt, pre-charge or pressure-check the Accumulator. If other
attachment operation, and load handling. If necessary, charging equipment is used, make sure it is compatible with
fabricate a mounting plate to provide a suitable location. the gas valve assembly on the Accumulator. When pre-
charging, it is strongly recommended that the nitrogen bottle
be equipped with a high pressure regulator as shown opposite.
Truck
Connection 3 Shut-Off
Hoist
Cylinders
CAUTION: Do not attempt to reduce pre-charge in Accu-
mulator by depressing valve core with foreign object. High
pressure may rupture valve seat.
Auxiliary Valve
Valve 8 Screw gas chuck 'T' handle all the way out (CCW), then
slowly open bleed valve to relieve gas trapped in charging
manifold.
9 Using a wrench to prevent gas valve on Accumulator from
Push turning, remove gas chuck.
Attachment Valve Cylinders 10 Replace gas valve cap and valve guard. Tighten valve cap
(or alternate)
check valve capscrews to 15 in.-lbs. (17 cm kg).
AC0197.ill
Troubleshooting & Maintenance
Gas Valve Guard • Verify accumulator operation during normally scheduled
3 and Cap truck maintenance by checking for load cushioning effect
in hydraulic circuit.
• Check for external hydraulic leaks at the accumulator fill
valve, shutoff valve (if equipped), and hose connection.
• Check for proper pre-charge pressure one week after
installation, then every 1000 hours or 6 months, whichever
occurs first (see Pre-charging or Pressure Checking,
Accumulator Charging Steps 1 through 5.
Kit (Part No. 228235) NOTE: Pre-charge pressure will be higher than normal if
'T' Handle hydraulic fluid leaks into the gas side, and lower than
normal if gas leaks into the hydraulic side (or externally
Bleed past the end caps or charging valve).
Valve • Service accumulator if it does not hold the pre-charge.
Gas Chuck (See Accumulator Service on back page).
Accumulator
Gas Valve
Charging
Accumulator Manifold
Hydraulic End Cap Free Floating Piston Gas End Cap Gas Charging Valve
AC0184.ill
Seal Kit
2 1 5
Hydraulic Fitting Accumulator
4 Pressure Seal Back-Up Ring (2) O-Ring (2) Back-Up Ring (2)
AC0196.ill
Shut-off Valve
Load Cushion™ Accumulator
Parts List
REF QTY PART NO. DESCRIPTION
3 6 227201 Accumulator Kit w/Mount (29 cu. in.) ●
227202 Accumulator Kit w/Mount (58 cu. in.) ●
1 1 227199 Accumulator (4000 psi, 29 cu. in.)
1 1 227197 Accumulator (4000 psi, 58 cu. in.)
AC0191.ill 2 1 601377 Fitting, 8-8 SAE 37°/O-Ring
Mounting Clamps 3 2 227200 Mounting Clamps
AC0193.ill 4 227839 Shut-off Valve
5 227253 Seal Service Kit
Charging Kit
6 228235 Charging Kit
● Includes Items 1, 2 and 3.
1 Locate the existing truck control valve low pressure tank line.In a
location close to the tank, cut and remove a 1.5 in. (40 mm) section of
hose as shown. 1.5 in.
2 Determine the adapter fitting that fits the tank line hose.
Install the (40 mm)
adapter fitting and hose clamps. Tighten the hose clamps. AC0018.eps
3 Install the adapter fitting in the attachment accessory valve tank port.
4 Install the push-on hose fitting (Push-Lok/JIC female) to the low
pressure hose supplied with the kit. Determine hose length required
and cut to length. Attach the hose to the attachment accessory valve
fitting. Install the other hose end to the adapter fitting. Avoid pinch
and wear points. Tighten hose fittings and clamps.
CAUTION: Secure the hose with
2
cable ties as necessary to avoid
pinch and wear points. Dual Line
Adapter Fitting
Return line from
truck control valve
3 Adapter
Fitting
2 Single Line
4
Adapter Fitting
From accessory Push-On Type
valve tank port Hose Fitting AC1822.eps
Return line to
truck tank
cascade
corporation
For Technical Support . . . 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
Tank Line Adapter Kits
2
4
5 3
6
REF QTY PART NO. DESCRIPTION AC0281.eps
4
3
5
AC2527.eps
6 REF QTY PART NO. DESCRIPTION
6848585 Adapter Kit – Dual Line
1 6049379 Adapter Tee – .75 in. (19 mm) Hose ID
1 1 6049384 Adapter Tee – 1.00 in. (25 mm) Hose ID
1 6048999 Adapter Tee – 1.25 in. (31 mm) Hose ID
2 2 211742 Hose Clamp, .38 ➔ .87 in.
2 211743 Hose Clamp – .50 ➔ 1.25 in.
3
2 213140 Hose Clamp – .75 ➔ 1.75 in.
4 2 211740 Hose, 72 in.
5 2 211741 Fitting, 8
6 2 601377 Fitting, 8-8
− AC2028.eps
4 2 7
8
I
N
P
U
T
O
U
T
P
6 U
T
9
1
AC2033.eps
Priority Flow
Control Valve
No. 10
2 To Proportional O-Ring Port
1 Flow Valve Return to
3 Pump Port Tank Fitting
Truck Truck
Hydraulic Relief Truck
Pump Valve Tank
AC0289.eps
From truck
control valve
Return-to-tank
fitting
To Proportional Truck
valve tank port tank line
AC0291.eps
To truck tank
AC0290.tif
NOTE: This information should not be interpreted as the basis for warranty claims unless so designated.
cascade W
corporation
For Technical Support . . . 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
Hyster S70-120 XL2
To Proportional
Flow Valve
Tank Port
Hoist Clamp
Control Auxiliary No. 6
Valve Valve No. 10 O-Ring Port
Auxiliary O-Ring Port
Valve
3
Priority Flow
Control Valve 2
2 To Proportional
1 Flow Valve Return to
3 Pump Port Tank Fitting 1
AC0445.eps
AC0289.eps
From truck
control valve
Return-to-tank
fitting
To Proportional Truck
valve tank port tank line
AC0291.eps
To truck tank
AC1769.jpg
2
Caterpillar 50 2EC25
To Proportional
Flow Valve
Tank Port
Hoist Clamp
Control Auxiliary No. 6
Valve Valve No. 10 O-Ring Port
Auxiliary O-Ring Port
Valve
3
Priority Flow
Control Valve 2
2 To Proportional
1 Flow Valve Return to
3 Pump Port Tank Fitting 1
AC0445.eps
AC0289.eps
From truck
control valve
Return-to-tank
fitting
To Proportional Truck
valve tank port tank line
AC0291.eps
To truck tank
AC1770.jpg
3
Clark CGC25
To Proportional
Flow Valve
Tank Port
Hoist Clamp
Control Auxiliary No. 6
Valve Valve No. 10 O-Ring Port
Auxiliary O-Ring Port
Valve
3
Priority Flow
Control Valve 2
2 To Proportional
1 Flow Valve Return to
3 Pump Port Tank Fitting 1
AC0287.eps
Truck No. 10
Truck
Relief O-Ring Port
Hydraulic Truck
Pump Valve Tank
AC0289.eps
From truck
control valve
Return-to-tank
fitting
To Proportional Truck
valve tank port tank line
AC0291.eps
To truck tank
AC1771.jpg
cascade W
corporation
For Technical Support . . . 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
Pendant Key Functions:
NOTE: The truck and AFC system must be powered on
before the pendant can be plugged in or it will not function. Cascade AFC
Number Keys – Use to select and enter a menu item or Please Select Option Display
use to enter values in submenus. >1 Calibration Menu
Arrow Keys – Use to move the cursor (>) and scroll 2 Operation Menu
Indicates item
through menu and submenu items. is selected
Enter Key – Used to accept a user input value.
F1 F2 F3 F4
NOTE: If the displayed value is zero, the AFC controller
will ignore it. Use the arrow keys to skip through the Pendant 1 2 3 YES Key
submenus. Pad
Other keys – These keys do not work for operating the 4 5 6 NO
pendant.
7 8 9 BKSP
1
locknut. Proportional Pressure
CAUTION: Tighten the screw to finger tight. Do NOT use Control Valve
Driver’s
tools. Display
2 6095125-R3
MENU 1 – Calibration
NOTE: Refer to the Pendants Key Functions Section for more IMPORTANT: When installing a new controller or
detailed information on operating the pendant. updating/changing the software revision, reset
NOTE: Where a sequence of X’s appear, this indicates that a controller to the defaults (AFC pendant Menu 5.7)
numeric value is in its place or will need to be keyed in. prior to clamp calibration and setup.
Disconnect hose to
Adjust accumulator to HOIST circuit and plug
end when charging
this pressure. Refer to
Accumulator User Guide
227196 for precharging and AC0273.eps
1.1_Accumulator adjustment procedures.
Use Charging Kit 228235 to
Set_Accumulator_to charge or adjust accumulator.
____________906 psi When the accumulator is
Accumulator
FREELIFT:
Carriage only
AFC measures no-load has moved
hydraulic pressure in freelift
stage while carriage is not
1.2_Calibration moving.
Carriage_in_Freelif t Raise the carriage, keeping
In_memory__3580 psi the carriage in freelift. Press
the ENTER key to accept the
Hit_Enter___XXXX psi value.
AC1668.eps AC0249.eps
6095125-R3 3
MAINLIFT: Mast inner
rail has moved
AC1668.eps
AC0251.eps
AC1668.eps
4 6095125-R3
Attachment Factor (AF),
mathematically represents the
clamp force generated for a
given cylinder pressure.
1.7_At t ac h men t_F acto To determine the AF factor
for typical Cascade Clamps,
Enter_AF refer to the Chart A (page 24).
In_memory___4 40 NOTE: For custom designed
Hit_Enter____XXX units, the AF may be found on
the attachment nameplate or
consult Cascade.
AC1668.eps
AC1668.eps
AC1668.eps
6095125-R3 5
For No Switch:
AC1668.eps
6 6095125-R3
For Auto Switch or Manual Switch: Medium Large
NOTE: For manual switch, skip to 2.2a.
Close long
For Auto Switch only – sets arm to high-
AFC for medium diameter/ to-medium trip
medium weight rolls. point (example:
2.1a_Position Arm 75% of maximum
arm opening).
NOTE: Open short arm to
Between_Hi_and_Med maximum.
Press_Enter_when_set
AC1668.eps AC1938.eps
Small Medium
AC0517.eps
AC1951.eps
Minimum Maximum
Arm Arm
Opening Opening
6095125-R3 7
For Auto Switch or Manual Switch (Continued):
Hit_Enter_____XX
AC1668.eps
8 6095125-R3
For Auto Switch or Manual Switch (Continued):
AC1668.eps
Refer to 2.3a
Hit_Enter____XXX
AC1682.eps
AC1668.eps
Refer to 2.3a
AC1668.eps
6095125-R3 9
For Auto Switch or Manual Switch (Continued):
Try the default value first.
The arm speed for a large
roll, (Scale 0–50) in rare
cases, may require slight
adjustment so AFC can
2.4a_Hi_Arm_Speed properly adjust to start
pressure and status light
Enter_value show steady green.
In_memory____25 Too low = Will cause slow
arm speed.
Hit_Enter_____XX Too high = Will not adjust
accurately to start pressure.
AC1668.eps
2.4b_Med_Arm_Speed
Enter value Try the default value first.
Arm speed for a medium roll.
In_memory____20
Hit_Enter_____XX
AC1668.eps
10 6095125-R3
For Clamp Change Option:
With 3-position switch box set to Clamp 1 and attachment #1
mounted, re-calibrate using Menu 1 before entering values for
operation Menu 2.2a–2.4a.
AC1668.eps
6095125-R3 11
MENU 3 – Drop Stop Menu
NOTE: Refer to the Pendants Key Functions Section for more
detailed information on operating the pendant.
AC1668.eps
Pushbutton
Configures AFC system to
3.2_Drop_Stop_Sw? provide pushbutton control AC0364.eps
Yes_or_No? of drop stop features.
>Yes_DS_Switch
_No_DS_Switch
HOIST control lever
AC1668.eps
12 6095125-R3
For this value, monitor P1
while lowering a light load.
Subtract 75 psi (5 bar) from
the P1 value. This is the Drop
3.4_DS Activation P Switch Activation Pressure to
Enter_value in psi record.
NOTE: To monitor P1 use
In_Memory__ 350 psi display gauge button or
Hit_Enter____ 0 psi pendant as described in
Troubleshooting Section 3.3-3.
AC1668.eps
Please_Select_Option
: 60
7586
3
TM
_3_Drop_Stop_Menu arrow keys to go to the next
>4_Datalogger Menu submenu.
AC1668.eps AC1393.eps
If Datalogger equipped,
type in a unique
4.2_Truck ID Number number for each truck.
Enter Number This ID number will
be used in the AFC
In Memory 4562 Datalogger software.
New Value 0
AC1668.eps
6095125-R3 13
If Datalogger equipped,
4.3_CF Capture Time set the capture time
for the data being
Enter Number collected in seconds (3
In Memory 3 recommended).
New Value 0
AC1668.eps
If “Load Wt Capture” is
selected, an approximate
load weight will be
recorded with the clamp
force.
4.4_Capture_Load_Wt
Yes or No? If “No Load Wt Capture” is
selected, the Auto Switch
_Load Wt Capture arm position or manual
switch selection (11-3) will
>No Load Wt Capture be displayed in the weight
field of the Datalogger
AC1668.eps report.
14 6095125-R3
MENU 5 – Preferences Menu
NOTE: Refer to the Pendants Key Functions Section for more
detailed information on operating the pendant.
(psi)
0
5.1_Display_Buttons Enables or disables the use
of the display buttons.
Yes_and_No? M/E P/F
>Enable_Buttons
_Disable_Buttons AC1681.eps
AC1668.eps
Display Button
AC1668.eps
Percentage change
before display value
5.3_Display_Change_% updates. This is used
to keep display value
Enter_Value from bouncing (5% is
In_memory_____5 recommended).
Hit_Enter______X
AC1668.eps
6095125-R3 15
Sets maximum AFC relief
pressure (Scale 0–2600 psi
or 0–180 bar).
Example: If set at 1500 psi
5.4_Max_Clamp_Pres . (103 bar), AFC system will
not allow pressure to
Enter_value_in_psi increase beyond that setting,
except when in override or in
In_memory__2600_psi maximum lift.
Hit_Enter_ _ XXXX_psi CAUTION: Do not exceed
the Clamp’s maximum
AC1668.eps operating pressure (refer to
Clamp’s Service Manual).
Hit_Enter_____XX
Reclamp Differential, 5.5
AC1668.eps
Target
Pressure
Pressure
Clamp
Cylinder
Pressure
Time AC1937.eps
A mathematical number
assigned by Cascade
5.6_PT_Factor to define the pressure
Enter_Value_X_10 transducer.
16 6095125-R3
MENU 6 – Advanced Settings Menu
NOTE: Refer to the Pendants Key Functions Section for more
detailed information on operating the pendant.
Use caution – contact a Cascade service technician for further
assistance.
AC1668.eps
Pressure
Truck Clamp
Line Pressure
Clamp Cylinder
Pressure
Time
AC1690.eps
6095125-R3 17
Initial PWM ramping up to PWM (Pulse-Width Modulation) –
the start clamp pressure. A A signal over a communication
percentage of start pressure channel of a power source’s duty
arm speed. cycle.
6.3_SP_Arm_Spd_% If overshooting start
clamp pressure, lower in
Enter_value_in_% increments of 5. If the
In_memory____90_% system is slow to reach start
clamp pressure, increase in
Hit_Enter____XXX_% increments of 2.
Scale: 50–90 %
AC1668.eps
AC1668.eps
6.4
Ramp
PWM
Rise
Run
Start Pressure Arm Speed
(Initial PWM), 6.3
Time
AC1921.eps
Clamp
Pressure Cylinder
Pressure
Pilot
Pressure
Time
AC1940.eps
18 6095125-R3
A hoist filter that
reduces the hoist target
to this percentage.
To offset overshoot of
6.6_Hoist_Tgt_Pct hoist target pressure,
lower in increments of 2
Enter_Value
Scale 80–95 %
In_memory____90
Hit_Enter_____XX
Theoretical Clamp Force
AC1668.eps
Actual Clamp Force
Clamp Force
based on Hoist
Target Pressure, % Hoist Target
Pressure %, 6.6
Frictional
Hoist Dampening, 6.8
Pressure
Dampening
Time, 6.7
Time AC1947.eps
A dampening factor to
overcome an increase
in Hoist Pressure
6.8 Frictional_Damp caused by movement
of empty clamp and
Enter_in_Pressure carriage. To determine
an approximate value,
In_Memory____90_psi monitor PT1 when
Hit_Enter______X_psi hoisting the empty
clamp and subtract the
static pressure.
AC1668.eps
6095125-R3 19
A dampening factor to
overcome an increase
in Hoist Pressure
6.9_Iner tial Damp caused by inertia of
the load, a percentage
Enter_in_Percent value. A higher
In_Memory____80_pct value results in less
dampening or possible
Hit_Enter______X_pct over clamping.
AC1668.eps
Target
Force
Inertial
Dampening, 6.9
Dampening Time
Time
AC1948.eps
Adjustable pressure
ramp factor. Speeds
up or slows down
6.10_K_Factor the rate of increasing
clamp pressure.
Enter_Value An increase in this
value increases the
In_Memory_____4 ramp slope. Change
Hit_Enter______X in increments of 1.
AC1668.eps
High K
PWM Value Low K Value
Time
AC1949.eps
20 6095125-R3
The number of counts
6.11_Rclmp Pause Cnt (10 ms per count)
that indicate a need
to re-clamp before
initiating the reclamp.
In_Memory____60
Hit_Enter______0
AC1668.eps
Reclamp
Actual Clamp
Clamp Force
Force Target Force
Counts
AC1950.eps
6095125-R3 21
MENU 7 – Diagnostics Menu
NOTE: Refer to the Pendants Key Functions Section for more
detailed information on operating the pendant.
ENTER
7.0_I/O_Testing 7.1_Transducers
Please_Select_Option Values_in_PSI
>1_Test_Transducer Pt1__XXXX__Pt3__XXXX
_2_Test_Solenoids Pt2__XXXX__Pt4__XXXX
AC1668.eps AC1668.eps
7.0_I/O_Testing 7.2_Solenoids
Please_Select_Option Values_in_%_Current
_1_Test_Transducer Sol1__Off_Sol3___Off
>2_Test_Solenoids Sol2__XXX_Sol4___Off
AC1668.eps AC1668.eps
Real time solenoid output (On or off,
percent pwm).
PWM (Pulse-Width Modulation) – A signal
over a communication channel of a power
source’s duty cycle.
7.0_I/O_Testing 7.3_Switches
Please_Select_Option On_or_Off
_2_Test_Solenoids Max___Off_OvrRd__Off
>3_Test_Switches Main_ _ Off_AS_____10
AC1668.eps AC1668.eps
Real time switch data.
22 6095125-R3
MENU 8 – Error Codes Menu
NOTE: Refer to the Pendants Key Functions Section for more
detailed information on operating the pendant.
6095125-R3 23
24
Attachment Factor Chart
Chart A
200 300 400 500 600 700 800 900 1000 1100 1200 1300
13000 6000
12000 5500
110F: 1075
11000 5000
100F: 980
10000 4500
90F: 880
9000 4000
Clamp Clamp
8000 3500
Rating 77F: 750 Rating
(Lbs.) 72G: 700 (Kg.)
7000 3000
66F, 66G: 650 33H: 695
60F, 60G: 590 30H: 630
6000 2500
25H: 500
5000 2000
24H: 485
20H: 400 45F: 440 NOTE: For custom clamps,
4000 check nameplate for AF or 1500
18H: 365 consult Cascade.
38F: 370
3000 1000
2000 500
AC1680.eps
6095125-R3
Chart B
Liner Board (low recycle), 600 (41) 800 (55) 1000 (69) 2.0 2.2 2.4
Bleached White, Virgin Kraft
Liner Board (med. recycle), 600 (41) 800 (55) 1000 (69) 2.2 2.5 2.8
Bond, Card Stock, Fine Paper
Tissue 600 (41) 700 (50) 800 (55) 1.6 1.6 1.6
Liner Board (high recycle), 600 (41) 800 (55) 1000 (69) 2.2 2.4 2.6
Slick/Coated, Magazine Stock
100% Recycled Kraft w/wax, 800 (55) 1000 (69) 1200 (83) 2.4 2.6 2.8
Medium – Corrugated
Wax Paper, Mylar Film 600 (41) 800 (55) 1000 (69) 2.8 3.0 4.2
1
IMPORTANT: Values are recommended starting points only. Verification by testing is required, to
include clamping, hoisting, traveling over dockplates, floor bumps, and unloading. Make sure that load
is clamped correctly so contact pads provide maximum surface friction. See appropriate Cascade
Operator's Guide for recommended safe handling procedures.
2
For light weight or butt rolls use lower end of range, for medium weight rolls use middle of range, for
heaviest rolls use upper end of range.
3
Factors are for standard cast or spray metal surfaces. Lower or higher values may be required when
using rubber, urethane, ribbed, or convex pads.
6095125-R3 25
26 6095125-R3
Adaptive Force Control - AFC
Calibration Settings Log
Calibration SWITCH NOT EQUIPPED
6095125-R3
Load Weight
Clamp
Accumulator CARRIAGE CARRIAGE LOAD IN LOAD IN LOAD Attachment Force Start Arm
Date/Set By Pressure IN FREELIFT IN MAINLIFT FREELIFT MAINLIFT WEIGHT Factor Factor Pressure Speed
27
28 6095125-R3
Adaptive Force Control - AFC
Calibration Settings Log (Continued)
AUTO SWITCH ONLY AUTO SWITCH AND MANUAL SWITCH
6095125-R3
Long Arm Trip Point Clamp Force Factor Start Pressure Arm Speed
At Roll Diameter
Date/Set By HIGH-TO-MED MED-TO-LOW LOW MED HIGH LOW MED HIGH LOW MED HIGH
29
30 6095125-R3
Adaptive Force Control - AFC
6095125-R3
Calibration Settings Log (Continued)
CLAMP CHANGE ONLY
31
32 6095125-R3
Adaptive Force Control - AFC
6095125-R3
Drop Stop Log Datalogger Log Preferences Log
33
34 6095125-R3
Adaptive Force Control - AFC
Advanced Settings Log
6095125-R3
Start Start
Date/Time/ Pilot On Roll Start Pressure Pressure Pressure Hoist Target Dampening
Set By Pressure Differential Arm Speed % Ramp Differential Pressure Time
35
36 6095125-R3
Adaptive Force Control - AFC
Advanced Settings Log (Continued)
6095125-R3
Reclamp
Date/Time/ Frictional Pause Open Reset
Set By Damp Inertial Damp K Factor Count Pressure
37
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 Cascade Canada Inc. Cascade do Brasil
U.S. Headquarters 5570 Timberlea Blvd. Praça Salvador Rosa,
2201 NE 201st Mississauga, Ontario 131/141-Jordanópolis,
Fairview, OR 97024-9718 Canada L4W-4M6 São Bernardo do Campo - SP
Tel: 800-CASCADE (227-2233) Tel: 905-629-7777 CEP 09891-430
Fax: 888-329-8207 Fax: 905-629-7785 Tel: 55-13-2105-8800
Fax: 55-13-2105-8899
EUROPE-AFRICA
Cascade Italia S.R.L. Cascade (Africa) Pty. Ltd.
European Headquarters PO Box 625, Isando 1600
Via Dell’Artigianato 1 60A Steel Road
37030 Vago di Lavagno (VR) Sparton, Kempton Park
Italy South Africa
Tel: 39-045-8989111 Tel: 27-11-975-9240
Fax: 39-045-8989160 Fax: 27-11-394-1147
ASIA-PACIFIC
Cascade Japan Ltd. Cascade Korea Cascade-Xiamen Cascade India Material
2-23, 2-Chome, 121B 9L Namdong Ind. No. 668 Yangguang Rd. Handling Private Limited
Kukuchi Nishimachi Complex, 691-8 Gojan-Dong Xinyang Industrial Zone No 34, Global Trade Centre
Amagasaki, Hyogo Namdong-Ku Haicang, Xiamen City 1/1 Rambaugh Colony
Japan, 661-0978 Inchon, Korea Fujian Province Lal Bahadur Shastri Road,
Tel: 81-6-6420-9771 Tel: +82-32-821-2051 P.R. China 361026 Navi Peth, Pune 411 030
Fax: 81-6-6420-9777 Fax: +82-32-821-2055 Tel: 86-592-651-2500 (Maharashtra) India
Fax: 86-592-651-2571 Phone: +91 020 2432 5490
Fax: +91 020 2433 0881
Cascade Australia Pty. Ltd. Cascade New Zealand Sunstream Industries
1445 Ipswich Road 15 Ra Ora Drive Pte. Ltd.
Rocklea, QLD 4107 East Tamaki, Auckland 18 Tuas South Street 5
Australia New Zealand Singapore 637796
Tel: 1-800-227-223 Tel: +64-9-273-9136 Tel: +65-6795-7555
Fax: +61 7 3373-7333 Fax: +64-9-273-9137 Fax: +65-6863-1368
c
© Cascade Corporation 2010 07-2010 Part Number 6095125-R3
O PERATOR'S GUIDE
D, F, G & H-Series
Fixed Frame
Paper Roll Clamps
cascade
corporation
Cascade is a Registered Trademark of Cascade Corporation
C ONTENTS
Page
Introduction 1 WARNING: Rated capacity of the
truck/attachment combination is a
Safety Rules 2 responsibility of the original truck
Daily Inspection 4 manufacturer and may be less than
Clamp Operation 5 shown on the attachment nameplate.
Roll-Handling Basics 6 Consult the truck nameplate.
Handling two rolls using split-arm clamp 7 WARNING: Do not operate this
Upending 8 attachment unless you are a trained
Vertical Pickup, Transport, Unloading 9 and authorized lift truck driver.
Bilge (Horizontal) Pickup, Transport 10
Stacking, Unstacking 11 CAUTION: This guide shows load handling
Unloading procedures for most products. Ask your company
Truck Trailers Breakout - Fixed Frame Clamp 12 or organization about any special procedures for the
loads you may be handling.
Boxcars Breakout - Fixed Frame Clamp 13
Loading
Truck Trailers 14
Boxcars 15
Tower Clamp Loading, Transport, Unloading, Stacking 16
Loading with Adjustable Bumper Option 18
Load Troubleshooting 18
Safe Operation and Maintenance
OHSA Regulations 19
I NTRODUCTION
Fixed Frame Paper Roll Clamp – Cascade Fixed Clamping Long Arm Hydraulic Cylinders
Frame Paper Roll Clamps, Models D, F, G & H-Series
are multiple-function attachments for handling all types
of paper roll products. Clamps are designed for both
bilge and vertical roll handling for transport, stacking, Baseplate
breakout, van trailer, boxcar and ship loading and
unloading. Clamps can rotate through 360 degrees and
can have a fixed short arm for full rolls or adjustable
short arm for butt rolls, and a single or split long arm.
Tower clamp versions provide bulk roll handling in many
configurations.
About this Guide – The information in this Guide is Contact Pads
intended to simplify operator understanding about
effective and safe Clamp use and operation. Read
this guide thoroughly before operating the attachment.
Be sure you know and understand all operating
procedures and safety precautions. If you have any
questions, or don’t understand a procedure, ask your RC0025.eps
supervisor.
Mounting Hooks
Emphasize Safety! Most accidents are caused by
operator carelessness or misjudgment. You must
watch for poorly maintained equipment and hazardous
situations and correct them. Fixed or Adjustable Short Arm
1 210135-R9
S AFETY RULES
Industrial Lift Trucks
No reaching through mast No standing under load
No riders
RC0026.eps
3 in.
(8 cm)
No load
P P
Traveling RAMPS
Motor off, park, lower load empty
RC0027.eps
TRAFFIC
STOP
Observe
Workers Stops
210135-R9 2
S AFETY RULES
Handling Loads: Rolls must be secure prior to lifting and transporting.
Center of
Rotation
RC3942.eps
Lateral Offset
3 210135-R9
D AILY INSPECTION
Pad edges
Fasteners
RC0029.eps
Safety decals
& nameplate
Cylinders and
Lower hook
hoses for leaks
engagement
210135-R9 4
C LAMP OPERATION
AUXILIARY VALVE
FUNCTIONS Tilt forward WARNING: Truck control handle and
Hoist down attachment function activation shown
here conforms to ASME/ANSI B56.1
A C 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
B D practices for safe operation.
GA0005.eps
Hoist up Tilt back
ROTATE
LONG ARM
(Driver's view)
(Vert. & horiz. positions only)
A Counterclockwise (CCW)
B
C Release
B Clockwise (CW)
D Clamp
D A
SHORT ARM
C D (45-degree position only)
C C Open
D Close
RC0030.eps RC0031.eps
RC3739.eps
The following identification decal (located on the baseplate), shows how the split-arm roll clamp functions:
1 1
OR
1
TYPE O 2 6096928-R1 TYPE 1 2 6093628-R1
RC4075.eps
Clamp force is developed without the The top arm must fully close before
need for the top arm to fully close. clamp pressure is developed.
5 210135-R9
R OLL-HANDLING BASICS
RC0033.eps
RC0032.eps
Clamp through roll centerlines
RC0037.eps
12 in. (30 cm)
RC0036.eps
Roll vertical, tilted back
CLAMP FORCE
Kraft Tissue
GA0072.eps
210135-R9 6
R OLL-HANDLING BASICS
Handling two rolls using split-arm clamp
RC0038.eps
Center of
Rotation
RC3942.eps
RC0789.eps
Lateral Offset
RC1188.eps
RC0039.eps
7 210135-R9
R OLL-HANDLING BASICS
Upending
Center clamp pads
vertically on roll,
if possible
RC3740.eps RC3763.eps
Clamp through roll centerline CAUTION: Verify the clearance between the bottom
of the roll and mast prior to tilting the roll forward.
RC3741.eps RC3743.eps
RC3742.eps
Transporting CAUTION: Transporting in any position other than vertical is not acceptable
unless attachment is specifically designed for that application.
RC4141.eps
210135-R9 8
V ERTICAL PICKUP, TRANSPORT, UNLOADING
RC2167.eps
3-4°
4 Tilt vertical before lowering to floor
12 in.
(30 cm)
RC0043.eps RC0044.eps
9 210135-R9
B ILGE (HORIZONTAL) PICKUP
Short arm
down
RC0046.eps
RC0045.eps
4
A) Tilt, raise roll
3
A) Drive forward, touch short arm to roll
B) Clamp with
long arm
3-4°
2-4 in.
(5-10 cm)
RC0047.eps
RC0049.eps
B) Rotate to vertical
for transport
RC0048.eps
Center of
Rotation
RC3942.eps
Lateral Offset
210135-R9 10
S TACKING, UNSTACKING
1 2
A) Drive slowly forward, touch A) Raise roll for B) Tilt back for
short arm to roll clearance 3-4°
transport
12 in.
(30 cm)
RC2160.eps
3 4
A) Slowly approach stack A) Square truck B) Set roll
to stack, down
drive slowly squarely
forward, stop
B) Tilt roll to 2-4 in.
vertical, raise
for clearance (5-10 cm)
RC1020.eps
RC1009.eps
5 6
HIGH STACKING ABOVE TWO ROLLS: PADS AT BOTTOM OF ROLL:
A) Square truck to stack, drive slowly A) Contact truck OEM to check truck stability
forward, stop B) Perform rotation drift test per Cascade TB258
RC1059.eps RC1021.eps
11 210135-R9
U NLOADING TRUCK TRAILERS (BREAKOUT)
Fixed-Frame Clamp
unloading.
Short Arm
Dockplate required
RC0055.eps
3 4
Drive forward, angle truck to grip Clamp 1st roll, move back
1st roll behind centerline for clearance to re-clamp
RC0056.eps
RC0057.eps
5 6
Re-clamp through roll centerline Raise, tilt back for transport
with long arm, withdraw roll
3-4°
12 in.
(30 cm)
RC0059.eps
RC0058.eps
210135-R9 12
U NLOADING BOXCARS (BREAKOUT)
Fixed-Frame Clamp
1 2
Tilt, center Clamp to 1st roll Position arms to
roll diameter
RC0061.eps
RC0060.eps RC0060.eps
3 4
Drive forward, angle truck to grip roll behind centerline Clamp 1st roll, move back for clearance
to re-clamp
RC0062.eps RC0063.eps
5
Re-clamp through roll centerline with long
arm, withdraw roll
6 Raise, tilt back for transport
3-4°
12 in.
RC0064.eps (30 cm)
RC0059.eps
13 210135-R9
L OADING TRUCK TRAILERS
1
Rotate roll to position
short arm toward wall CAUTION: Trailer
must be inspected
for damage before
loading
Dockplate required
12 in.
(30 cm)
RC0066.eps
3 4
A) Reposition truck to place rolls Position rolls together / use spacers to
against wall prevent load shifting
Short Arm
B) Release
long arm
RC0067.eps RC0068.eps
210135-R9 14
L OADING BOXCARS
1 B) Tilt to
vertical
A) Rotate roll to
position short
arm toward
wall
Dockplate
required
RC0069.eps
RC0070.eps
B) Lower to floor,
release long arm
3
Position arms to
roll diameter, grip
last rolls behind
centerline
RC0061.eps
4
Angle truck to place interior and last rolls
RC0062.eps
Arms not
wedged
15 210135-R9
T OWER CLAMP
Loading, Transport, Unloading, Stacking
B) Touch center
pads to rolls
RC2028.eps
RC1870.eps
(shown: powered
center arms)
3 B) Adjust telescoping
upper clamp arms to
center on upper rolls
A) Center lower
clamp arms on
lower rolls
RC1866.eps
4
Clamp through roll
centerlines
RC1869.eps
(shown: non-powered
center arms)
210135-R9 16
T OWER CLAMP
Loading, Transport, Unloading, Stacking
5
Lift load, proceed slowly
12 in.
(30 cm)
RC2038.eps
6 A) Check Clamp
Pads are vertical
Shut Off Unused Arms
RC2556.eps
No L-shaped loads
B) Check clearances –
• Roll-to-roll
• Truck-to-stack
RC2029.eps
RC1868.eps
17 210135-R9
L OADING WITH ADJUSTABLE BUMPER OPTION
2-4 in.
(5-10 cm)
RC2169.eps
RC0074.eps
C) Clamp with long arm
B) Tilt, drive forward touching bumper to roll
D) When clamping with the long arm, allow the truck
to move in neutral or with clutch disengaged.
The bumper may have a tendency to move the
truck forward or backward when adjusting to the
roll size.
L OAD TROUBLESHOOTING
IF LOAD IS SLIPPING:
Check hydraulic supply pressure and
clamp force, see following:
3
Check weight
1
of roll is within • Appropriate Clamp Service Manual
capacity range of • Clamp Force Indicator
Clamp Operator Guide 214750
• Establish Clamp Force TB 284
(See nameplate)
2 4
Check condition and
Re-clamp load, type of contact pad
contact pads surface, change or
centered on and replace if necessary
parallel to roll, roll
against bumper
RC2166.eps
(if equipped)
210135-R9 18
S AFE OPERATION AND MAINTENANCE
OSHA Regulations – Industrial Trucks and Attachments
(6) A safe distance shall be maintained from the edge of ramps or
WARNING: The safe operation and maintenance of
platforms while on any elevated dock or platform or freight car.
industrial trucks is regulated by Occupational Safety
Trucks shall not be used for opening or closing freight doors.
and Health (OSHA) regulations 1910.178 and Ameri-
can National Standards Institute (ANSI) Safety (10) A load backrest extension shall be used whenever necessary
Standard for Powered Industrial Trucks, ANSI B56.1. When to minimize the possibility of the load or part of it from falling
operating and maintaining industrial trucks equipped with rearward.
attachments you should pay particular attention to the following (n) Traveling
sections of these regulations. You should be familiar with all
sections of these regulations. Ask your employer for the (4) The driver shall be required to slow down and sound the horn
complete regulations. at cross isles and other locations where vision is obstructed. If
the load being carried obstructs forward view, the driver shall be
required to travel with the load trailing.
(a) General Requirement
(7i) When ascending or descending grades in excess of 10 percent,
(4) Modifications and additions which affect capacity and safe
loaded trucks shall be driven with the load upgrade.
operation shall not be performed by the customer or user without
manufacturers prior written approval. Capacity, operation and (7iii) On all grades the load and load engaging means shall be tilted
maintenance instruction plates, tags or decals shall be changed back if applicable, and raised only as far as necessary to clear
accordingly. the road surface.
(5) If the truck is equipped with front-end attachments other than (o) Loading
factory installed attachments, the user shall request that the truck (1) Only stable or safely arranged loads shall be handled. Caution
be marked to identify the attachments and show the appropriate shall be exercised when handling off-center loads which cannot
weight of the truck and attachment combination at maximum be centered.
elevation with load laterally centered.
(2) Only loads within the rated capacity of the truck shall be handled.
(6) The user shall see that all nameplates and markings are in place
and maintained in a legible condition. (3) The long or high (including multiple-tiered) loads which may
affect capacity shall be adjusted.
(e) Safety Guards
(4) Trucks equipped with attachments shall be operated as partially
(2) If the type of load presents a hazard, the user shall equip fork loaded trucks when not handling a load.
trucks with a vertical load backrest extension in accordance with
(a)(2) following. (5) A load engaging means shall be placed under the load as far as
possible; the mast shall be carefully tilted backward to stabilize
(a)(2) All new powered industrial trucks acquired and used the load.
by an employer after February 15, 1972 shall meet the design
and construction requirements for powered industrial trucks (6) Extreme care shall be used when tilting the load forward or
established in the “American National Standard for Powered backward, particularly when high tiering. Tilting forward with load
engaging means elevated shall be prohibited except to pick up a
Industrial Trucks, Part II, ANSI B56.1”, except for vehicles
load. An elevated load shall not be tilted forward except when the
intended primarily for earth moving or over-the-road hauling.
load is in a deposit position over a rack or stack. When stacking
(l) Operator Training or tiering, only enough backward tilt to stabilize the load shall be
used.
Only trained and authorized operators shall be permitted to operate a
powered industrial truck. Methods shall be devised to train operators (p) Operation of the Truck
in the safe operation of powered industrial trucks. (1) If at any time a powered industrial truck is found to be in need
of repair, defective, or in any way unsafe, the truck shall be
(m) Truck Operations
taken out of service until it has been restored to safe operating
(1) Trucks shall not be driven up to anyone standing in front of a condition.
bench or other fixed object.
(q) Maintenance of Industrial Trucks
(2) No person shall be allowed to stand or pass under the elevated
(1) Any power-operated industrial truck not in safe operating
portion of any truck, whether loaded or empty.
condition shall be removed from service. All repairs shall be
(3) Unauthorized personnel shall not be permitted to ride on made by authorized personnel.
powered industrial trucks. A safe place to ride shall be provided
(5) All parts of any such industrial truck requiring replacement shall
where riding of trucks is authorized.
be replaced only by parts equivalent as to safety with those used
(4) The employer shall prohibit arms or legs from being placed in the original design.
between the uprights of the mast or outside the running lines of
(6) Industrial trucks shall not be altered so that the relative positions
the truck.
of the various parts are different from what they were when
(5i) When a powered industrial truck is left unattended, load originally received from the manufacturer, nor shall they be
engaging means shall be fully lowered, controls shall be altered either by the addition of extra parts not provided by
neutralized, power shall be shut off and brakes set. Wheels shall the manufacturer or by the elimination of any parts. Additional
be blocked if the truck is parked on an incline. counter-weighting of fork trucks shall not be done unless
(5ii) A powered industrial truck is unattended when the operator is 25 approved by the truck manufacturer.
feet or more away from the vehicle which remains in his view, or (7) Industrial trucks shall be examined before being placed in service
whenever the operator leaves the vehicle and it is not in his view. and shall not be placed in service if the examination shows any
(5iii) When the operator of an industrial truck is dismounted and within condition adversely affecting the safety of the vehicle. Such
25 feet of the truck still in his view, the load engaging means examinations shall be made at least daily. When industrial trucks
shall be fully lowered, controls neutralized and the brakes set to are used on a round-the-clock basis, they shall be examined after
each shift. Defects when found shall be immediately reported
prevent movement.
and corrected.
19 210135-R9
BLANK
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 Cascade Canada Inc. Cascade do Brasil
U.S. Headquarters 5570 Timberlea Blvd. Praça Salvador Rosa,
2201 NE 201st Mississauga, Ontario 131/141-Jordanópolis,
Fairview, OR 97024-9718 Canada L4W-4M6 São Bernardo do Campo - SP
Tel: 800-CASCADE (227-2233) Tel: 905-629-7777 CEP 09891-430
Fax: 888-329-8207 Fax: 905-629-7785 Tel: 55-13-2105-8800
Fax: 55-13-2105-8899
EUROPE-AFRICA
Cascade Italia S.R.L. Cascade (Africa) Pty. Ltd.
European Headquarters PO Box 625, Isando 1600
Via Dell’Artigianato 1 60A Steel Road
37030 Vago di Lavagno (VR) Sparton, Kempton Park
Italy South Africa
Tel: 39-045-8989111 Tel: 27-11-975-9240
Fax: 39-045-8989160 Fax: 27-11-394-1147
ASIA-PACIFIC
Cascade Japan Ltd. Cascade Korea Cascade-Xiamen Cascade India Material
2-23, 2-Chome, 121B 9L Namdong Ind. No. 668 Yangguang Rd. Handling Private Limited
Kukuchi Nishimachi Complex, 691-8 Gojan-Dong Xinyang Industrial Zone No 34, Global Trade Centre
Amagasaki, Hyogo Namdong-Ku Haicang, Xiamen City 1/1 Rambaugh Colony
Japan, 661-0978 Inchon, Korea Fujian Province Lal Bahadur Shastri Road,
Tel: 81-6-6420-9771 Tel: +82-32-821-2051 P.R. China 361026 Navi Peth, Pune 411 030
Fax: 81-6-6420-9777 Fax: +82-32-821-2055 Tel: 86-592-651-2500 (Maharashtra) India
Fax: 86-592-651-2571 Phone: +91 020 2432 5490
Fax: +91 020 2433 0881
Cascade Australia Pty. Ltd. Cascade New Zealand Sunstream Industries
1445 Ipswich Road 15 Ra Ora Drive Pte. Ltd.
Rocklea, QLD 4107 East Tamaki, Auckland 18 Tuas South Street 5
Australia New Zealand Singapore 637796
Tel: 1-800-227-223 Tel: +64-9-273-9136 Tel: +65-6795-7555
Fax: +61 7 3373-7333 Fax: +64-9-273-9137 Fax: +65-6863-1368
c
© Cascade Corporation 2011 08-2011 Part Number 210135-R9
O PERATOR'S GUIDE SUPPLEMENT
cascade
corporation
Cascade is a Registered Trademark of Cascade Corporation
C ONTENTS
Introduction i
WARNING: Rated capacity of the
Display Basics 1 truck/attachment combination is a
Status Light Basics 1 responsibility of the original truck
Start-Up, Traveling Empty, Addressing Load 2 manufacturer and may be less than
Clamping Loads 2 shown on the attachment nameplate.
Consult the truck nameplate.
Clamping Loads in Override (or at maximum lift) 3
Hoist Load, Traveling 3 WARNING: Do not operate an
Setting Load Down, Unclamping 4 attachment equipped with Adaptive
Force Control (AFC) unless you have
Display Indications when Operating Clamp 5 been trained in its' use.
Optional Damage-Reduction Features 6
I NTRODUCTION
AFC Override
Switch (optional)
AC1673.eps
i 6095126-R1
D ISPLAY BASICS
Pressure/Force Icons
Value or Error Code
Clamp pressure
(psi) values in psi
(bar)
Clamp pressure
values in bar
Clamp force
(psi)
0
values in pounds Other Icons
(lbf)
Imperial NA
NA
or
Low Medium High Metric* Force Gauges*
Range Range Range or (Service option
Arm Arm Arm Appears Pressure* setting that is
Position Position Position when an typically disabled)
error
occurs * Icon shown on display
above button
AC1642.ai
AC1643.ai
6095126-R1 1
S TART-UP, TRAVELING EMPTY, ADDRESSING LOAD
Pressure or force
should show "0" Shows steady
red
AC1630.ai
C LAMPING LOADS
2
AC1631.ai
Clamp with long arm
until pads are secure
on roll
AC0499.eps Starting
Upper arm needs to clamp force/
900
be clamped on roll pressure
or closed completely before
before hoisting hoisting
OK Shows
steady
M/E P/F green
Shows
WARNING: When status
light shows flashing
Arm OK to Hoist
green: AFC in override Position Icon will
mode. Driver controls appear
clamp force/pressure.
2 6095126-R1
C LAMPING LOADS IN OVERRIDE (or at maximum lift)
1
CAUTION: Use optional override pushbutton Press AFC CLAMP Lever
if required for trailer and railcar breakout or system override
when maximum pressure is required. Status pushbutton
Light shows flashing green. Driver controls
clamp force/pressure.
Driver controls
2 Shows flashing
green, in override
AC1104.eps
clamp force/pressure
3 Clamp roll
2300
AC1632.ai
1 2
Drive must see pads Real time clamp Hoist load, display shows:
are secure on roll. force/pressure Real time clamp force/pressure
NOTE: Value may fluctuate as truck Shows steady
travels over rough terrain. green, OK to lift
1700
OK
M/E P/F
OK to hoist
6095126-R1 3
S ETTING LOAD DOWN, UNCLAMPING
1 Tilt to vertical,
(back-tilt required
if angled clamp
2 Lower load.
NOTE: If equiped with optional
'Drop/Stop' valve, the system
will automatically limit
mount used) lowering to prevent slack in
chains.
2-12 in.
(5-30 cm)
3
AC1634.ai
Unclamp
Shows steady red,
once unclamped
4 6095126-R1
D ISPLAY INDICATIONS WHEN OPERATING CLAMP
Clamp force/pressure.
Clamp force shown.
900
maximum lift, driver controls clamp
force/pressure. Display will show
real time force/pressure.
1700
Maximum clamp force/pressure
achieved during hoist/clamp cycle.
AC1636.ai AC1636.ai
AC0379.eps
6095126-R1
AC1637.ai 5
U SE OF OPTIONAL DAMAGE-REDUCTION FEATURES
TILT CONTROL
Mast automatically stops at vertical position when tilting
forward or backward.
OR
AC0373.eps AC0369.eps
ROTATIONAL CONTROL
Clamp automatically stops at both vertical positions, and
at horizontal (bilge) position when rotating.
ROTATE
To continue rotating from vertical or horizontal position,
wait 3 seconds for reset,
OR
Press override button on ROTATE control lever to
rotate continuously without stopping.
AC0367.eps
AC0374.eps
OK
To
UnclampUnclamp
Circuit Enabled
PowerLower
Decal Part
ON To
Unclamp
No. 6026655
CLAMP
Decal Part No. 6026655-R1
CAUTION
Press button to
release Clamp AC0622.eps
6 6095126-R1
BLANK
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 Cascade Canada Inc. Cascade do Brasil
U.S. Headquarters 5570 Timberlea Blvd. Praça Salvador Rosa,
2201 NE 201st Mississauga, Ontario 131/141-Jordanópolis,
Fairview, OR 97024-9718 Canada L4W-4M6 São Bernardo do Campo - SP
Tel: 800-CASCADE (227-2233) Tel: 905-629-7777 CEP 09891-430
Fax: 888-329-8207 Fax: 905-629-7785 Tel: 55-13-2105-8800
Fax: 55-13-2105-8899
EUROPE-AFRICA
Cascade Italia S.R.L. Cascade (Africa) Pty. Ltd.
European Headquarters PO Box 625, Isando 1600
Via Dell’Artigianato 1 60A Steel Road
37030 Vago di Lavagno (VR) Sparton, Kempton Park
Italy South Africa
Tel: 39-045-8989111 Tel: 27-11-975-9240
Fax: 39-045-8989160 Fax: 27-11-394-1147
ASIA-PACIFIC
Cascade Japan Ltd. Cascade Korea Cascade-Xiamen Cascade India Material
2-23, 2-Chome, 121B 9L Namdong Ind. No. 668 Yangguang Rd. Handling Private Limited
Kukuchi Nishimachi Complex, 691-8 Gojan-Dong Xinyang Industrial Zone No 34, Global Trade Centre
Amagasaki, Hyogo Namdong-Ku Haicang, Xiamen City 1/1 Rambaugh Colony
Japan, 661-0978 Inchon, Korea Fujian Province Lal Bahadur Shastri Road,
Tel: 81-6-6420-9771 Tel: +82-32-821-2051 P.R. China 361026 Navi Peth, Pune 411 030
Fax: 81-6-6420-9777 Fax: +82-32-821-2055 Tel: 86-592-651-2500 (Maharashtra) India
Fax: 86-592-651-2571 Phone: +91 020 2432 5490
Fax: +91 020 2433 0881
Cascade Australia Pty. Ltd. Cascade New Zealand Sunstream Industries
1445 Ipswich Road 15 Ra Ora Drive Pte. Ltd.
Rocklea, QLD 4107 East Tamaki, Auckland 18 Tuas South Street 5
Australia New Zealand Singapore 637796
Tel: 1-800-227-223 Tel: +64-9-273-9136 Tel: +65-6795-7555
Fax: +61 7 3373-7333 Fax: +64-9-273-9137 Fax: +65-6863-1368
c
© Cascade Corporation 2012 03-2012 Part Number 6095125-R1
T ROUBLESHOOTING
AFC System
7 SP
AC
Tools Required
.
2.1-2
In addition to a normal selection of technician’s hand tools,
the following are needed to troubleshoot the AFC system:
• Cascade Service Pendant 6095901 (includes cable).
IMPORTANT: Most troubleshooting requires a service
pendant connected to the AFC controller.
AC1692.ai
• Digital Multimeter, test leads, adapters (Service Kit
213867).
• 5000 psi (345 bar) pressure gauge and hose, No. 4 & 6 Digital Multimeter Kit 213867
connect-under-pressure test fittings, and adapters
(Service Kit 6004960).
• Accumulator Charging/Adjusting Kit (Service Kit
228236). !
Service Pendant
AC0311.eps
2.1-3
• Refer to Setup Instructions 6095125 for basic pendant
operation. Quick-Connect Pressure Gauge
• The service pendant is used for the following: Kit 6004960
–– Find error codes
–– Verify the function of pressure transducers,
GA0150.eps
solenoids, switches and display (if equipped)
–– Adjust operating parameters
–– Reset operating parameters to factory default
–– Verify code and controller function
Cascade Corp.
File No. AU3546
6095127-R4 1
T ROUBLESHOOTING
3.1 Troubleshooting
AFC problems and solutions are listed on the following
pages, under one of the categories shown below.
Determine All The Facts – It is important to gather all
the facts about the problem before beginning any service
procedures. The first step is to talk to the equipment
operator and ask for a complete description of the
malfunction or problem.
For new AFC Setup – Follow Setup Instructions 6095125,
in this manual first, before changing any values using the
troubleshooting charts.
IMPORTANT: Log all parameter changes on the log sheets
located at the end of the Setup Instructions 6095125.
AFC System
2 6095127-R4
T ROUBLESHOOTING
6.0_Error_Codes
_____131 131
AC1668.eps
Component
131
Component Type Identification Error Type
1 = Pressure Transducer Refer to diagram 1 = Open Circuit
2 = Solenoid below or schematic 2 = Short Circuit
3 = Switch for location.
AC1693.ai
SW1
SW2
RC3349.eps
SOL1
PT3
SOL2 SOL3
6095127-R4 3
T ROUBLESHOOTING
Flash
Yellow
Test Solenoid 2,
Test Solenoids,
Low Voltage System 3.3-4
Power Cycle 3.3-4
has a Verify PWM
display NO
YES
Test Display, 3.3-7
Replace cable and
NO Datalogger, 3.3-11
Test Status
Lights, 3.3-6
Junction YES Test 30
Box Supply pin cable,
12V OK? NO
NO
Display
Replace Troubleshoot NO (if equipped) YES NO
Section 3.3-7 Solenoids
Junction Box Operation OK?
Hardware Check Screen
Complete YES
YES
Auto Test autoswitch
Switch (if equipped), use
YES
OK Service Pendant, 5.3
tester. 1 1
Y2 X2 W2 T2 S2 R2 P2 N2 M2 L2
Y3 X3 W3 T3 S3 R3 P3 N3 M3 L3
Continuity Test
X
O
B
N
O
TI
N
JU
D1
P1
D1 D2 E1 E2 F1 F2 F3 G3
Junction Box Terminal Blocks
D1- D2- E1- E2- F1- F2- F3- G3- B1 A1 B2 E3 E3 G1- G2- H3- J1- J2- J3- H1- H2- U1 U3 U5
AC1698.eps
6095127-R4 5
T ROUBLESHOOTING
Pressure
Transducer
Connector
1 3
2 4
Connector End
AC1703.ai
6 6095127-R4
T ROUBLESHOOTING
3.3-4 Solenoids
Solenoid connectors are equipped with an status LED
to verify electrical connection.
Testing – 5.2_Solenoids
Use the service pendant (submenu 5.2) to verify
solenoid status LED is illuminated when indicated by Values_in_%_Current
pendant menu. Sol1__off_Sol3___off
NOTE: Sol 1 and Sol 4 are equipped only with the
optional drop stop valve.
Sol2__XXX_Sol4___off
NOTE: Sol 2 is a PWM value. To change PWM level at
AC1668.eps
Sol 2, do one of the following:
• If equipped, press override button or,
• Close the maximum lift switch by hoisting to
maximum lift or,
• Place a metal object in front of the maximum lift
switch to close it.
Service Pendant Unavailable – To verify solenoid
function, disconnect the solenoid wires at the junction
box terminal and connect the brown wire to a 12v Solenoid
supply (+) terminal and the blue wire to (-) terminal in Status LED
the junction box. If solenoid valve does not operate
with direct connection, test coil continuity/resistance.
Troubleshooting –
• Verify connection polarity brown (+) and blue (-)
• If coil continuity is open, replace coil. Refer to
Service Manual 6095128.
• If coil continuity is OK, solenoid valve may need
replacement. Refer to Service Manual 6095128.
Brown Wire
• Verify Sol 2 brown (BN) wire is connected to
terminal G2 and blue (BU) wire is connected to
terminal H2.
AC1704.ai
6095127-R4 7
T ROUBLESHOOTING
4 mm Switch
Connector
AC1706.ai
8 6095127-R4
T ROUBLESHOOTING
Test
Status Light Turn truck on
Start
Verify junction
box terminal
Got to Power NO Any LED connections: NO Any LED YES
Tree 3.5-1 illuminated Black – H3- illuminated Open Clamp
White – H3
Red – J3
YES
NO Status
NO NO 2X
light is steady
red
Verify continuity:
Junction Box to Controller
(Section 3.3-2)
H3 to W3, J3 to X3 and
H3- to negative (-) Junction Status
NO NO 2X
Box Terminal light is steady
green
YES
NO NO
Replace Replace
cable junction box
AC1700.ai
6095127-R4 9
T ROUBLESHOOTING
3.3-7 Display
When initially powering on, the display will show a flash
screen of part numbers for 5 seconds.
NOTE: To enable the gauge button, use the service
pendant and select 4 Advanced Settings. Go to menu 4.16
to enable display buttons.
Test Display
Start
No
display
but
Shows powered
operating NO First screen only
screen
(5 sec)
YES
Show Values
error NO change NO Perform Hardware
screen appropriately Check, 3.3-1
Any
other
NO color Cotnroller:
Display Replace Green
LED1 - color
buttons work display LED 2 - Green
YES
YES Display
consistent with
Display Test operator
Complete guide
NO
AC1701.ai
Replace
controller
10 6095127-R4
T ROUBLESHOOTING
TM
3.3-11 Datalogger
• Verify continuity between datalogger connector and
junction box. Refer to Electrical Schematic (Section 12 Pin Connector
3.5-3) and Junction Box Terminal Table (Section 3.5-4) (socket side shown)
to check the following: 1
6
Pin 9 ➝ B1
Pin 10 ➝ C1
• See Datalogger User Manual (6075865) for setup and Connection to
troubleshooting. junction box and
other components
7 Test: 9 10 12
6095127-R4 AC1828.eps 11
T ROUBLESHOOTING
9 R
8
If the pendant does not start correctly, verify cable terminal
TE
EN
CE
7 SPA
Baud 9600
Backlight On
Disable Break CMND
Scroll on 81
Shift Lock Disable
Test Disable
CL/LF Node Normal
Escape Mode ANSI
Echo Disable
Handshake Disable
Xon/Xoff Enable
Cursor Disable
KNP Function Disable
Key Click Disable
Repeat Medium
Stop Bits 1
Parity None
Data Bits 8
12 6095127-R4
T ROUBLESHOOTING
3.4 Performance
3.4-1 Status Light and Loads
Problem Solution
6095127-R4 13
T ROUBLESHOOTING
Load slips when lift truck Using the service pendant, select 2 Operation
hits bump or dockplate Menu and choose 2.2 CFF (no auto switch) OR
2.2a, 2.2b and 2.2c (with auto switch). Increase
clamp force factor in .2 increment from previous
setting. Try again.
When handling two rolls: Verify that the larger diameter roll is on the
A) lower roll does not hoist, bottom.
B) lower roll slips out
14 6095127-R4
T ROUBLESHOOTING
Large pressure increase Test maximum lift switch. Refer to Section 3.3-5.
when mast reaches full lift
Status light shows steady Using the service pendant, select 4 Advanced
green LED is ON but initial Settings and go to 4.3 Start P Diff. Increase
pressure is higher than start pressure differential by 25 psi (1.7 bar).
maximum pressure Try again.
6095127-R4 15
T ROUBLESHOOTING
Display’s arm position does Check auto switch mechanism inside long arm
not change for damage.
16 6095127-R4
T ROUBLESHOOTING
Pressure remains the same Check solenoid 2 and 3 coils for continuity
while AFC tries to increase polarity at junction box (measure across
pressure opposite spade terminals). Replace if required.
Relief valve squeals when Check priority flow valve for missing or split
lifting heavy load O-ring or contamination.
6095127-R4 17
T ROUBLESHOOTING
PUMP AC1969.eps
Problem Solution
18 6095127-R4
T ROUBLESHOOTING
NO
YES
YES
YES
OK
Verify Menu 3.4 value Menu 7.2 Refer to Quick
is 75 psi less than YES NO Hardware Check,
shows Sol 1 &
lowering pressure (P1) Sol 4 are on Troubleshooting NO
value Section 3.3-1
Menu 3.3 NO
value is less
then 1000 lbs.
NO
YES
OK Increase Menu 3.3
value by 50 lbs
YES
Troubleshooting
Complete
AC1970.eps
6095127-R4 19
T ROUBLESHOOTING
3.5 Appendix
3.5-1 Power Tree
Power Check
Start
YES Display
illuminated
12V-14V
NO across junction
box terminals NO
(+) and (-)
YES
YES Controller
LED’s
illuminate
Power Check
Complete NO
YES Voltage at
Junction Box
Terminals
NO
AC1702.ai
20 6095127-R4
T ROUBLESHOOTING
Revolving Connection,
Slip Ring
OPEN CLAMP
Hose Reel
or IHR
Proportional
Pressure OPEN CLAMP
Control Valve
OPEN CLAMP
PT2
Pressure
Transducer
Manifold
SOL3
PT1
TRUCK ACCUM
Hoist
Drop-Stop PT1
PT1
Valve
(optional)
To Mast
SOL 1
Valve PUMP TANK
SOL4
PUMP OR
Priority Flow
Control Valve Truck Relief
CONTROL Return-to-Tank
VALVE Fitting
PRIORITY
PUMP
Truck
Tank
AC1669.eps Truck Pump
6095127-R4 21
T ROUBLESHOOTING
OR SOL2 SOL3
Pressure PT1
Transducer SOL4
To Junction Manifold PT1
Box Port 1 SOL1
Junction Hoist Drop/
Box Stop Valve
Optional AFC (Optional)
Override Switch Controller
(Normally Open)
1 2 3 4
Service Pendant
Status Light
Unswitched
Ground
Scanner
Switched WARNING: For UL
Classified kits, to
DC Converter
reduce the risk of
(if equipped) fire, replace only
Datalogger
Status LED Truck with same type
Fuse Block and rating of fuse.
Key
X
O
B
N
O
BK Black OG Orange
TI
Example:
N
JU
BU Blue RD Red D1 terminal
BN Brown WH White
GN Green YE Yellow
4
3
2 Junction
Box Ports
1
D1 D2 E1 E2 F1 F2 F3 G3
D1- D2- E1- E2- F1- F2- F3- G3- B1 A1 B2 E3 E3 G1- G2- H3- J1- J2- J3- H1- H2- U1 U3 U5
AC1728.eps
6095127-R4 23
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 Cascade Canada Inc. Cascade do Brasil
U.S. Headquarters 5570 Timberlea Blvd. Praça Salvador Rosa,
2201 NE 201st Mississauga, Ontario 131/141-Jordanópolis,
Fairview, OR 97024-9718 Canada L4W-4M6 São Bernardo do Campo - SP
Tel: 800-CASCADE (227-2233) Tel: 905-629-7777 CEP 09891-430
Fax: 888-329-8207 Fax: 905-629-7785 Tel: 55-13-2105-8800
Fax: 55-13-2105-8899
EUROPE-AFRICA
Cascade Italia S.R.L. Cascade (Africa) Pty. Ltd.
European Headquarters PO Box 625, Isando 1600
Via Dell’Artigianato 1 60A Steel Road
37030 Vago di Lavagno (VR) Sparton, Kempton Park
Italy South Africa
Tel: 39-045-8989111 Tel: 27-11-975-9240
Fax: 39-045-8989160 Fax: 27-11-394-1147
ASIA-PACIFIC
Cascade Japan Ltd. Cascade Korea Cascade-Xiamen Cascade India Material
2-23, 2-Chome, 121B 9L Namdong Ind. No. 668 Yangguang Rd. Handling Private Limited
Kukuchi Nishimachi Complex, 691-8 Gojan-Dong Xinyang Industrial Zone No 34, Global Trade Centre
Amagasaki, Hyogo Namdong-Ku Haicang, Xiamen City 1/1 Rambaugh Colony
Japan, 661-0978 Inchon, Korea Fujian Province Lal Bahadur Shastri Road,
Tel: 81-6-6420-9771 Tel: +82-32-821-2051 P.R. China 361026 Navi Peth, Pune 411 030
Fax: 81-6-6420-9777 Fax: +82-32-821-2055 Tel: 86-592-651-2500 (Maharashtra) India
Fax: 86-592-651-2571 Phone: +91 020 2432 5490
Fax: +91 020 2433 0881
Cascade Australia Pty. Ltd. Cascade New Zealand Sunstream Industries
1445 Ipswich Road 15 Ra Ora Drive Pte. Ltd.
Rocklea, QLD 4107 East Tamaki, Auckland 18 Tuas South Street 5
Australia New Zealand Singapore 637796
Tel: 1-800-227-223 Tel: +64-9-273-9136 Tel: +65-6795-7555
Fax: +61 7 3373-7333 Fax: +64-9-273-9137 Fax: +65-6863-1368
c
© Cascade Corporation 2010 09-2010 Part Number 6095127-R4
P ERIODIC MAINTENANCE
500-Hour
Maintenance
Every time the lift truck is serviced or every 500 hours
of truck operation, whichever comes first, complete
the following maintenance procedures on the AFC
components:
• Check for loose or missing bolts, worn or damaged
supply hoses and hydraulic leaks.
• Check for wire pinch points and inspect wires for
damage.
• Check accumulator pressure. See the Load
Cushion User Guide in the Install section. Follow the
pressure checking procedures.
• Check transducer operation for each valve. See the
Setup Instructions in the Setup section to the test
the transducers. Follow the procedures in the Test
Pressure Transducers section.
6012810-R1 1
S ERVICE
Cascade Corp.
File No. AU3546
6095128-R1 1
S ERVICE
Connector
PO Check
Pressure Cartridge
Transducers
PT2, PT4
PO Check
Cartridge
NC Modulating
Cartridge
AC1664.eps
Relief
Cartridge Proportional Relief
Cartridge
Solenoid Coil SOL2
Solenoid w/Manual Override Screw
Valve
Cartridge Connector
Mounting
Screw
Solenoid
Coil SOL3
Plastic
Nut Screws
(M3 x 42)
Solenoid Coil,
Plastic Retaining Nut
O-Rings (3) Tamperproof Cap O-Rings (2)
SOL3
AC0685.eps AC0686.eps
Back-Up Rings (4) Back-Up Rings (2)
2 6095128-R1
S ERVICE
O-Rings (3)
O-Rings (3)
AC0681.eps
Back-Up Rings (3)
AC0682.eps
6095128-R1 3
S ERVICE
Solenoid
Coil
SOL4
Pressure
Solenoid Valve Transducer PT1
Cartridge
Solenoid
Coil
Valve Body Solenoid Valve SOL1
Cartridge
2 Position 2 Way
Valve Cartridge
Priority Flow
Control Cartridge
AC1674.eps
Hoist Drop-Stop Valve (optional)
O-Rings (2)
Nut SOL4
AC0684.eps
Solenoid Coil
SOL1
AC0717.eps
AC1687.eps
Back-Up Ring (1) Back-Up Ring (1) Back-Up Rings (2)
4 6095128-R1
S ERVICE
Replacement Cover
4
Reel Screw
8 While holding the reel stationary, unwrap the string from
the reel and pull back through the guide holes.
IMPORTANT: Make sure string does not kink or knot.
9 While holding the string taught, slowly let the reel’s Cover Capscrews
tension wind the string onto the reel.
10 Install new dust wipers and wiper cover.
11 Install cover and tighten capscrews to finger tight. End Piece
5
Reel
Surface
Hole
Screw
AC1552.eps AC1553.eps
7
Reel Slot
Rotate Reel
Clockwise
6095128-R1 5
S ERVICE
Revolving Connection,
Slip Ring
OPEN CLAMP
Hose Reel
or IHR
Proportional
Pressure OPEN CLAMP
Control Valve
OPEN CLAMP
PT2
Pressure
Transducer
Manifold
SOL3
PT1
TRUCK ACCUM
Hoist
Drop-Stop PT1
PT1
Valve
(optional)
SOL 1
To Mast PUMP TANK
SOL4
PUMP
Priority Flow
Control Valve Truck Relief
CONTROL Return-to-Tank
VALVE Fitting
PRIORITY
PUMP
Truck
Tank
AC1669.eps Truck Pump
6 6095128-R1
S ERVICE
OR SOL2 SOL3
Pressure PT1
Transducer SOL4
To Junction Manifold PT1
Box Port 1 SOL1
Junction Hoist Drop/
Box Stop Valve
Optional AFC (Optional)
Override Switch Controller
(Normally Open)
1 2 3 4
Service Pendant
Status Light
Unswitched
Ground
Scanner
Switched WARNING: For UL
Classified kits, to
DC Converter
reduce the risk of
(if equipped) fire, replace only
Datalogger
Status LED Truck with same type
Fuse Block and rating of fuse.
Key
AMERICAS
Cascade Corporation Cascade Canada Inc. Cascade do Brasil
U.S. Headquarters 5570 Timberlea Blvd. Praça Salvador Rosa,
2201 NE 201st Mississauga, Ontario 131/141-Jordanópolis,
Fairview, OR 97024-9718 Canada L4W-4M6 São Bernardo do Campo - SP
Tel: 800-CASCADE (227-2233) Tel: 905-629-7777 CEP 09891-430
Fax: 888-329-8207 Fax: 905-629-7785 Tel: 55-13-2105-8800
Fax: 55-13-2105-8899
EUROPE-AFRICA
Cascade Italia S.R.L. Cascade (Africa) Pty. Ltd.
European Headquarters PO Box 625, Isando 1600
Via Dell’Artigianato 1 60A Steel Road
37030 Vago di Lavagno (VR) Sparton, Kempton Park
Italy South Africa
Tel: 39-045-8989111 Tel: 27-11-975-9240
Fax: 39-045-8989160 Fax: 27-11-394-1147
ASIA-PACIFIC
Cascade Japan Ltd. Cascade Korea Cascade-Xiamen Cascade India Material
2-23, 2-Chome, 121B 9L Namdong Ind. No. 668 Yangguang Rd. Handling Private Limited
Kukuchi Nishimachi Complex, 691-8 Gojan-Dong Xinyang Industrial Zone No 34, Global Trade Centre
Amagasaki, Hyogo Namdong-Ku Haicang, Xiamen City 1/1 Rambaugh Colony
Japan, 661-0978 Inchon, Korea Fujian Province Lal Bahadur Shastri Road,
Tel: 81-6-6420-9771 Tel: +82-32-821-2051 P.R. China 361026 Navi Peth, Pune 411 030
Fax: 81-6-6420-9777 Fax: +82-32-821-2055 Tel: 86-592-651-2500 (Maharashtra) India
Fax: 86-592-651-2571 Phone: +91 020 2432 5490
Fax: +91 020 2433 0881
Cascade Australia Pty. Ltd. Cascade New Zealand Sunstream Industries
1445 Ipswich Road 15 Ra Ora Drive Pte. Ltd.
Rocklea, QLD 4107 East Tamaki, Auckland 18 Tuas South Street 5
Australia New Zealand Singapore 637796
Tel: 1-800-227-223 Tel: +64-9-273-9136 Tel: +65-6795-7555
Fax: +61 7 3373-7333 Fax: +64-9-273-9137 Fax: +65-6863-1368
c
© Cascade Corporation 2010 09-2010 Part Number 6095128-R1
P ARTS MANUAL
Adaptive Force
Control
2 NO
Assembly 1
5
6
BK
SP
4 9
8
R
TE
EN
7
E
AC
SP
0
.
Scanner
Junction Box
Auto-Switch
Datalogger
Override
Cylinder Switch
Revolving
Connection
& Slip Ring
To Truck Power
LED
Pressure
Control Valve
To Truck Power
or DC to DC
Voltage Converter
AC1694.ai
1 2
AC1628.ai
0 1 8%
7#
4^
3
AC1641.ai
2&
3
@
5$
6
REF QTY PART NO. DESCRIPTION
9# 6091349 Proportional Pressure Control Valve
1 1 6091350 Valve Body
2 1 227785 Relief Cartridge
3 1 227836 Solenoid Coil – 12V
4 1 227787 Valve Cartridge
5 1 228739 Solenoid Valve
6 1 227835 Solenoid Coil – 12V
7 1 228738 Check Valve
8 1 228737 Check Valve
9 1 228740 Relief Valve
10 2 6091233 Pressure Transducer
11 1 6092862 Cable Assembly
12 2 6090961 Solenoid Cable Assembly
13 2 6024967 Seal Kit
14 1 6024970 Seal Kit
15 1 6024968 Seal Kit
16 1 6024964 Seal Kit
17 1 6024969 Seal Kit
1 2
AC1646.ai
9 1 6#
5@ 4$
AC1645.ai
7 3
2%
8 3
!
5@
1
2
3
4
AC1647.ai
4000 mm 5000 mm
Cable Cable
REF QTY PART NO. PART NO. DESCRIPTION
6092329 6803005 Display Assembly
1 1 6093132 6093132 Display
2 1 6092322 6092322 Bracket
3 4 6071505 6071505 Capscrew, M4 x 6
4 1 6090897 6803006 Cable Assembly
TM
3
86
75
60
r:
be
um
tN r
Pa
e
vic
De
3
86
75
60
r:
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um
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Kit
Q
1
2
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9
8
6
8
AC1836.eps
5 4
AC1662.ai
Long Short
Range Range
9
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2 3
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AC2672.eps
Power Maximum
Supply Mast fork Conductors Supply
Group Height (in.) (No. @ AWG) Application
6844333 166 2 @ 18 ERC – Unswitched
6844335 166 2 @ 20 & 4 @ 26 AFC & ERC – Unswitched 1
1 Do not use 26 AWG for high voltage or high current applications; 26 AWG rated @ .25A,
20 AWG rated @ 5A.
AFC: Adaptive Force Control
ERC: Electronic Rotational Control
Common Parts
REF QTY PART NO. DESCRIPTION REF QTY PART NO. DESCRIPTION
6844329 Power Supply Install Kit ● 15 1 6832205 Clamp
3 1 6818145 Sheave Assembly ■ 16 2 6026763 Spacer Plate
4 1 6820449 Conduit 17 1 6819937 Spacer Block
5 1 6838404 Nut 1 206321 Capscrew, M6 x 16
18
6 1 6819600 Back Plate 1 763169 Capscrew, M6 x 20
7 1 6818146 Bracket 19 1 206323 Washer, M6
8 2 6819200 Bearing 20 1 6844372 Junction Block
9 1 6806108 Roller 21 2 767614 Capscrew, M10 x 20
10 1 6819224 Spacer Plate 22 1 6400135 Washer, M10
11 2 786881 Nut 23 1 6846510 Hose Clamp
12 2 6819533 Capscrew, M8 x 65 24 1 6846511 Anchor Plate
2 6819534 Capscrew, M8 x 70 25 1 6027117 Alignment Tool
13
2 6026778 Capscrew, M8 x 80 26 1 6846222 UL Decal
14 2 6820902 Spacer Plate
● Includes items 14 - 26.
■ Includes items 7 - 12.
9
8 7
0
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$
2 3
6
fl 5 4
) 1
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AC2672.eps
Power Maximum
Supply Mast fork Conductors Supply
Group Height (in.) (No. @ AWG) Application
6844338 189 2 @ 18 ERC – Unswitched
6844340 189 2 @ 20 & 4 @ 26 AFC & ERC – Unswitched 1
1 Do not use 26 AWG for high voltage or high current applications; 26 AWG rated @ .25A,
20 AWG rated @ 5A.
AFC: Adaptive Force Control
ERC: Electronic Rotational Control
Common Parts
REF QTY PART NO. DESCRIPTION REF QTY PART NO. DESCRIPTION
6844329 Power Supply Install Kit ● 15 1 6832205 Clamp
3 1 6818145 Sheave Assembly ■ 16 2 6026763 Spacer Plate
4 1 6820449 Conduit 17 1 6819937 Spacer Block
5 1 6838404 Nut 1 206321 Capscrew, M6 x 16
18
6 1 6819600 Back Plate 1 763169 Capscrew, M6 x 20
7 1 6818146 Bracket 19 1 206323 Washer, M6
8 2 6819200 Bearing 20 1 6844372 Junction Block
9 1 6806108 Roller 21 2 767614 Capscrew, M10 x 20
10 1 6819224 Spacer Plate 22 1 6400135 Washer, M10
11 2 786881 Nut 23 1 6846510 Hose Clamp
12 2 6819533 Capscrew, M8 x 65 24 1 6846511 Anchor Plate
2 6819534 Capscrew, M8 x 70 25 1 6027117 Alignment Tool
13
2 6026778 Capscrew, M8 x 80 26 1 6846222 UL Decal
14 2 6820902 Spacer Plate
● Includes items 14 - 26.
■ Includes items 7 - 12.
9
8 7
0
!
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$
2 3
6
fl 5 4
) 1
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AC2672.eps
Power Maximum
Supply Mast fork Conductors Supply
Group Height (in.) (No. @ AWG) Application
6844343 218 2 @ 18 ERC – Unswitched
6844345 218 2 @ 20 & 4 @ 26 AFC & ERC – Unswitched 1
1 Do not use 26 AWG for high voltage or high current applications; 26 AWG rated @ .25A,
20 AWG rated @ 5A.
AFC: Adaptive Force Control
ERC: Electronic Rotational Control
Common Parts
REF QTY PART NO. DESCRIPTION REF QTY PART NO. DESCRIPTION
6844329 Power Supply Install Kit ● 15 1 6832205 Clamp
3 1 6818145 Sheave Assembly ■ 16 2 6026763 Spacer Plate
4 1 6820449 Conduit 17 1 6819937 Spacer Block
5 1 6838404 Nut 1 206321 Capscrew, M6 x 16
18
6 1 6819600 Back Plate 1 763169 Capscrew, M6 x 20
7 1 6818146 Bracket 19 1 206323 Washer, M6
8 2 6819200 Bearing 20 1 6844372 Junction Block
9 1 6806108 Roller 21 2 767614 Capscrew, M10 x 20
10 1 6819224 Spacer Plate 22 1 6400135 Washer, M10
11 2 786881 Nut 23 1 6846510 Hose Clamp
12 2 6819533 Capscrew, M8 x 65 24 1 6846511 Anchor Plate
2 6819534 Capscrew, M8 x 70 25 1 6027117 Alignment Tool
13
2 6026778 Capscrew, M8 x 80 26 1 6846222 UL Decal
14 2 6820902 Spacer Plate
● Includes items 14 - 26.
■ Includes items 7 - 12.
9
8 7
0
!
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$
2 3
6
fl 5 4
) 1
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AC2672.eps
Power Maximum
Supply Mast fork Conductors Supply
Group Height (in.) (No. @ AWG) Application
6844348 240 2 @ 18 ERC – Unswitched
6844350 240 2 @ 20 & 4 @ 26 AFC & ERC – Unswitched 1
1 Do not use 26 AWG for high voltage or high current applications; 26 AWG rated @ .25A,
20 AWG rated @ 5A.
AFC: Adaptive Force Control
ERC: Electronic Rotational Control
Common Parts
REF QTY PART NO. DESCRIPTION REF QTY PART NO. DESCRIPTION
6844329 Power Supply Install Kit ● 15 1 6832205 Clamp
3 1 6818145 Sheave Assembly ■ 16 2 6026763 Spacer Plate
4 1 6820449 Conduit 17 1 6819937 Spacer Block
5 1 6838404 Nut 1 206321 Capscrew, M6 x 16
18
6 1 6819600 Back Plate 1 763169 Capscrew, M6 x 20
7 1 6818146 Bracket 19 1 206323 Washer, M6
8 2 6819200 Bearing 20 1 6844372 Junction Block
9 1 6806108 Roller 21 2 767614 Capscrew, M10 x 20
10 1 6819224 Spacer Plate 22 1 6400135 Washer, M10
11 2 786881 Nut 23 1 6846510 Hose Clamp
12 2 6819533 Capscrew, M8 x 65 24 1 6846511 Anchor Plate
2 6819534 Capscrew, M8 x 70 25 1 6027117 Alignment Tool
13
2 6026778 Capscrew, M8 x 80 26 1 6846222 UL Decal
14 2 6820902 Spacer Plate
● Includes items 14 - 26.
■ Includes items 7 - 12.
9
8 7
0
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2 3
6
fl 5 4
) 1
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AC2672.eps
Power Maximum
Supply Mast fork Conductors Supply
Group Height (in.) (No. @ AWG) Application
6844353 320 2 @ 18 ERC – Unswitched
6844355 320 2 @ 20 & 4 @ 26 AFC & ERC – Unswitched 1
1 Do not use 26 AWG for high voltage or high current applications; 26 AWG rated @ .25A,
20 AWG rated @ 5A.
AFC: Adaptive Force Control
ERC: Electronic Rotational Control
Common Parts
REF QTY PART NO. DESCRIPTION REF QTY PART NO. DESCRIPTION
6844329 Power Supply Install Kit ● 15 1 6832205 Clamp
3 1 6818145 Sheave Assembly ■ 16 2 6026763 Spacer Plate
4 1 6820449 Conduit 17 1 6819937 Spacer Block
5 1 6838404 Nut 1 206321 Capscrew, M6 x 16
18
6 1 6819600 Back Plate 1 763169 Capscrew, M6 x 20
7 1 6818146 Bracket 19 1 206323 Washer, M6
8 2 6819200 Bearing 20 1 6844372 Junction Block
9 1 6806108 Roller 21 2 767614 Capscrew, M10 x 20
10 1 6819224 Spacer Plate 22 1 6400135 Washer, M10
11 2 786881 Nut 23 1 6846510 Hose Clamp
12 2 6819533 Capscrew, M8 x 65 24 1 6846511 Anchor Plate
2 6819534 Capscrew, M8 x 70 25 1 6027117 Alignment Tool
13
2 6026778 Capscrew, M8 x 80 26 1 6846222 UL Decal
14 2 6820902 Spacer Plate
● Includes items 14 - 26.
■ Includes items 7 - 12.
2
Junction Box
AC1721.ai
2
1
AC2502.eps
Display 6
Controller
F4
Service
F3
F1
F2
3
YE
S
Pendant
2 NO
1 6
5 BK
SP
4 9
5 7
.
8
0
SP
AC
E
EN
TE
R
Scanner
4 2
1
Auto-Switch
Datalogger
Override
Cylinder Switch
Revolving
Connection
& Slip Ring
To Truck Power
LED
Pressure
Control Valve
To Truck Power
or DC to DC
Voltage Converter
AC2673.eps
Hoist Drop
Stop Valve
1000 mm 400 mm
Cable Cable
REF QTY PART NO. PART NO. DESCRIPTION
6091457 (R4) 6091458 (R4) Junction Box Wire Group
1 1 6090349 6090349 Junction Box Assembly
2 1 6091456 6090637 Cable Assembly
3 1 6090962 6090962 Communication Cable
4 1 6090924 6090924 Mast Cable
5 2 6091601 6091601 Switch Group u
6 1 6092913 6092913 Status Light Assembly
u See Switch Group page for parts breakdown.
Reference: SK-11059.
AC1667.ai
5
4 #
$
59 @
1 %
7
20 68
3!
AC1644.ai
AC1714.ai
5
4
@
59
1 #
7
20 68
3!
AC1712.ai
1
5
4
AC1707.ai 2
F3
F4
S
1
F2 YE
F1 3
2 N O
1 6 P
5 BK
S
4 9
ER
8 E
EN
T
7 SP
AC
0
.
2
AC1715.ai
4 2 7
8
I
N
P
U
T
O
U
T
P
6 U
T
9
1
AC2033.eps
Cascade Corp.
File No. AU3546
AC1804.ai
5
1
6
4
3
2
AC0325.ill
X
BO HIGH
H
ITC
SW M
ED
C
AF
LOW
AC2037.ai
5 # 2
7 @
!
AC1527.eps
8
4
6 9 2
7 8
6
AC1532.eps
#
!
@
0 4
6 9 2
7 8
6
AC1670.ai
#
!
@
2 6
5 7 # %
@ 0
!
AC1528.eps
^
7
4
9
8
4
@
6 9 3
7 8
0
!
AC1529.eps
9
4
@
6 9 3
7 8
0
!
AC1530.eps
%
8
4
@
6 9 3
7 8
$
0
AC1531.eps
9
4 0 8
6 9 3
7 8
6
!
7 AC1671.ai
5 # %
9 @
!
AC1780.ai
$
7
4
REF QTY PART NO. DESCRIPTION
6084864 Truck Fitting Kit
1 1 6031683 Valve Assembly u
2 1 227202 Accumulator Kit l
3 2 6085772 Fitting, 12-16
4 2 6029635 Fitting, 8-8
5 2 6049349 Fitting, 6-6
6 1 6063826 Fitting, 12-12
7 3 6066414 Fitting, 8-8
8 1 6075586 Fitting, 16-16
9 1 208728 Fitting, 6-6
10 2 200376 Fitting, 8-8
11 2 202350 Fitting, 6-8
12 1 601377 Fitting, 8-8
13 1 605761 Fitting, 8-8
14 1 6071703 Pigtail
15 1 214066 Connector Kit l
16 1 6095556 Fitting, 12-10
u See Valve page for parts breakdown.
l See Kit page for parts breakdown.
5 # ^
9 @
!
AC1726.ai
$
7
4
REF QTY PART NO. DESCRIPTION
6095872 Truck Fitting Kit
1 1 6029966 Valve Assembly u
2 1 227202 Accumulator Kit l
3 2 6028969 Fitting, 12-12
4 2 6029635 Fitting, 8-8
5 2 6049349 Fitting, 6-6
6 1 6045329 Fitting, 16-16
7 3 6066414 Fitting, 8-8
8 1 6068966 Fitting, 12-12
9 1 208728 Fitting, 6-6
10 2 200376 Fitting, 8-8
11 2 202350 Fitting, 6-8
12 1 601377 Fitting, 8-8
13 1 605761 Fitting, 8-8
14 1 6071703 Pigtail
15 1 6095875 Fitting, 20-16
16 1 214066 Connector Kit l
u See Valve page for parts breakdown.
l See Kit page for parts breakdown.
2 3
5 # %
9 @
!
AC1672.ai
$
7
4
REF QTY PART NO. DESCRIPTION
6095871 Truck Fitting Kit
1 1 6031683 Valve Assembly u
2 1 227202 Accumulator Kit l
3 3 6095556 Fitting, 10-12
4 2 6029635 Fitting, 8-8
5 2 6049349 Fitting, 6-6
6 1 6063826 Fitting, 12-12
7 3 6066414 Fitting, 8-8
8 1 6067596 Fitting, 10-10
9 1 208728 Fitting, 6-6
10 2 200376 Fitting, 8-8
11 2 202350 Fitting, 6-8
12 1 601377 Fitting, 8-8
13 1 605761 Fitting, 8-8
14 1 6071703 Pigtail
15 1 214066 Connector Kit l
u See Valve page for parts breakdown.
l See Kit page for parts breakdown.
2 6
1
3 #
4
9
% 8
5
6 9 $
7 8
0
!
AC1525.eps
9
2 6 %
1
3 OR #
4
9
8
5
6 9 $
7 8
0
!
AC1523.eps
9
2 6 5 #
1
3
4
6 9 $
7 8
0
AC1490.eps
!
AC1732.ai
AC1732.ai
! $
0 %
@
5
@
9
9
7
AC1526.eps
2
3
5 $ %
@ #
!
AC1348.eps
8
4
! $
0 %
@
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@
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9
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AC1526.eps
! $
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9
9
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7 8
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$
9
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7 8
AC2038.ai
5 8
6 7 @
! #
5 $
%
^
0 &
8
REF QTY PART NO. DESCRIPTION
6802873 Truck Fitting Kit
1 1 6097233 Valve Assembly u
2 1 602580 Fitting, 8
3 2 611293 Fitting, 12-12
4 2 6074561 Fitting, 12-12
5 6 604511 Fitting, 6-6
6 1 2680 Fitting, 6-6
7 2 601377 Fitting, 8-8
8 3 605761 Fitting, 8-8
9 1 611324 Fitting, 12-12
10 2 611330 Fitting, 8-8
11 2 2671 Reducer Fitting, 8-6
12 2 2618 Nut, 8
13 4 6802875 Fitting, 6 ORB – 6 BSP
14 4 6802916 Fitting, 6 ORB – 8 BSP
15 2 6802917 Fitting, 8 ORB – 8 BSP
16 2 6802918 Fitting, 12 ORB – 8 BSP
17 2 6802919 Fitting, 12 ORB – 12 BSP
u See Valve Assembly page for parts breakdown.
23
1
WARNING
Do not block priority
port and start truck.
Decal 6011850
PRIORITY
Do not block priority
port and start truck.
WARNING
CONTROL
VALVE
4
Decal 6011850
MP
PU
AC0313.eps
REF QTY PART NO. PART NO. PART NO. PART NO. DESCRIPTION
6029966 6031683 6097232 6097233 Priority Flow Valve
1 1 6051828 6031649 6025514 6025463 Valve Body
2 1 6032653 6032653 6030805 6030805 Priority Flow Control Cartridge
3 1 6026295 6026295 6024964 6024964 Seal Kit
4 1 6011850 6011850 6011850 6011850 Warning Label
46 5
1
2
WARNING
Do not block priority
port and start truck.
36 Decal 6011850
AC0885.eps
46 5
1
2
WARNING
Do not block priority
port and start truck.
36 Decal 6011850
AC0884.eps
Hydraulic End Cap Free Floating Piston Gas End Cap Gas Charging Valve
AC0184.eps
Seal Kit
2 1 5
Hydraulic Fitting Accumulator
Pressure Seal Back-Up Ring (2) O-Ring (2) Back-Up Ring (2)
4 6
3
AC0196.eps
AC0191.eps
AC0193.eps
2
1
4 3
5
6 AC0281.eps
AMERICAS
Cascade Corporation Cascade Canada Inc. Cascade do Brasil
U.S. Headquarters 5570 Timberlea Blvd. Praça Salvador Rosa,
2201 NE 201st Mississauga, Ontario 131/141-Jordanópolis,
Fairview, OR 97024-9718 Canada L4W-4M6 São Bernardo do Campo - SP
Tel: 800-CASCADE (227-2233) Tel: 905-629-7777 CEP 09891-430
Fax: 888-329-8207 Fax: 905-629-7785 Tel: 55-13-2105-8800
Fax: 55-13-2105-8899
EUROPE-AFRICA
Cascade Italia S.R.L. Cascade (Africa) Pty. Ltd.
European Headquarters PO Box 625, Isando 1600
Via Dell’Artigianato 1 60A Steel Road
37030 Vago di Lavagno (VR) Sparton, Kempton Park
Italy South Africa
Tel: 39-045-8989111 Tel: 27-11-975-9240
Fax: 39-045-8989160 Fax: 27-11-394-1147
ASIA-PACIFIC
Cascade Japan Ltd. Cascade Korea Cascade-Xiamen Cascade India Material
2-23, 2-Chome, 121B 9L Namdong Ind. No. 668 Yangguang Rd. Handling Private Limited
Kukuchi Nishimachi Complex, 691-8 Gojan-Dong Xinyang Industrial Zone No 34, Global Trade Centre
Amagasaki, Hyogo Namdong-Ku Haicang, Xiamen City 1/1 Rambaugh Colony
Japan, 661-0978 Inchon, Korea Fujian Province Lal Bahadur Shastri Road,
Tel: 81-6-6420-9771 Tel: +82-32-821-2051 P.R. China 361026 Navi Peth, Pune 411 030
Fax: 81-6-6420-9777 Fax: +82-32-821-2055 Tel: 86-592-651-2500 (Maharashtra) India
Fax: 86-592-651-2571 Phone: +91 020 2432 5490
Fax: +91 020 2433 0881
Cascade Australia Pty. Ltd. Cascade New Zealand Sunstream Industries
1445 Ipswich Road 15 Ra Ora Drive Pte. Ltd.
Rocklea, QLD 4107 East Tamaki, Auckland 18 Tuas South Street 5
Australia New Zealand Singapore 637796
Tel: 1-800-227-223 Tel: +64-9-273-9136 Tel: +65-6795-7555
Fax: +61 7 3373-7333 Fax: +64-9-273-9137 Fax: +65-6863-1368
c
© Cascade Corporation 2014 08-2014 Part Number 6095129-R4
G LOSSARY
6095130-R1 1
G LOSSARY
Pilot Pressure
Minimum pressure required to allow AFC to function.
Pressure Differential
Pressure difference between PT3 and PT4 indicating Arm
contact with the load.
Pressure Transducer
Provides pressure feedback to the controller.
Scanner
Reads barcodes for information that the datalogger or
warehouse management system needs.
Service Pendant
Sets up or changes settings for AFC Controller. Also used
for diagnostics and error code reporting.
Solenoid
Electrically activated valve to control oil flow.
Tilt Control
Stops the mast at true vertical.
2 6095130-R1
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 Cascade Canada Inc. Cascade do Brasil
U.S. Headquarters 5570 Timberlea Blvd. Praça Salvador Rosa,
2201 NE 201st Mississauga, Ontario 131/141-Jordanópolis,
Fairview, OR 97024-9718 Canada L4W-4M6 São Bernardo do Campo - SP
Tel: 800-CASCADE (227-2233) Tel: 905-629-7777 CEP 09891-430
Fax: 888-329-8207 Fax: 905-629-7785 Tel: 55-13-2105-8800
Fax: 55-13-2105-8899
EUROPE-AFRICA
Cascade Italia S.R.L. Cascade (Africa) Pty. Ltd.
European Headquarters PO Box 625, Isando 1600
Via Dell’Artigianato 1 60A Steel Road
37030 Vago di Lavagno (VR) Sparton, Kempton Park
Italy South Africa
Tel: 39-045-8989111 Tel: 27-11-975-9240
Fax: 39-045-8989160 Fax: 27-11-394-1147
ASIA-PACIFIC
Cascade Japan Ltd. Cascade Korea Cascade-Xiamen Cascade India Material
2-23, 2-Chome, 121B 9L Namdong Ind. No. 668 Yangguang Rd. Handling Private Limited
Kukuchi Nishimachi Complex, 691-8 Gojan-Dong Xinyang Industrial Zone No 34, Global Trade Centre
Amagasaki, Hyogo Namdong-Ku Haicang, Xiamen City 1/1 Rambaugh Colony
Japan, 661-0978 Inchon, Korea Fujian Province Lal Bahadur Shastri Road,
Tel: 81-6-6420-9771 Tel: +82-32-821-2051 P.R. China 361026 Navi Peth, Pune 411 030
Fax: 81-6-6420-9777 Fax: +82-32-821-2055 Tel: 86-592-651-2500 (Maharashtra) India
Fax: 86-592-651-2571 Phone: +91 020 2432 5490
Fax: +91 020 2433 0881
Cascade Australia Pty. Ltd. Cascade New Zealand Sunstream Industries
1445 Ipswich Road 15 Ra Ora Drive Pte. Ltd.
Rocklea, QLD 4107 East Tamaki, Auckland 18 Tuas South Street 5
Australia New Zealand Singapore 637796
Tel: 1-800-227-223 Tel: +64-9-273-9136 Tel: +65-6795-7555
Fax: +61 7 3373-7333 Fax: +64-9-273-9137 Fax: +65-6863-1368
c
© Cascade Corporation 2014 08-2014 Part Number 6093305-R6