Manual Service Clamp Cascade PDF

ADAPTIVE FORCE CONTROL
cascade
corporation
c
Technical
Documentation
Adaptive Force
Control (AFC)
• Introduction
• Installation
• Setup
• Operation
• Troubleshooting
• Periodic Maintenance
• Service
• Parts
Document Number 6093305-R6
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
ADAPTIVE FORCE CONTROL (AFC)

This binder provides all the technical documentation necessary
to install, setup, troubleshoot, service, and order parts for the
Adaptive Force Control system (AFC). See the tabbed dividers
for appropriate manuals and technical bulletins. If you need Special Requirements for Dealers
additional information or assistance, refer to the back cover for
Cascade Corporation contact information. AFC Installation requires the following (see Installation Section
in this manual for details):
AFC System Description • An attachment/mast in good working order, properly
The Adaptive Force Control System (AFC) enables Cascade lift serviced and maintained.
truck attachments to apply the minimum clamp force necessary • Correct contact pads for the loads being handled.
to handle a specific load. The key benefits the system provides
is reduced product damage, equipment wear and driver • When AFC is installed with Electronic Rotational Control and
fatigue. Tilt Control, Cascade recommends the truck be equipped
with four auxiliary valve control levers. Three auxiliary
The AFC uses a computer controller and hydraulic pressure valve control handles with 'H' pattern operation is not
sensors to determine the weight of the load as it is lifted. recommended due to the placement of multiple pushbutton
An initial no-slip starting pressure is applied to the load when it switches on the control levers.
is first clamped. As the load is lifted, the AFC system increases
the clamp force proportional to load weight. A consistent • Connection into the truck main hydraulic circuit for a priority
clamp force is applied each time, to each load lifted. The flow valve and dedicated return-to-tank line.
system prevents drivers from unintentionally over-clamping a • Connection to the truck auxiliary valve clamp circuit for a
load, reducing the potential for load damage. proportional flow valve.
The system initiates a reclamp if a change is sensed due to • Connection into the mast hoist circuit for a load sensor,
internal cylinder leakage, load compression, or when driving optional drop/stop valve and accumulator.
over dockplates or bumps. The system also prevents the • Connection into the truck electrical system for a power bus/
clamp contact pads from sliding or jumping with the optional relay, and (electric truck only) DC-to-DC converter.
Drop/Stop feature.
Special Tools and Equipment
An optional driver's display shows actual cylinder pressure
at all times, and indicates when the load is ready to lift. • Service Pendant (Cascade Part No. 6092042) for AFC
Also shown is load range, error codes and AFC power status. Controller setup changes and diagnostics.
The AFC system is designed to have a minimal impact on the • Accumulator Charging Kit (Cascade Part No. 228236) and
truck's hydraulic and electrical systems, and can be locked out nitrogen bottle to precharge or adjust accumulator.
at any time by removing the electrical power fuse and locking • Digital Multimeter (Cascade Part No. 213867).
the manual override on the proportioning valve. An optional
momentary override switch is also available.
AFC SYSTEM BLOCK DIAGRAM
Maximum Free Lift Clamp

Hoist Display Sensor
Lift Sensor Cylinders
Cylinders Switch
Switch
Accumulator
Proportional
Drop/Stop
Computer Controller Pressure
Valve
Control Valve
Load Parameter
Override
Selector:
Switch
Auto Switch
Truck Main Priority Truck

Valve: HOIST Flow Valve Auxiliary
Valve: CLAMP
AC1659.eps
6095121-R1 1
O VERVIEW
AFC System Components

AFC system components are described below and shown on
the opposite page. Refer to Installation Instructions 6095124 to
install the components on the truck and clamp.
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)
Light Tower Junction Box

(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)
AFC System components shown in approximate locations
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:
Spray-Metal Rubber Urethane Flexible Pad
RC1129.eps
Ribbed Tissue - Convex Tissue - Multiple Radii
4 6095121-R1
O VERVIEW
AFC Operational Characteristics

IMPORTANT: The clamp attachment and mast must be in
proper working order for the AFC to function properly. See
appropriate clamp or mast service manuals for periodic
maintenance and service procedures.
Following are the operational characteristics of the Adaptive 8. The pressure display is slightly delayed in presentation.
Force Control (AFC) system. For detailed troubleshooting It is not normally necessary to monitor clamp pressures
procedures, refer to the Troubleshooting Section in this manual. during load handling.
1. The AFC system actively monitors lift cylinder hydraulic 9. When lifting light loads, the displayed clamp pressure may
pressure and calculates the appropriate clamp cylinder be below the displayed start pressure. This is normal due
hydraulic pressure required. A no-slip start pressure is to load sharing between cylinders (pressure transducer
applied initially when the load is first clamped. The final in one cylinder only), load shifting during lift, or cylinder
required clamp force is then applied, proportional to the internal leakage.
weight of the load being lifted.
10. Displayed clamp cylinder pressure may decrease or
2. The system will initiate reclamp if there is internal leakage increase when the attachment is rotated, but required
through check valves or cylinders, if load compression clamp force is still maintained. The effect is due to the
occurs, or during heavy shock loads from dock plates pressure transducer being in one cylinder only.
or bumps. It will also readjust the clamp pressure if an
11. The calculated accumulator pressure is for optimal
additional load is added.
performance. It may be set higher, but may reduce clamp
3. AFC provides a significant improvement over standard 3 force accuracy.
or 4-position relief valves by automatically determining the
12. Before hoisting, the status light must show steady green
relief pressure for the driver when picking up different load
and driver display must show "OK to lift" icon. This verifies
weights. This feature is based directly on monitored lift
that the AFC system has adjusted to start pressure and the
cylinder pressure.
load can be hoisted and transported.
4. AFC does not detect slip like the Cascade Auto Clamp™,
13. The AFC system reverts to manual mode if the mast is
instead applies a calculated proportional clamp pressure
fully extended and status light will show flashing green.
based on the load weight being handled. The system must
Maximum lift limit switch SW2 sends a signal, which sets
therefore be set for the load types and load weights being
AFC system relief to approximately truck relief setting. In
handled.
this condition the driver is in control of clamping pressure
5. Recommended procedure is to set the AFC Start Pressure on the roll. The display readout will show actual clamp
and Clamp Force-to-Weight-Ratio parameters for the worst pressure/force in the cylinders. When the mast lowers from
case or hardest to handle loads. maximum lift, AFC resumes normal operation.
6. Start Pressure is the minimum pressure that will be applied,
even on small, light loads. If that is not acceptable, an
optional Auto Switch can set different pressures for different
load weights/diameters automatically, based on arm
position.
7. Lifting a load very slowly may result in a different clamp
pressure displayed than when lifting fast. This is normal due
to the inertia of the load.
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.
Major components are shown below.
Junction Box
Light Tower
(Optional) Display
(optional) Maximum Lift
Sensor Switch
Scanner Power and

(optional) Communications
Supply Group
Kit
Datalogg
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
NOTE: Kits are UL Classified (File # AU3546) for safety in

Electric Battery (UL 583) and IC Engine (UL 558) Indust. Truck Auto Switch Linear
type E, ES, G, GS,G/LP/ GS/LPS, LP, LPS, D and DS. Transducer (optional)
cascade Cascade Corp.

corporation File No. AU3546
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

Valve and Hose Installation Main Control
Valve
IMPORTANT: Leave clearance between components to allow
for fittings, hoses and cables.
1 Install the priority flow control valve in the main hydraulic
circuit between the truck pump and main control valve.
1 Priority Flow
Control Valve
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.
NOTE: Cascade provides many of the special fittings

needed for efficient installation. Check your installation Hose from
kit. truck pump
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
2 Install the return to tank fitting in the tank line.

Lube
2 Return to
tank fitting
the hose ends and fitting for easy assembly. Refer to

document 211744 for complete installation instructions.
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
3 If equipped, mount Hoist

Drop Stop Valve on truck
cowl or directly to mast
valve. Optional 5 Connect
hose
to mast
Hoist Drop
supply.
Stop Valve
No. 12
O-Ring
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.
4 Connect a hose (user supplied) from the hoist control valve to

the drop stop valve's HOIST TRUCK port.
5 Connect a hose (user supplied) from the hoist drop stop valve's
HOIST MAST port to the mast supply.
6 Install a No. 8 fitting for connection to the accumulator later in
step 14.
3 Mount Hoist Drop Stop Valve

on truck cowl or directly to
mast valve.
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.
9 Install a low pressure hose from the proportional pressure

control valve tank port to the return to tank fitting.
10 Connect a hose (user supplied) to the proportional
pressure control valve PRIORITY port and the priority flow
control valve PRIORITY port.
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
to attachment Plug side

supply hoses. ports
TANK TANK
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.
Optional Hoist Drop Stop Valve Equipped – Connect
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
Accumulator Clamp Open

Pressure
Accum Transducer
Hoist Drop Hoist
OR Manifold
Stop Valve Truck Filter
Hoist Mast
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
NOTE: UL Classified Kits require installation by qualified

personnel only without major disturbance, cutting, splicing for
soldering of factory installed wiring.
1 Remove junction box cover. Mount the junction box on
the truck cowl using the 4.3 mm mounting holes. Keep
junction box cover off until all component wires are routed
and installed in terminals.
NOTE: When choosing a location for the junction box, the
controller will need to be mounted near the junction box
due to the harness length of 15 in. (400 mm).
2 Use .25 in. (6mm) capscrews (user supplied) to mount
the controller on the truck cowl or under the dashboard.
2 Mount
controller
AC1615.eps
The controller must be mounted near the junction box.

Connect the harness to the junction box and controller.
IMPORTANT: The harness has two labels, "Controller" on
one end and "Junction Box" on the other end.
3 Mount the display (if equipped) on the truck overhead

guard or dashboard using the provided mounting bracket.
The mounting bracket can be reformed. Connect the
3 Mount
display
display connector and route the free end cable wires to

the junction box. Watch for cable interference with moving
objects.
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
5 Mount the status light on the mast or the truck overhead

MED
X
BO
H
ITC
SW
C
AF
guard in driver's view. Route the free end cable wires to

the junction box. Mount
selector
switch
6 Mount the selector switch in a convenient location for easy
access. Plug in the cable and route the free end cable AC1778.eps
wires to the junction box.
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
10 Route connector cable with free end cable wires (part

number 6091024) to the junction box. This cable will 3 in. for
AC0402.eps
connect to the override switch connector. typical hand
11 Datalogger (if equipped) – Install datalogger according to Cut tubing
installation instructions 6075865. Route the cable labeled around button
Tape
"CN1" (part number 6071871) to the junction box.
12 Determine a convenient location to for the service pendant
connection and route cable 6090897 to junction box. Shrink Tube
13 Mount the power bus (if equipped) in an easy access

Handle and
WARNING: For UL Classified kits, to reduce Knob
the risk of fire, replace only with same type and
rating of fuse.
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
2 19 4 6090961 SOL3 J2- / BU J2 / BN

SOL4
Pressure PT1
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
Abbreviation Color Abbreviation Color Abbreviation Color

BK Black OG Orange GN Green
9 Service Pendant
BU
BN
Blue
Brown
RD
WH
Red
White
YE Yellow
Display
10 12 Wire Preparation and Installation

(optional)
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
23 Connect the revolving connection cable end to the power

supply connector at the carriage terminal.
23
24 Apply SMARTCLAMP labels to the truck dashboard

or dashboard side panel and clamp baseplate in the
approximate locations shown.
AC1711.ai
25 Go to Setup Instructions 6095125 to complete the
installation.
24
AC1135.eps
Disabling AFC
C
L
A
M
P
The AFC control features can be temporarily disabled by Proportional

performing the following steps:
Pressure
• Loosen the locknut and allen head screw on the Control Valve
proportional pressure control valve relief cartridge and turn
in the screw CW all the way. Tighten the locknut.
CAUTION: Tighten the screw to finger tight. Do NOT use
tools.
• Remove the fuse in the junction box from the terminals and
install one blade of fuse in one of the terminals.
The truck and attachment will now operate in the standard AC1621.eps
mode.
Proportional Flow
Relief Cartridge
To enable the AFC features:
• Loosen the locknut and allen head screw on the Turn in the screw
proportional flow relief cartridge and turn out the screw CW all the way on
CCW two full turns. Tighten the locknut. the proportional
AC0390.eps
• Install the fuse in the junction box to both terminals. flow relief cartridge.
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
c be carefully followed to preserve
Installation
warranty coverage.
UL Classified
Instructions Power Supply/

Communication Groups
This manual provides installation instructions for Cascade Power Supply/Communication Kits for simplex, dual and triple-stage
masts (Contact Cascade for quad mast application). The kit (refer to next page) is a compact two, four or six-conductor electrical
supply/communications cable that provides a connection between the truck’s electrical circuit and a carriage mounted Cascade
attachment equipped or Cascade accessory with electrical and electronic components. The kit greatly improves driver visibility
over alternative cable reels.
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)
AC2509.eps Power Wire Harness Part No. 6844330-R1
cascade W Cascade Corp.

File# AU3546
corporation
Call: 1-800-227-2233 Fax: 1-888-329-8207 Call: 1-888-227-2233 Fax: 1-888-329-0234
BLANK
2
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.
WARNING: For UL Classified kits, to reduce

the risk of fire, replace only with same type and
rating of fuse.
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
6844338 189 2 @ 18 ERC – Unswitched
6844343 218 2 @ 18 ERC – Unswitched
6844348 240 2 @ 18 ERC – Unswitched
6844353 320 2 @ 18 ERC – Unswitched
1 Simplex, dual or triple masts only.
2 To maintain UL rating, do not exceed 5A 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 Determine a mounting location for the roller assembly on the

mast upper outer rail. Locate the roller assembly as far back
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
4 Grind the spacer mounting area on the mast to bare metal.

Prep the mounting surface of the spacer with a grinder,
leaving a coarse surface. Clean the contact areas with
contact or brake cleaner. Surface prep is critical for the
adhesive to bond properly to the metal.
5 Mix and apply adhesive (user supplied) to attach the
subplate to the mast rail. Adhesives approved for this
installation:
•
•
Loctite 332 with Activator 7380
Devcon S-220 two part epoxy
3 Spacer
Block
• Devcon Plastic Welder 14320

• JB Weld 8265-S
Apply per manufacturer’s instructions.
IMPORTANT: Remove adhesive residue from hands
immediately. Once dry it is permanent to your skin.
6 Temporarily install the roller assembly to the spacer block.
Use the spacer plate and longer capscrews if required
for conduit clearance on the mast. Leave the capscrews
finger tight.
WARNING: If welding is used to attach
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
NOTE: If replacing an older supply/communication kit,

install new roller assembly so that the roller hole is aligned
4,5 Angle Subplate
Mount (if required)
with old location of the roller hole, facing forward.

4
7 Raise and position the upper carriage bar just below the Roller
roller assembly. Assembly
8 Locate and mark a mounting location for the carriage
cable junction block and anchor plate on the back side of
the upper carriage bar. Use the alignment tool to center
the cable junction block and anchor plate on the carriage
bar. Tool length can be adjusted by breaking off the end Alignment tool
at the required length.
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
9 Clean area to be welded. Remove paint, oil, grease and

other contaminants. Tack weld the anchor plate.
10 Install the cable junction block to the anchor plate. AC2485.eps
Tighten the left (driver's view) capscrew and washer to

28 ft.-lbs. (38 Nm).
10
Cable
Junction
Block
Capscrew
and
Washer
11 Feed the cable up through the roller

assembly. Clip the cable clamp onto
11
Install
the cable with the connector 2 in.
(50 mm) below the cable clamp. cable
Attach the cable clamp with the Cable
remaining capscrew to right hole on Junction
the cable junction block. Tighten the Block
capscrew to 28 ft.-lbs. (38 Nm).
11Cable Cable
Clamp Clamp
Capscrew
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
IMPORTANT: If the cable end is released and gets stuck

17 Roller
Assembly
inside the cable conduit, use a coat hanger or welding Spacer Block
rod to retrieve the cable end. The end is about 10 in.
(254 mm) inside the housing.
14 Grind the lower spacer mounting area on the mast to bare
metal. Prep the mounting surface of the lower spacer with
a grinder, leaving a coarse surface. Clean the contact
13
areas with contact or brake cleaner. Surface prep is
critical for the adhesive to bond properly to the metal.
15 Mix and apply adhesive to the lower spacer. Keep Conduit
adhesive out of the threaded holes. Position the lower Spacer
spacer on the mast. Hold in place until the adhesive sets Carriage Block
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
C Tighten nut to 7 ft.-lbs. (10 Nm). Verify that no required)

more than 3/16 in. (5 mm) of threads shows
through bottom of roller assembly.
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.
Connect attachment Power

cable to carriage cable Cable
junction
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
23 Connect the battery cable(s) to their proper terminals.

WARNING: For UL Classified kits, to reduce
24 Test the electrical functions for proper operation. Raise the risk of fire, replace only with same type
and lower the mast to check the coil cable for proper and rating of fuse.
alignment, extension and retraction.
IMPORTANT: Spray the coil cord, roller and inside of
conduit with a Teflon based dry film lubricant similar to
McGee McLube 1700L or Dupont Dryfilm WDL-10A. The
lubricant significantly reduces wear on the coil cord and
provides smooth coil extension and retraction.
Coil Cord Maintenance

Lubrication – Every three months, spray the coil cord with a
Teflon based dry film lubricant. See description above.
Cord Tension – The coil cord can be retensioned by pulling a

maximum of 10 coil loops out of the clamp at the bottom of the
cable assembly.
7
Power Supply/Communication Groups
Maximum Mast Fork Height – 166 in.
@
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9
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AC2510.eps
8
Power Maximum
Supply Mast ➀ Fork Conductors Supply
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
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
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AC2510.eps
10
Power Maximum
6844338 189 2 @ 18 ERC – Unswitched
1 1 6844357 6844357 6844357 6844362 6844367 Cable Assembly
3
4 1 6009994 6009994 — — — Switch
Common Parts
8 1 6838404 Nut 1 206321 Capscrew, M6 x 16
21
10 1 6818146 Bracket 22 1 206323 Washer, M6
14 2 786881 Nut 26 1 6846510 Hose Clamp
16
11
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AC2510.eps
12
Power Maximum
6844343 218 2 @ 18 ERC – Unswitched
1 1 6844358 6844358 6844358 6844363 6844368 Cable Assembly
3
4 1 6009994 6009994 — — — Switch
Common Parts
8 1 6838404 Nut 1 206321 Capscrew, M6 x 16
21
10 1 6818146 Bracket 22 1 206323 Washer, M6
14 2 786881 Nut 26 1 6846510 Hose Clamp
16
13
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&
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9
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2
AC2510.eps
14
Power Maximum
6844348 240 2 @ 18 ERC – Unswitched
1 1 6844359 6844359 6844359 6844364 6844369 Cable Assembly
3
4 1 6009994 6009994 — — — Switch
Common Parts
8 1 6838404 Nut 1 206321 Capscrew, M6 x 16
21
10 1 6818146 Bracket 22 1 206323 Washer, M6
14 2 786881 Nut 26 1 6846510 Hose Clamp
16
15
@
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&
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9
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2
AC2510.eps
16
Power Maximum
6844353 320 2 @ 18 ERC – Unswitched
1 1 6844360 6844360 6844360 6844365 6844370 Cable Assembly
3
4 1 6009994 6009994 — — — Switch
Common Parts
8 1 6838404 Nut 1 206321 Capscrew, M6 x 16
21
10 1 6818146 Bracket 22 1 206323 Washer, M6
14 2 786881 Nut 26 1 6846510 Hose Clamp
16
17
AMERICAS
Fax: 888-329-8207 Fax: 905-629-7785 Tel: 55-13-2105-8800
Fax: 55-13-2105-8899
EUROPE-AFRICA
Italy South Africa
Tel: 39-045-8989111 Tel: 27-11-975-9240
Fax: 39-045-8989160 Fax: 27-11-394-1147
ASIA-PACIFIC
Fax: 86-592-651-2571 Phone: +91 020 2432 5490
Fax: +91 020 2433 0881
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
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
Attachment/Hydraulic Circuit Purpose Accumulator Pre-Charge
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)
4 Auto Clamp™: 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
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.
1 With the engine off, make sure pressure is relieved in the

truck and Attachment hydraulic systems. Move truck
auxiliary control levers to the OPEN or DOWN position to
relieve any trapped pressure to tank.
2 If pre-charging, make sure nitrogen bottle valve is closed.
Attach charging kit hose to nitrogen bottle as shown.
NOTE: Hose is not necessary if checking Accumulator
pressure only.
GA0134.ill 3 Remove Accumulator gas valve guard and protective cap.
4 Make sure gas chuck 'T' handle is screwed all the way out
1 (CCW) and attach gas chuck to Accumulator gas valve as

shown. If pre-charging, do not allow hose to twist or kink.
2 Remove protective cap (if installed) from hydraulic port 5 Close bleed valve on charging manifold and slowly screw
fitting and install a No. 8-8 SAE 37 degree/O-Ring fitting gas chuck 'T' handle all the way in (CW) to open Accumula-
provided in the kit. tor gas valve. If pre-charging, proceed to Step 6. If pres-
sure-checking, follow the procedures below:
WARNING: Before removing hydraulic A Pressure Correct – Unscrew 'T' handle all the way out
lines or hoses, relieve pressure in the (CCW) and slowly open bleed valve to relieve gas
hydraulic system. With the truck off, move trapped in charging manifold. NOTE: A small amount of
the truck auxiliary control levers several gas is lost during each test, eventually requiring that gas
times in both directions. Crack fittings be added to maintain the correct charge.
slowly to assure pressure is released.
B Pressure High – Slowly open (crack) bleed valve until
3 Connect the Accumulator into the hydraulic system in a desired pressure is indicated. Close bleed valve.
Unscrew 'T' handle on gas chuck and open bleed valve
'Tee' configuration as shown:
to relieve gas trapped in charging manifold.
A Hoist Circuits: Accumulator must be between hoist
C Pressure Low – Connect charging hose and proceed to
cylinders and truck auxiliary valve.
Step 6.
B Push circuits: Accumulator must be between push
cylinders and attachment check valve, or an alternate 6 Slowly open (crack) nitrogen bottle valve and slowly fill
check valve (Contact Cascade Service). Accumulator to desired pre-charge indicated in Table on
front page of this Manual.
Accumulator
7 Let pre-charge sit for 10–15 minutes and recheck pressure.
If desired pre-charge is exceeded, close nitrogen bottle
valve, disconnect hose, and slowly open bleed valve until
Test Gauge desired pressure is indicated. Close bleed valve.
'Tee'
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
Removing from Hydraulic System

If it is determined that internal or external leakage is occur-
ring, the Accumulator must be discharged, and the unit
removed from the hydraulic system for service. Use the
following procedure:
1 Make sure that the Accumulator shut-off valve (if
equipped) is open to avoid trapping pressure in the
3000 psi maximum hydraulic side of the Accumulator.
bottle pressure (if
regulator not used) 2 Turn the truck off and relieve pressure in the hydraulic
system by moving the truck auxiliary control levers several
times in both directions.
3 Remove Accumulator gas valve guard and protective cap.
4 Make sure gas chuck 'T' handle is screwed all the way out
(CCW) and connect gas chuck to Accumulator gas valve
as shown.
5 Make sure bleed valve is closed and screw gas chuck 'T'
High Pressure
handle all the way in (CW) to open Accumulator gas valve.
Regulator 6 Slowly open (crack) bleed valve and allow Accumulator to
Nitrogen Bottle
(Recommended) fully discharge. Close bleed valve. Gauge pressure
Valve
should indicate zero.
CAUTION: Do not attempt to discharge the Accumulator
by depressing the valve core with a foreign object. High
pressure may rupture the valve seat.
2 7 Use a wrench to prevent gas valve on Accumulator from

turning and remove the gas chuck. Replace cap and
valve guard on Accumulator.
AC0186.ill 8 Disconnect hydraulic connection to Accumulator and
remove Accumulator from truck. Service unit as described
Nitrogen Bottle in Accumulator Service on back page.
NOTE: After servicing, Accumulator must be pre-
charged. Follow the procedure in Pre-charging or
Pressure Checking on previous page.
WARNING: After completing any service
procedure, always test the Attachment
through 5 complete cycles. First test empty,
then test with a load to make sure operation
is correct before returning to the job.
Accumulator Service
WARNING: Release pressure in unit before 5 Clean all parts in solvent and dry with compressed air.
repairing (see Pre-Charging or Pressure Coat all parts with clean hydraulic fluid before assembly.
Checking for proper bleeding procedure).
6 For reassembly, reverse the above procedures with the
following exceptions:
1 Clamp the Accumulator at the hydraulic end in a soft-jawed
vise. Remove gas valve and hydraulic fitting. • Install new O-rings, back-up rings and seals as shown.
2 Remove the gas end cap by unscrewing with a pin • Install piston with hollow (concave) side toward gas end.
wrench. Remove O-ring and back-up ring by prying out Use wooden block and gently drive into bore.
with a brass seal removal tool. Do not scratch grooves. CAUTION: Piston must go into bore squarely and
For reassembly, tighten the end cap securely. NOTE: slowly to avoid damaging seals.
Cap will be flush or extended by 1/32–3/32 in (.8–2.5 mm). Position piston against hydraulic/fitting end of Accumu-
3 Remove the piston by inserting a brass drift punch through lator to assure full gas charge during pre-charging.
the hydraulic port and driving the piston out of the bore. • Make sure Accumulator does not contain hydraulic fluid.
Remove piston seals. CAUTION: Do not use air pressure
to remove the piston, which may fly out unexpectedly • Reinstall Accumulator. Make sure shut-off valve (if
causing personnel injury or equipment damage. equipped) is open, and pre-charge Accumulator as
described previously under Pre-Charging or Pressure-
4 Inspect Accumulator bore, piston, and end caps for Checking.
scoring, burrs, damaged threads or obvious cracks. Minor
nicks, scratches or scoring may be removed by using fine
emery paper or crocus cloth. If cracks are found, or
imperfections that cannot be removed, replace the unit.
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.
© Cascade Corporation 2002 6-2002 Part No. 227196 R-3

c
Installation Low Pressure Tank
Instructions Line Adapter Kits

6807816 & 6848585
This sheet describes installation of a low pressure hydraulic return line

from an attachment accessory valve to the truck low pressure tank line. Tank Hose ID
Each kit includes three sizes of adapter fittings for the truck tank line .75 in. (19 mm)
hose, 72 in. (183 cm) of low pressure hose, fittings for connection to 1.00 in. (25 mm)
the attachment accessory valve and hose clamps. 1.25 in. (31 mm)
NOTE: This installation requires splicing into the truck control valve low
pressure tank line.
WARNING: Do not install the tank line adapter

fitting in the power steering or braking system return
1 Truck Control Valve Low
Pressure Tank Line
line. Improper installation can cause erratic brake or

steering functions. Install the tank line fitting as close
as possible to the tank.
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
Call: 1-800-227-2233 Fax: 1-888-329-8207 Call: 1-888-227-2233 Fax: 1-888-329-0234
Tank Line Adapter Kits
2
4
5 3
6
REF QTY PART NO. DESCRIPTION AC0281.eps
6807816 Adapter Kit – Single Line

1 214056 Adapter Tee – .75 in. (19 mm) Hose ID
1 1 211739 Adapter Tee – 1.00 in. (25 mm) Hose ID
1 212891 Adapter Tee – 1.25 in. (31 mm) Hose ID
2 1 211742 Hose Clamp, .38 ➔ .87 in.
2 211743 Hose Clamp – .50 ➔ 1.25 in.
3
2 213140 Hose Clamp – .75 ➔ 1.75 in.
4 1 211740 Hose, 72 in.
5 1 211741 Fitting, 8
6 1 601377 Fitting, 8-8
4
3
5
AC2527.eps
6 REF QTY PART NO. DESCRIPTION
6848585 Adapter Kit – Dual Line
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

c
Installation DC-to-DC Converter
6009393 – 24/36V to 12V
Instructions 6007579 – 48/60V to 12V

6009394 – 72/80/96V to 12V
This sheet contains a general description, installation and Applications
application information for DC-to-DC Converters for electric
powered lift trucks. Use the DC-to-DC Converter on electric trucks to provide
12V power to the following electrical accessory products:
Electric Battery (UL 583) and IC Engine (UL 558) Indust. Truck • Adaptive Force Control (AFC)
type E, ES, G, GS,G/LP/ GS/LPS, LP, LPS, D and DS. • Force Control 250
• Electronic Rotational Control (ERC)
• Tilt Control
General Description and Use • Clamp Open Guard ™
A DC-to-DC converter is required on electric trucks to step Light Bar Kits
down the truck's motive power source to provide a low voltage, • Electronic Stop Groups
12V power source for Cascade electrical accessories. It is • Solenoid Adaption
recommended that the Cascade Power Bus/Relay be used
in conjunction with the DC-to-DC converter. Good practice 24-96V unswitched
is to connect the Power Bus/Relay so that the circuit(s) are
+ input (18 AWG wire
required)
energized when the truck key is on and deenergized when the −
key is off.
The converter is a solid state unit with internal overvoltage and 2 Amp
thermal overload protection, and a fused output. Fuse
DC-to-DC
Converter
Installation
1 Determine a suitable mounting location for the DC-to-DC I
N
Converter where it will be accessible for wiring connections P
U
and changing fuses. Mount the unit using screws to a T
metal surface for maximum heat transfer and dissipation. O
U
2 Use the 18 AWG output wiring harness provided to connect T
P
the Converter to electrical accessories, or the Power Bus/ U
T
Relay (recommended).
NOTE: See Installation Instructions 6811916 to install the
Power Bus/Relay. For non UL classified, refer to installation
6019876.
3 Test the electrical circuits to verify correct accessory
operation before operating the truck.
WARNING: For UL Classified kits, to reduce 12V

the risk of fire, replace only with same type Output Wire Harness
and rating of fuse. + (18 AWG wire)
− AC2028.eps
cascade W Cascade Corp.

File No. AU3546
corporation
Call: 1-800-227-2233 Fax: 1-888-329-8207 Call: 1-888-227-2233 Fax: 1-888-329-0234
DC-to-DC Voltage Converter Groups
4 2 7
8
I
N
P
U
T
O
U
T
P
6 U
T
9
1
AC2033.eps
24-36V to 48-60V to 76-96V to

12V 12V 12V
REF QTY PART NO. PART NO. PART NO. DESCRIPTION
6009393 6007579 6009394 DC/DC Converter Group
1 1 6017868 6017869 6017870 DC/DC Converter
2 1 TT25A TT15A TT12A Fuse
3 1 6018819 6018819 6018819 Power Cord
4 1 6811767 6811767 6811767 Power In
5 1 6806701 6806701 6806701 Fuse, 2 amp
6 1 6811745 6811745 6811745 Plate
7 4 6405318 6405318 6405318 Capscrew
8 4 685866 685866 685866 Lockwasher
9 4 768202 768202 768202 Nut
© Cascade Corporation 2010 2

09-2010 Part Number 6009167-R4
c
Installation Priority Flow
Instructions Control Valve
For Example:
Hyster S40-65 XL2 No. 10
No. 6
O-Ring Port
Auxiliary O-Ring Port
To Proportional Valve
Flow Valve 3
Tank Port
Hoist Clamp
Control
2
Auxiliary
Valve Valve
1
AC0287.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
Call: 1-800-227-2233 Fax: 1-888-329-8207 Call: 1-888-227-2233 Fax: 1-888-329-0234
Hyster S70-120 XL2
To Proportional
Flow Valve
Tank Port
Hoist Clamp
Control Auxiliary No. 6
Valve Valve No. 10 O-Ring Port
Valve
3
Priority Flow
Control Valve 2
2 To Proportional
3 Pump Port Tank Fitting 1
AC0445.eps
Truck Truck No. 10

Hydraulic Relief O-Ring Port
Truck
Pump Valve Tank
AC0289.eps
From truck
control valve
Return-to-tank
fitting
AC0291.eps
To truck tank
AC1769.jpg
2
Caterpillar 50 2EC25
To Proportional
Flow Valve
Tank Port
Hoist Clamp
Valve
3
Priority Flow
Control Valve 2
2 To Proportional
AC0445.eps
Truck Truck No. 10

Hydraulic Relief O-Ring Port
Truck
Pump Valve Tank
AC0289.eps
From truck
control valve
Return-to-tank
fitting
AC0291.eps
To truck tank
AC1770.jpg
3
Clark CGC25
To Proportional
Flow Valve
Tank Port
Hoist Clamp
Valve
3
Priority Flow
Control Valve 2
2 To Proportional
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
AC0291.eps
To truck tank
AC1771.jpg
 Cascade Corporation 2009 4

03-2009 Part Number 6012808-R1
c
Setup
Instructions Adaptive Force Control (AFC)
Software 6088346
These instructions describe the calibration procedures to
setup the Adaptive Force Control (AFC) system. System AFC Setup Summary
components should be installed using Installation Instructions
6095124. Read through the following pages before starting
calibration and setup for the AFC system. WARM UP TRUCK/ATTACHMENT
HYDRAULIC SYSTEM, CONDUCT
AFC Setup Summary HARDWARE CHECK
The block diagram and discussion below summarize AFC

setup. The service pendant main menu is the starting and
ending point for all system setup procedures. The program
CONNECT SERVICE PENDANT
prompts a specific action to be completed or a specific
parameter value to be keyed in.
NOTE: To pick up a load before the AFC is setup, lock the
system in manual mode. Refer to page 2.
CALIBRATE AFC SYSTEM
• Hydraulic System Warm up, Hardware Check – The
truck and attachment hydraulic system must be warmed
up in manual mode before calibrating the system. A ‘Quick
Hardware Check’ (Troubleshooting Section 3.3-1) must be
conducted to make sure that electrical components are ADJUST OPERATION SETTINGS
functioning and connected properly. If the system is not
properly functioning, refer to the Troubleshooting Section
(6095127) in this manual.
• AFC System Calibration – The calibration procedure
SELECT DROP STOP SETTINGS
requires a service pendant. A typical load is used during (if equipped)
calibration process. Stand clear of hoisted loads at all
times.
• Operation Settings – This menu is used to set the Clamp
Force Factor, Starting Pressure and Arm Speed settings. SELECT DATALOGGER SETTING
• Drop Stop Settings – For systems with Hoist Drop Stop, (If equipped)
this feature must be enabled in Menu 3.
• Datalogger Settings – For systems with Datalogger, this
feature must be enabled in Menu 4. HANDLE SOME LOADS, LOOK FOR
• AFC Load Test – Once the AFC system is internally SLIPPAGE OR CREASING
calibrated, it must be tested by picking up loads and
looking for slippage or creasing. If either is visible, the Start
Pressure and Clamp Force Factor values must be adjusted.
CHANGE USER SETTINGS
• Preferences – AFC system user settings. AS NECESSARY
• Advanced Settings (if required) – For AFC systems that
require fine tuning, the advanced settings menu can be
accessed after troubleshooting. Use caution - contact a
ADJUST THRESHOLD PRESSURE &
Cascade technician for further assistance. CLAMP-FORCE-TO-WEIGH RATIO
(if required)
cascade W
corporation
Call: 1-800-227-2233 Fax: 1-888-329-8207 Call: 1-888-227-2233 Fax: 1-888-329-0234
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
Before AFC Setup: . 0 SPACE ENTER
1 Warm up both the truck and attachment hydraulic systems.

IMPORTANT: Lock the AFC in manual override by AC1610.eps
releasing the locknut on the relief cartridge solenoid and
turning the Allen-head screw CW all the way in. Cycle
the mast and clamp ten full cycles. Unlock the manual
override by unscrewing CCW two full turns. Tighten the
1
locknut. Proportional Pressure
CAUTION: Tighten the screw to finger tight. Do NOT use Control Valve
Driver’s
tools. Display
2 To verify proper installation, perform a ‘Quick Hardware

Check’ (Troubleshooting Section 3.3-1). If the system
check fails, refer to Troubleshooting Section (6095127)
in this manual. Check the following: Turn
4
Pendant
CW to
• Electrical Power manually
• Solenoids override
AFC
• Pressure Transducers
• Sensor Switches
3 Adjust mainlift switch to activate as the mast transitions

from freelift to mainlift. Adjust the maximum lift switch to
activate .25 in. (6 mm) from the end of stroke.
4 With the truck and AFC system powered on, connect

service pendant to the AFC junction box pigtail using the Junction Box
cable provided. The service pendant screen will show
the main menu items. The following bullets describe each
menu item: RC3289.eps
Controller
• 1 Calibration Menu – This menu allows for:
–– Units to be selected (Imperial or Metric)
–– Calibration values are indicated for the Accumulator
–– Freelift and mainlift empty clamp pressure are • 5 Preferences – AFC User settings.
recorded
• 6 Advanced Settings – Accessed only for fine tuning
–– Freelift and mainlift load pressure are recorded the AFC system. Troubleshoot the AFC system before
–– Load weight and attachment factor are entered changing the advanced settings. Use caution - contact
a Cascade technician for further assistance.
• 2 Operation Menu – If AFC is equipped with auto
switch, the feature needs to be enabled and set for • 7 Diagnostics Menu – Performs system checks on
customer specific parameters including CFF (Clamp transducers, solenoids and switches.
Force Factor), AF (Attachment Factor) and Arm Speed • 8 Error Codes – Shows error code(s) when the AFC
Factor. system is not functioning properly.
• 3 Drop Stop Menu – If AFC is equipped with Hoist Drop
Stop system, the feature needs to be enabled.
5 Using the service pendant, press the “1” key or use the
cursor (“>”) to align with the menu item “1 Calibration
• 4 Datalogger Menu – If AFC is equipped with Menu” and press the ENTER key. Continue to next page to
Datalogger system, the feature needs to be enabled. begin the setup menu procedures.
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.
Use the cursor to select “1

Calibration Menu” and press
____Cascade_AFC the ENTER key.
Please_Select_Option To skip a submenu, use the
>1_Calibration_Menu arrow keys to go to the next
submenu.
_2_Operation_Menu
AC1668.eps
Specify units using the arrow

1.0_Unit_Type keys to move the cursor
and press the ENTER key to
Select_Unit_Type select.
>Imperial_Units
_Metric_Units
AC1668.eps
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
____________XXX psi charged or adjusted, press

the ENTER key to accept the
NOTE: Accumulator hydraulic end
must be open to atmosphere when
value. adjusting precharge.
AC1668.eps
Reconnect accumulator
before proceeding.
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
AFC measures no-load

hydraulic pressure in mainlift
1.3_Calibration stage while carriage is not
moving.
Carriage_in_Mainlif t
In_memory__3580 psi Raise the carriage into
mainlift. Press the ENTER key
Hit_Enter___XXXX psi to accept the value.
AC1668.eps
AC0251.eps
AFC measures load hydraulic

pressure in freelift stage while
carriage is not moving.
NOTE: Load should be
1.4_Calibration typical or midrange load
Load_into_Freelif t weight you will be handling.
In_memory__3580 psi Raise the load, keeping the

load in freelift. Press the
Hit_Enter___XXXX psi ENTER key to accept the AC0454.eps
value.
AC1668.eps
AFC measures load hydraulic

pressure in mainlift stage
1.5_Calibration while mast is not moving.
Load_into_Mainlif t Raise the carriage into
mainlift. Press the ENTER
In_memory__3580 psi key to accept the value.
Hit_Enter___XXXX psi
AC1668.eps
AC0452.eps
Key in load weight you are

handling. Press the ENTER
key.
1.6_Cal_Load_Weight Provides AFC system with
known load weight for proper
Enter_weight_in_lbs calibration.
In_memory__3580 lbs NOTE: Enter the weight of the
Hit_Enter___XXXX lbs load used in step 1.4 and 1.5.
AC0257.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
MENU 2 – Operation Menu

NOTE: Refer to the Pendants Key Functions Section for more
detailed information on operating the pendant.

Cascade_AFC Operation Menu” and press
the ENTER key.
Please_Select_Option
To skip a submenu, use the
_1_Calibration_Menu arrow keys to go to the next
>2_Operation_Menu submenu.
AC1668.eps
Choosing “Auto Switch”

2.1_Parameter Sw? or “Manual Switch” (with
3 position box) configures
Please Select Option the AFC System to provide
>Auto Switch multiple starting pressures
and clamp force factors.
_Manual_Switch
Choosing “Clamp Changing”
AC1668.eps
allows the user to set
calibration points and
OR parameters for up to three
separate attachments using
the 3-position box.
NOTE: Prior to setup,

the switch must be set to
2.1_Parameter Sw? appropriate position to
calibrate.
Please Select Option
If “Clamp Changing” is
_Clamp Changing selected, calibration is
_None required for each attachment
AC1668.eps
6095125-R3 5
For No Switch:
Clamp force factor (CFF) is the 1.6 Ratio

amount of clamp force applied
versus load weight.
4000 lb
Example: Clamp Force Factor (1800 kg)
of 1.6 results in approximately Clamp Force
2.2_CFF 4000 lbs. (1800 Kg) clamp force
Enter_the_CFF applied to 2500 lb. (1125 Kg)
load.
2500 lb
In_Memory____20 To determine CFF, refer to
(1125 kg)
Weight
Hit_Enter_ _ _ _ _ 0 Chart B (page 25). Enter the
value without the decimal. For AC0256.eps
example, if the value is 6.6, key
AC1668.eps
in 66 and press the ENTER key.
Starting pressure is the

hydraulic pressure in cylinders
after clamping but before hoist
2.3_Star t_Pressure cycle begins.
Enter_value_in_psi To determine start pressure,
refer to Chart B (page 25). Key
In_Memory__1000 in the start pressure and press
Hit_Enter_ _ _ _ _ 0 the ENTER key.
AC1682.eps
AC1668.eps
Try the default value first.

The arm speed, (Scale
0–50) in rare cases, may
require slight adjustment so
AFC can properly adjust to
2.4_Arm_Speed start pressure and status
Enter_Value light show steady green.
In_Memory____25 Too low = Will cause slow

arm speed.
Hit_Enter_ _ _ _ _ 0 Too high = Will not adjust
accurately to start pressure.
AC1668.eps
Continue to page 12.
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
Small Medium
Close long arm to

For Auto Switch only – sets
medium-to-low trip
AFC for small diameter/low point (example: 55%
weight rolls. of maximum arm
2.1b Position Arm NOTE: If Clamp has
opening).
Between Med and Low two-stage cylinders set

trip point where cylinder
transitions into second stage.
Press_Enter_when_set
AC1668.eps
AC1939.eps
Close long arm fully,

then open 1 inch
(25 mm) then set.
For Auto Switch only – sets

2.1c_Position_Arm minimum position.
to_1_inch
from_full_close
Press_Enter_When_Set
AC1668.eps
AC0517.eps
Example: Setting Auto Switch trip points to handle different loads
(Step 2.1b) (Step 2.1a)
Medium-to-low trip High-to-medium trip

Small Roll Medium Roll Large Roll
point set to occur at point set to occur at
(Example: (Example: (Example:
40 in. (102 cm) arm 50 in. (127 cm) arm
35 in. dia.) 45 in. dia.) 55 in. dia.)
opening. opening.
AC1951.eps
Minimum Maximum
Arm Arm
Opening Opening
6095125-R3 7
For Auto Switch or Manual Switch (Continued):
Amount of applied clamp force

1.6 Ratio
for a given load weight at High
Setting. 4000 lb
(1800 kg)
Example: Clamp Force Factor Clamp Force
2.2a_CFF_-_High of 1.6 results in approximately
4000 lbs. (1800 Kg) clamp force
Enter_the_High_CFF applied to 2500 lb. (1125 Kg) 2500 lb
(1125 kg)
load.
In_memory____25 To determine High Setting
Weight
Hit_Enter_____XX CFF, refer to Chart B (page AC0256.eps

25). Enter the value without
AC1668.eps
the decimal. For example, if
the value is 6.6, type in 66 and
press the ENTER key.

2.2b_CFF_-_Medium for a given load weight at
Medium Setting.
Enter_the_Medium_CFF To determine Medium Setting
In_memory____22 CFF, refer to Chart B (page 25).
Hit_Enter_____XX
AC1668.eps

2.2c CFF - Low for a given load weight at Low
Setting.
Enter the Low CFF To determine Low Setting CFF,
In_memory____16 refer to Chart B (page 25).
Hit_Enter_____XX
AC1668.eps
8 6095125-R3
Starting Pressure is hydraulic

pressure in cylinders after
clamping but before hoist
cycle begins.
2.3a_High_Star t_Pres Refer to Chart B (page 25)
Enter_value_in_psi to determine High Start
Pressure. Key in the high
In_memory__1000 start pressure and press the
Hit_Enter___XXXX ENTER key.
AC1682.eps
AC1668.eps
Refer to 2.3a
Refer to Chart B (page 25)

2.3b_Med_Star t_Pres to determine medium start
pressure. Key in the medium
Enter_value_in_psi start pressure and press the
In_memory___900 ENTER key.
Hit_Enter____XXX
AC1682.eps
AC1668.eps
Refer to 2.3a
Refer to Chart B (page 25) to

2.3c_Low_Star t_Pres determine low start pressure.
Enter_value_in_psi Key in the low start pressure
and press the ENTER key.
In_memory___800
Hit Enter____XXX AC1682.eps
AC1668.eps
6095125-R3 9
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
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
2.4c Low Arm Speed

Enter value Arm speed for a small roll.
In_memory____18
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.
Clamp force factor (CFF) is the 1.6 Ratio

amount of applied clamp force
for a given load weight.
4000 lb
Example: Clamp Force Factor (1800 kg)
of 1.6 results in approximately Clamp Force
2.2a_CFF Clamp 1 4000 lbs. (1800 Kg) clamp force
Enter_Clamp 1 CFF applied to 2500 lb. (1125 Kg)
load.
2500 lb
In_Memory____20 To determine CFF, refer to
(1125 kg)
Weight
Hit_Enter_ _ _ _ _ 0 Chart B (page 25). Enter the
value without the decimal. For AC0256.eps
example, if the value is 6.6, key
AC1668.eps
in 66 and press the ENTER key.
Starting pressure is the

hydraulic pressure in cylinders
after clamping but before hoist
2.3a_Clamp 1 Star t P cycle begins.
Enter_value_in_psi To determine start pressure,
refer to Chart B (page 25). Key
In_Memory__1000 in the start pressure and press
Hit_Enter_ _ _ _ _ 0 the ENTER key.
AC1682.eps
AC1668.eps

The arm speed, (Scale
0–50) in rare cases, may
require slight adjustment so
2.4a Clamp 1 Arm Spd AFC can properly adjust to
start pressure and status
Enter_Value light show steady green.
In_Memory____17 Too low = Will cause slow
arm speed.
Hit_Enter_ _ _ _ _ 0 Too high = Will not adjust
AC1668.eps
Mount attachment #2. Turn 3-position selector to Clamp 2

position, re-calibrate using Menu 1 before entering values for
operation Menu 2.2b–2.4b
Repeat for attachment #3, if required.
6095125-R3 11
MENU 3 – Drop Stop Menu

Cascade_AFC Drop Stop Menu” and press
the ENTER key.
>3_Drop_Stop_Menu arrow keys to go to the next
_4_Datalogger Menu submenu.
AC1668.eps
Enables / disables drop stop

3.1_Drop_Stop? features.
Yes_or_No? NOTE: If hoist drop stop

valve is installed, choose
>Yes_Drop_Stop “Yes Drop Stop”.
_No_Drop_Stop
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
Sets minimum load weight

where hoist drop stop valve
will function.
Example: If set at 500 lbs.
(227 kg), drop/stop valve
3.3_Min_Drop_Stop_Wt does not function below
Enter_Weight_in_Lbs 500 lbs. (unless hoist
drop stop switch option is
In_Memory___450 Lbs included).
Hit_Enter____XXX Lbs If set too low, the mast may
stop inappropriately while
lowering lighter loads.
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
MENU 4 – Datalogger Menu

Use the cursor to select “4 Datal

Kit
ogge
r,
Par
t Num
Cascade_AFC Datalogger Menu” and press

ber
: 60
7586
3
Dev
ic
the ENTER key.

eP
art
Num
ber
: 60
7586
3
TM
_3_Drop_Stop_Menu arrow keys to go to the next
>4_Datalogger Menu submenu.
4.1_Datalogger? If equipped with

Datalogger, enable the
Yes_or_No? feature.
>Enable Datalogger
_Disable Datalogger
AC1668.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
Use the cursor to select

“5 Preferences” and
Cascade_AFC press the ENTER key.
Please_Select_Option To skip a submenu, use
>5_Preferences the arrow keys to go to
the next submenu.
_6_Advanced_Settings
AC1668.eps
(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
Sets operator display to read

• Clamp hydraulic pressure
(psi)
0
5.2_Disp_Pres_or_Frc • Clamp force Pressure
Press_Enter_When_Set If enabled, the display buttons or Force M/E P/F
can also be used to choose

_Display_in_Force between pressure and force
>Display_in_Pressure (see 5.1).
AC1719.eps
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).
5.5_Reclamp_% Percentage the pressure is

allowed to drop in the clamp
Enter_Value cylinder from target pressure
In_memory____20 before AFC initiates a reclamp.
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.
In_memory____35 Default value 35 unless

changed by Cascade.
Hit_Enter_____XX
AC1668.eps
Resets all controller values

back to default.
NOTE: Recalibration with a
load will be required.
5.7_Reset_to_Default IMPORTANT: When installing
!!_USE_C AUTION_!! a new controller or updating/
changing the software
>Keep_Existing_Value revision, reset controller to
_!!Reset to Factory! the defaults prior to clamp
calibration and setup.
AC1668.eps
16 6095125-R3
MENU 6 – Advanced Settings Menu
Use caution – contact a Cascade service technician for further
assistance.
Use the cursor to select

“6 Advanced Settings”
and press the ENTER key.
NOTE: Refer to
Cascade_AFC Troubleshooting Section
(6095127) in this manual
Please_Select_Option before making changes
to the advanced settings
_5_Preferences sub menus.
>6_Advanced_Settings To skip a submenu, use
the arrow keys to go to
AC1668.eps
the next submenu.
While the clamp arms are

moving, pilot pressure
value prevents the AFC
system from doing
anything before minimum
6.1_Pilot_Pressure operating pressure is
achieved.
Enter_value_in_psi
Cylinder pressure rising
In_memory___250_psi above pilot pressure
Hit_Enter____XXX_psi unlocks the AFC system.
Scale: 200–500 psi
AC1668.eps
(14–34 bar)
Difference between truck

clamp line pressure and
6.2_On_Roll_Diff clamp cylinder pressure
Enter_value_in_psi indicating arm contact to
the load.
In_memory____40_psi Scale: 40–200 psi
Hit_Enter_____XX_psi (3–14 bar)
AC1668.eps
On Roll Differential, 6.2

Pilot Pressure, 6.1
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
Ramp value for start clamp

pressure before hoisting.
6.4_Star t_P_Ramp If overshooting start clamp

pressure, decrease in
Enter_value_in_% increments of 1. If the
start pressure is too slow,
In_memory___ 5_% increase in increments of 1.
Hit_Enter____XXX_% Scale: 0–10
AC1668.eps
6.4
Ramp
PWM
Rise
Run
Start Pressure Arm Speed
(Initial PWM), 6.3
Time
AC1921.eps
The difference between

clamp cylinder pressure
6.5_Star t_P_Diff and desired start clamp
pressure before status
Enter_value_in_psi light shows steady green.
In_memory___100_psi Scale: 50–150 psi
(3.5–10 bar)
Hit_Enter____XXX_psi
Start Pressure
Differential, 6.5
AC1668.eps Overshoot
Start Clamp
Pressure
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
AFC Clamp Cycle

AC1945.eps
The amount of time the

hoist filter will be applied.
6.7_Dampening_time For adjustment, start with
Enter_in_Seconds the duration of a typical
hoist plus 2 seconds.
In_ memory_____5_sec Scale: 5–15 seconds
Hit_ Enter_ _ _ _ _ 0_sec
AC1668.eps
Actual Hoist Pressure
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 Clamp Force
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
Target Clamp Force
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 less Counts greater

than Pause than Pause
Count, 6.11 Count, 6.11
Counts
AC1950.eps
The open line pressure

that resets after clamp
6.12_Open_Reset_Pres cycle. Set this value
45-60 psi (3-4 bar) below
Enter_value_in_psi open line (PT2) pressure
In_Memory___390_psi required To move arms
open.
Hit_Enter______0_psi
AC1668.eps
6.13_Prehoist_Pres Pressure increase above

Enter_value_in_psi static hoist to indicate
premature lift.
In_Memory___250_psi
AC1668.eps
Amount hoist pressure

6.14_Preopen_Pres needs to be above
Enter_value_in_psi static hoist to indicate
premature opening of
In_Memory___300_psi clamp.
AC1668.eps
6095125-R3 21
MENU 7 – Diagnostics Menu
Cascade_AFC Use the cursor to select

Please_Select_Option “7 Diagnostics Menu” and
press the ENTER key.
>7_Diagnostics_Menu
_8_Error_Codes_Menu
AC1668.eps
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
Real time transducer values in units

selected.
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
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
Real time switch data.
22 6095125-R3
MENU 8 – Error Codes Menu
Cascade_AFC Use the cursor to select

“8 Error Codes Menu” and
Please_Select_Option press the ENTER key.
_7_Diagnostics_Menu
>8_Error_Codes_Menu
AC1668.eps
8.0_Error_Codes Display errors based on

pressure transducers
and solenoids. Refer to
_____X Troubleshooting section
(6095127) in this manual.
_____X Example: 131(Pressure
Transducer 3 (PT3) is open)
AC1668.eps
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
Guidelines to Initial Settings for Typical Applications1
START PRESSURE 2 psi (bar) CLAMP FORCE FACTOR 3

ROLL CLAMP LOADS Low Medium High Roll Clampability Range
News Print 700 (48) 900 (62) 1100 (76) 1.6 1.8 2.0
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
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
6095125-R3
Calibration Settings Log (Continued)
CLAMP CHANGE ONLY
Clamp 1 Clamp 2 Clamp 3
Calibration Clamp Calibration Clamp Calibration Clamp

Load Wt Force Start Arm Load Wt Force Start Arm Load Wt Force Start Arm
Date/Set By Data Factor Pressure Speed Data Factor Pressure Speed Data Factor Pressure Speed
31
32 6095125-R3
6095125-R3
Drop Stop Log Datalogger Log Preferences Log
Minimum Drop Stop

Date/Time/ Drop Stop Activation Clamp Force Display Max Clamp
Set By Weight Pressure Capture Frame Change % Pressure Reclamp % PT Factor
33
34 6095125-R3
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
Advanced Settings Log (Continued)
6095125-R3
Reclamp
Date/Time/ Frictional Pause Open Reset
Set By Damp Inertial Damp K Factor Count Pressure
37
AMERICAS
Fax: 888-329-8207 Fax: 905-629-7785 Tel: 55-13-2105-8800
Fax: 55-13-2105-8899
EUROPE-AFRICA
Italy South Africa
Tel: 39-045-8989111 Tel: 27-11-975-9240
Fax: 39-045-8989160 Fax: 27-11-394-1147
ASIA-PACIFIC
Fax: 86-592-651-2571 Phone: +91 020 2432 5490
Fax: +91 020 2433 0881
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
O PERATOR'S GUIDE
D, F, G & H-Series
Fixed Frame
Paper Roll Clamps
Manual Number 210135-R9
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
Tilt With load

Raise
3 in.
(8 cm)
No load
P P
Traveling RAMPS
Motor off, park, lower load empty
No parking on ramp No turning on ramp Watch clearances
RC0027.eps
TRAFFIC
STOP
Observe
Workers Stops
Slow for Sound horn, slow Sound horn, slow

Wet floors Bumps Dips two-way traffic at intersection at corner
210135-R9 2
S AFETY RULES
Handling Loads: Rolls must be secure prior to lifting and transporting.
Limit swinging clamp

with raised load. LOAD
WEIGHT
Make sure load

is centered and
secure prior
to lifting and
traveling.
Check for load

Load weight must not exceed combined truck/ slippage (see Load
attachment capacity (see truck nameplate). Troubleshooting).
Use caution when

handling unitized
(wrapped) multiple
stacked rolls with
Single-Arm Clamp.
RC0721.eps
Limit truck movement
with raised load.
Split-Arm Clamp is recommended to handle two rolls (see Make sure bottom roll is secure.
Roll Handling Basics). Handling two rolls with Single-Arm
Clamp may be dangerous and lead to serious injury.
Position the paper roll

center of gravity as close
as possible to the center
of rotation to minimize
lateral offset.
Paper Roll
Center of Gravity
Center of
Rotation
RC3942.eps
Lateral Offset
3 210135-R9
D AILY INSPECTION
Check items each day. Report problems to

your supervisor. Check clamp force prior to
each operational shift. See Service Manual
for troubleshooting, maintenance and repair
procedures. Upper hook
engagement
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
B UPENDING TILT UPENDING TILT

(Non-Solenoid) (Solenoid Equipped)
A Tilt Forward A Rotate Counterclockwise
B Tilt Backward A Tilt Forward
A (Press Button)
B Rotate Clockwise
B Tilt Backward
(Press Button)
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
CLAMPING ROLL Center Clamp pads on roll
RC0033.eps
RC0032.eps
Clamp through roll centerlines
CARRYING Tilt 3-4°

ROLL
RC0037.eps
12 in. (30 cm)
RC0036.eps
Roll vertical, tilted back
CLAMP FORCE
Kraft Tissue
Use proper clamping

force for load being
handled
Also, see the following:
RC0034.eps RC0035.eps • Clamp Force Indicator
Operator Guide
214750
Pressure selection valve • Establishing Clamp
Force TB 284
GA0072.eps
210135-R9 6
Handling two rolls using split-arm clamp
Center Clamp pads between rolls

WARNING: Engine speed MUST be
CAUTION: Clamp multiple rolls increased when clamping or releasing
securely and properly prior to lifting or rolls with Split-Arm Clamps.
traveling.
RC0038.eps

Recommended roll width as possible to the center
2X pad height 'A' if rotating, of rotation to minimize
3X maximum lateral offset. This will
A reduce torque
requirements Paper Roll
and increase Center of Gravity
truck stability.
Center of
Rotation
RC3942.eps
RC0789.eps
Lateral Offset
Maximum roll Position short arm on

width 3X pad rolls before clamping
height 'A' if not
rotating
A
RC1188.eps
RC0039.eps
7 210135-R9
Upending
Center clamp pads
vertically on roll,
if possible
Clamp through roll centerline CAUTION: Verify the clearance between the bottom
of the roll and mast prior to tilting the roll forward.
Raise roll to clear

ground when tilted
Tilt roll forward
CAUTION: Verify the center of gravity for

the load does not exceed the capacity of
the truck. Consult OEM as required.
RC3742.eps
Transporting CAUTION: Transporting in any position other than vertical is not acceptable
unless attachment is specifically designed for that application.
RC4141.eps
Vertical transport position
210135-R9 8
V ERTICAL PICKUP, TRANSPORT, UNLOADING
1 Position Clamp parallel to and centered on roll

2 A) Adjust short arm
for roll diameter
B) Drive forward, touch
short arm to roll
RC2167.eps
C) Clamp with 2-4 in.

long arm (5-10 cm)
RC0041.eps
3 Raise, tilt back for transport
3-4°
4 Tilt vertical before lowering to floor
12 in.
(30 cm)
9 210135-R9
B ILGE (HORIZONTAL) PICKUP
1 Tilt, lower Clamp to ground
3-4° 2 Square truck to roll, position Clamp

parallel to roll
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

as possible to the center
of rotation to minimize
lateral offset. This will
reduce torque
requirements Paper Roll
and increase Center of Gravity
truck stability.
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
B) Clamp with long arm

2-4 in.
(5-10 cm) RC1010.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)
NOTE: Back tilt

required if angled
clamp mount used
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
Roll Vertical B) Set roll

Roll
down
Vertical
squarely
CAUTION: No
rotation when
clamped at
bottom of roll
CAUTION: 0 ° Clamp mount (shown) NOTE: Back tilt required

may be required above 130 in. if angled clamp mount
(330 cm) – check Clamp model (shown) is used
11 210135-R9
U NLOADING TRUCK TRAILERS (BREAKOUT)
Fixed-Frame Clamp
1 Tilt, center Clamp to

1st roll
CAUTION: Trailer must be
inspected for damage before 2
Position arms to roll diameter,
short arm toward wall
unloading.
Short Arm
Dockplate required
RC0055.eps
CAUTION: Block RC0054.eps

RC0054.eps
trailer wheels
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
3 4
Drive forward, angle truck to grip roll behind centerline Clamp 1st roll, move back for clearance
to re-clamp
Dockplate required Arms not wedged
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
CAUTION: Block trailer wheels

RC0065.eps
2 Drive down center of trailer,

tilt vertical, brake slowly
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
210135-R9 14
L OADING BOXCARS
1 B) Tilt to
vertical
A) Rotate roll to
position short
arm toward
wall
Dockplate
required
RC0069.eps
2 A) Reposition truck to place

rolls against wall
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
1 A) Align truck with rolls

B) Fully open arms
2
A) Approach
rolls slowly
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
CAUTION: Truck balance

may be critical when
turning with full loads
12 in.
(30 cm)
RC2038.eps
6 A) Check Clamp
Pads are vertical
Shut Off Unused Arms
RC2556.eps
No L-shaped loads
4 in. (10 cm)
B) Check clearances –
• Roll-to-roll
• Truck-to-stack
RC2029.eps
RC1868.eps
17 210135-R9
L OADING WITH ADJUSTABLE BUMPER OPTION
VERTICAL PICKUP BILGE PICKUP

A) Close arms to approximate A) Close arms to approximate
roll diameter roll diameter
C) Clamp with
B) Drive forward touching 3-4° long arm
bumper to roll
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
AMERICAS
Fax: 888-329-8207 Fax: 905-629-7785 Tel: 55-13-2105-8800
Fax: 55-13-2105-8899
EUROPE-AFRICA
Italy South Africa
Tel: 39-045-8989111 Tel: 27-11-975-9240
Fax: 39-045-8989160 Fax: 27-11-394-1147
ASIA-PACIFIC
Fax: 86-592-651-2571 Phone: +91 020 2432 5490
Fax: +91 020 2433 0881
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
O PERATOR'S GUIDE SUPPLEMENT
Adaptive Force Control
Manual No. 6095126-R1
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
Adaptive Force Control – Adaptive Force Control

(AFC) equipped Paper Roll Clamps ("Smart Clamp"
technology) are operated in a similar manner as a
standard Paper Roll Clamp, with the exception of the
actions and indications shown in this guide.
IMPORTANT: Refer to Cascade Paper Roll Clamp
Operator's Guide 210135 for complete suggested
load handling procedures and any other company
specific handling guidelines for your loads.
About this Guide – The information is this guide is
intended to provide operator understanding about
using Paper Roll Clamps equipped with Adaptive
Force Control. Read this guide thoroughly before
operating an attachment equipped with Adaptive Driver's
Force Control. If you have any questions or do not Display
understand a procedure or indication, ask your (optional)
supervisor.
Emphasize Safety! Most accidents are cause by Status
operator carelessness or misjudgment. You must Light
watch for hazardous situations and correct them.
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)
Clamp force values

OK Ok to hoist
(Kn) in kilo newtons M/E P/F

Appears when
an error occurs
Appears when
an error occurs
Arm Position Icons
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
S TATUS LIGHT BASICS
Steady Green – OK to lift load
Flashing Green – AFC is in override mode
Steady Red – Do not lift load
Flashing Red – Fault
AC1643.ai
6095126-R1 1
S TART-UP, TRAVELING EMPTY, ADDRESSING LOAD
1 Wait for status light to

illuminate.
Pressure or force
should show "0" Shows steady
red
2 Arm position icon will show a

low, medium or high position,
set by Auto Switch. If no
switch, low is always on.
AC1630.ai
3 Position Clamp parallel to and

centered vertically on load
C LAMPING LOADS
1 Drive forward, touch short

arm to roll
Split Arm Clamp
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
'OK' icon will not show
AC1632.ai
H OISTING LOAD, TRAVELING
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
12 in. (30 cm)

AC1633.ai
OK to hoist
WARNING: When status light shows WARNING: Status light must

flashing green: AFC in override mode. show steady green before
Driver controls clamp force/pressure. hoisting and during traveling.
6095126-R1 3
S ETTING LOAD DOWN, UNCLAMPING
'OK to hoist' icon goes

away after 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
STARTUP, TRAVELING EMPTY
Clamp force/pressure.
Clamp force shown.
Steady red light
Load parameter setting.

Automatically set by Auto
Switch option.
If no Auto Switch, LO always AC1636.ai AC1636.aiAC0302.eps
ON.
AC1635.ai
GRABBING LOAD AFC starting clamp force/pressure

before hoisting,
– OR –
If override engaged or Clamp at
900
maximum lift, driver controls clamp
force/pressure. Display will show
real time force/pressure.
If override engaged or at maximum

lift, Status light shows flashing
green. AFC in override mode.
– OR –
If starting clamp force/pressure
has not been achieved, load
AC1638.ai
should not be hoisted. Status light
AC1637.ai shows AC1636.ai
steady red. AC1636.ai AC1636.ai
HOISTING LOAD, TRAVELING

Real time clamp force/pressure.
– OR –
1700
Maximum clamp force/pressure
achieved during hoist/clamp cycle.
Steady green light, AFC is

functioning and will apply correct
clamp force.
– OR –
Flashing green, override engaged
or Clamp at maximum lift. Driver
controls clamp force/pressure.
AC1639.ai
AC1637.ai AC1636.ai AC1636.ai AC1636.ai AC1636.ai
SETTING LOAD DOWN, UNCLAMPING

Residual clamp force/pressure.
0 Steady red when load has been

released.
AC1636.ai AC1636.ai
AC0379.eps
6095126-R1
AC1637.ai 5
U SE OF OPTIONAL DAMAGE-REDUCTION FEATURES
DROP/STOP AND ACTIVATION SWITCH (if equipped)

Drop/Stop – Automatically prevents slack chain or
HOIST accumulator jump. Minimum Drop/Stop weight (Setup
3.2) used to adjust sensitivity. If problems occur, go to
Troubleshooting Section 3.4-7 or Setup Menu 3.0–3.2.
Drop/Stop Activation Switch – Provides extremely

accurate control over unwanted Clamp movement due to
slack chains or accumulator ‘jump’ when load is being set
AC1259.eps
down. AC0304.eps
Press activation button on HOIST control lever as

load reaches 2-12 in. (5-30 cm) above set-down. 2-12 in. (5-30 cm)
TILT CONTROL
Mast automatically stops at vertical position when tilting
forward or backward.
TILT To continue tilting, wait 3 seconds for reset,
OR
Press override button on TILT control

lever to tilt without stopping.
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
CLAMP OPEN GUARD

CAUTION
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
AMERICAS
Fax: 888-329-8207 Fax: 905-629-7785 Tel: 55-13-2105-8800
Fax: 55-13-2105-8899
EUROPE-AFRICA
Italy South Africa
Tel: 39-045-8989111 Tel: 27-11-975-9240
Fax: 39-045-8989160 Fax: 27-11-394-1147
ASIA-PACIFIC
Fax: 86-592-651-2571 Phone: +91 020 2432 5490
Fax: +91 020 2433 0881
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
T ROUBLESHOOTING
AFC System
1.1 Truck System WARNING: Before servicing any

hydraulic component, relieve pressure in
Requirements the attachment system. Turn the truck off

and move the truck auxiliary control lever
several times in both directions.
• Truck hydraulic flow and pressure should be within the
For electro-hydraulic systems, pulse the attachment
range shown in the appropriate service manual for the
open to relieve pressure trapped in the clamp circuit
clamp.
before turning truck off.
• Hydraulic fluid supplied to the AFC must meet the
After completing any service procedure, always test
requirements in the appropriate service manual for the
the attachment through several cycles. First test empty
clamp.
to bleed any air trapped in the system to the truck tank.
• Electrical power to the AFC must be from a circuit that Then test with a load to make sure that the attachment
can supply 12 Volts @ 7.5 Amps through a relay that is operates correctly before returning to the job. Stay
energized by the truck key/ignition circuit. clear of the load while testing. Do not raise the load
more than 4 in. (10 cm) off the floor while testing.
2.1 Before Starting Service Pendant 6095901

2.1-1 Power
Verify that the AFC has power. Refer to Power Tree,
Section 3.5-1.
F4
F3
F2 S
YE
F1 3
2 NO
1 6
SP
5 BK
4 9 R
8 E
EN
TE
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
3.2 Error Codes 3.3 Hardware 3.4 Performance

3.3-1 System Check 3.4-1 Load Status Indicators
3.3-2 Junction Box and Cable 3.4-2 Loads Slips
3.3-3 Pressure Transducers 3.4-3 Overclamping
3.3-4 Solenoids 3.4-4 Display Values
3.3-5 Mast Switches 3.4-5 Arm Movement
3.3-6 Status Light 3.4-6 Pressure Adjustment
3.3-7 Display (if equipped) 3.4-7 Drop Stop
3.3-8 Valves
3.3-9 Override Switch (if equipped)
3.3-10 Auto Switch (if equipped)
3.3-11 Datalogger (if equipped)
3.3-12 Service Pendant
2 6095127-R4
T ROUBLESHOOTING
3.2 Error Codes

If a hardware error occurs, the status light will flash Status Light
red. An error screen will appear on the display Flashing Red
(if equipped) or use service pendant and select 6
Error Codes Menu.
AC1636.ai AC1636.ai AC1636.ai AC1636.ai
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.
Example: 1 (Pressure Transducer), 3 (PT3), 1 (Open Circuit)
PT2 PT4 SOL4 PT1
AC1693.ai
SW1
SW2
RC3349.eps
SOL1
PT3
SOL2 SOL3
6095127-R4 3
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3.3 Hardware LED 1 LED 3
3.3-1 Quick Hardware Check

LED 2 LED 4
NOTE: Service pendant should be unplugged prior to
turning on the truck. Plug in service pendant after the truck AC1765.eps
and system is on. Face of Controller
Power-Up Test Status

System Start Lights, 3.3-6
Flash
Yellow
Red LED 2 Green LED 1 Green LED 3 Off LED 4 Red/Green

Bad Controller,
replace Color Color Color Color
Off or Flash
Red Yellow Red/ All
All
Flash Green others
others
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 YES Pressure Test Pressure YES Status NO

Transducers Transducers, Light LEDs,
OK? 3.3-3 OK?
Go to Power Test Junction
Tree, 3.5-1 Box, 3.3-2 YES
NO
Test mast Switches YES Test Solenoids,

switches, 3.3-5 OK? 3.3-4
YES Junction
Box,
OK?
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
Test Auto Switch NO Test override

(if equipped), Status Light (if equipped)
3.3-10 Flash Green press override
Troubleshoot button
Section 3.3-9
AC1764.eps
NO
4 6095127-R4
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3.3-2 Junction Box Junction Box

Terminal Block Key: K J H G F E D C B A
Terminals in the junction box can be traced to a pin on the

controller side of the harness using a volt-ohm multimeter Connector Key: Y X W T S R P N M L
tester. 1 1
NOTE: Terminals U1–U6 are unused. All (-) terminals 2 2

are common with power (-) terminal and pins B2, B3, C2, 3 3
C3 and D3. All (+) terminals are common with power (+)
terminal and pins K1, K2 and K3.
AC1699.ai
Testing – Example: Terminal D1 should be tested with

• Check fuse connector P1.
• Properly secure wires in terminals
• Check continuity from pins to terminals
If continuity test fails, determine if fault is in cable or
junction box. Controller Connector
Y1 X1 W1 T1 S1 R1 P1 N1 M1 L1
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+ C1 A2 A3 E3 E3 G1 G2 H3 J1 J2 J3 H1 H2 U2 U4 U6
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
3.3-3 Pressure Transducers

Testing –
• Use the service pendant (Menu 5.1) or display
gauges (press gauge button) to observe and verify
that pressure transducers are functioning properly
5.1_Transducers
by cycling the system through clamp, release, hoist Values_in_PSI
and lowering.
NOTE: If the display’s gauge button is disabled,
Pt1__XXXX__Pt3__XXXX
use the service pendant to enable this feature in Pt2__XXXX__Pt4__XXXX
submenu 4.10.
PT1 – Hoist AC1668.eps
PT2 – Open
PT3 – Cylinder
PT4 – Close
Pressure Transducer Connector –
1300 1300
Pin Wire Color 0 2600 0 2600
1 Black - 970 PSI 790 PSI

2 White + PT1 − Hoist PT2 − Open
4 Red signal 1300 1300
0 2600 0 2600
If Pressure Transducer is not
functioning – 1110 PSI 850 PSI
PT3 − Cylinder PT4 − Close
• Refer to Electrical Schematic (Section 3.5-3) and
Junction Box Terminal Table (Section 3.5-4) for
correct junction box terminal connection.
• Verify continuity between pressure transducer
connector and junction box terminals. AC1713.ai
• Replace pressure transducer if wiring is OK.
Gauge Button
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
3.3-5 Mast Switches

Testing –
1 Power up system.
2 Verify LED will illuminate when closed (proximity to 5.3_Switches
metal will close switch). On_or_Off
3 Use service pendant (submenu 5.3) to verify switch Max___off_OvrRd__off
state.
Main_ _ off_AS_____10
Switch is not functioning –
• Refer to Electrical Schematic (Section 3.5-3) and AC1668.eps
Junction Box Terminal Table (Section 3.5-4) for correct
junction box terminal connection.
• Verify continuity between switch connector and junction
box.
Pin Wire Color
4 Black signal
1 Brown +*
3 Blue -
* 10-30 VDC
• Verify that the switch, itself, is 12V (supply voltage) Switch LED
between the black signal wire and the blue ground
wire at the junction box when the switch is closed (LED
illuminated).
• Verify the clearance between sensing face, mounting
bracket (4 mm) and target surface (12 mm). Refer to
AC1705.ai
Installation Instructions 6095124.
Specifications – Target Surface

• Normally Open Range
• 10-30 VDC 12 mm
• PNP
Bracket
• When switched, LED illuminates
• Range 12 mm to flat iron surface
4 mm Switch
Connector
AC1706.ai
8 6095127-R4
T ROUBLESHOOTING
3.3-6 Status Light

Basic Function –
• Steady Red – Do not lift load.
• Steady Green – Ok to lift load.
• Flashing Green – Override or maximum lift, maximum pressure
determined by truck relief.
• Flashing Red – Error, service immediately.
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
Any LED YES

illuminated
NO Status
NO NO 2X
light is steady
red
Connect directly to terminals:

Black to (-) Test NO Replace status
White to (12V +), green LED OK YES
light
Red to (12V +), red LED
YES Clamp the load
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
Test cable NO Test YES

pin to pin OK
Status Light
OK
Cable YES Test junction YES Go to Performance

Junction
OK box, go to 3.3-2 Box Troubleshooting 3.4-1
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
Display NO Verify correct connection Display Display NO

NO Go to Power
illuminated at junction box, see illuminated illuminated
Tree 3.5-1 Direct
installation instructions
Power
YES YES YES
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
YES YES Any

other Cotnroller:
NO Display color
Replace cable (6090897) LED1 - color
Enable buttons cable continuity LED 2 - Green
Correct
errors (Pendant submenu OK?
4.10)
YES Green
YES
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
3.3-8 Hydraulic Valves

Verify the following:
Valves
• Valves installed correctly into hydraulic circuit. Refer to
Installation Instructions 6095124.
• Override screw is OUT on proportional pressure control
valve. Refer to Installation Instructions 6095124.
• Pressure transducers and solenoids are functioning as
described in sections 3.3-3 and 3.3-4.
NOTE: To tell if solenoids are turned on, a ‘click’ will be
heard or felt on solenoids 1, 3 and 4. If not, test coil for
continuity.
Follow Performance troubleshooting, Section 3.4, to identify
other hydraulic problems.
3.3-9 Override Switch

• Verify that the switch is normally open by testing. Override
Switch
• Test continuity at junction box terminals when switch is
depressed. AC1709.ai
• Use schematic to verify correct junction box terminal

connections.
• Verify switch function with service pendant
(submenu 5.3)
3.3-10 Auto Switch (Cable type)

• Inspect for damage and verify smooth cable operation.
• Verify continuity between auto switch slip ring connector
and junction box.
Pin 1 ➝ F1-
Pin 2 ➝ F1
Pin 3 ➝ E3
If there is a fault, use schematic to trace and locate the AC1710.ai
fault.
• Verify switch function by observing the following on the
service pendant (submenu 5.3):
A) As the roll clamp arm closes, the value increases
Kit
Pa
rt
Nu
B) As the roll clamp arm opens, the value decreases

m
be
r:
60
75
86
3
De
vic
e
Pa
rtN
um
be
r:
60
75
86
3
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
3.3-12 Service Pendant

• The service pendant must be connected to cable
6090962 AFTER the AFC system is powered on.
• The pendant can be plugged or unplugged as needed
as long as the power is on. F4
F3
• The AFC system will operate correctly with the pendant F2 S
YE
F1 3
2 NO
plugged in and while going through submenus. 1
4
5
6
BK
SP
9 R
8
If the pendant does not start correctly, verify cable terminal
TE
EN
CE
7 SPA
connection and cable continuity. Refer to Electrical

.
Schematic (Section 3.5-3) and Junction Box Terminal Table

(Section 3.5-4) to check the following:
A1 – Green
A2 – Orange
B2 – Black
A3 – Red
E3 – White
The pendant comes preconfigured. If information shows
but can’t be read, contact Cascade for configuration AC1692.ai
instructions.
For basic operation instructions refer to AFC Setup
Instructions 6095125.
To service the pendant, press and hold the following keys
“BKSP”, “ENTER” and “F1”. Verify the pendant has the
following option selected:
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
Status light shows flashing

red LED Hardware error. Refer to section 3.2.
Using the service pendant, select 4 Advanced

Status light shows steady
Settings and go to 4.3 Start P Diff. Decrease the
green LED is ON before
start pressure differential by 50 psi (3.5 bar).
pads have contacted load
Try again.
Verify short arm is properly positioned for roll

diameter.
Using the service pendant, select 5 I/O Testing

and choose 1 Test Transducer. Check PT2
green LED stays ON when
pressure. Replace PT2, located on Proportional
pads are unclamped
Valve, if required.
Verify setup is properly completed. Refer to

Setup Instructions 6095125.

green LED, which comes on Check for switched hydraulic hoses on
when the clamp is opened Proportional Pressure Control Valve (refer to
but shows steady red LED schematics in Installation Instructions).
when clamped

Status light shows steady and choose 1 Test Transducer. Clamp on a load
red LED when pads are and verify that PT3 and PT4 pressure readings
clamped on load increase during clamping.

Settings and go to 4.1 Pilot Pressure. Decrease
pilot pressure 50 psi (3.5 bar) below lowest start
pressure. Try again.

Settings and go to 4.2 On Roll Diff.. Increase on
roll differential pressure 50 psi (3.5 bar). Try
again.
Test status light 3.3-6
6095127-R4 13
T ROUBLESHOOTING
3.4-1 Status Light and Loads (continued)

Problem Solution
Both Status Lights are off

Test status light 3.3-6
when one should be on
Verify maximum lift switch is ON when at

Status light shows flashing maximum lift only. Check LED on switch or in
red LED service pendant, select 5 I/O Testing. Choose 5.3
Switches. If OvrRd reads ON, replace maximum
lift sensor switch SW2.
Test override switch, if equipped. Refer to

Section 3.3-9.
3.4-2 Load Slips

Problem Solution
Using the service pendant, select 2 Operation

Pads slip on load Menu and choose 2.3 Start Pressure (no auto
switch) OR 2.3a, 2.3b and 2.3c (with auto
switch). Increase start pressure in 100 psi (7
bar) increments from previous setting. Try
again.
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
A) Using the service pendant, select 2 Operation

Menu and choose 2.3 Start Pressure (no auto
switch) OR 2.3a, 2.3b and 2.3c (with auto
switch). Increase start pressure in 100 psi (7
bar) increment from previous setting. Try again.
B) Using the service pendant, select 2 Operation

Menu and choose 2.2 CFF (no auto switch) OR
2.2a, 2.2b and 2.2c (with auto switch). Increase
setting. Try again.
14 6095127-R4
T ROUBLESHOOTING
3.4-3 Over Clamping

Problem Solution

Menu and choose 2.3 Start Pressure (no auto
Pads crease or crush load
switch) OR 2.3a, 2.3b and 2.3c (with auto switch).
before hoisting
Decrease start pressure in 100 psi (7 bar)
increments from previous setting. Try again.

Pads crease or crush load Menu and choose 2.2 CFF (no auto switch) OR
after hoisting 2.2a, 2.2b and 2.2c (with auto switch). Decrease
setting. Try again.
Large pressure increase Test maximum lift switch. Refer to Section 3.3-5.
when mast reaches full lift
Adjust maximum lift switch to close (LED

illuminated) when .25 in. (6 mm) from full lift.
3.4-4 Measured Values

Problem Solution
Measured Start Pressure is Using the service pendant, select 2 Operation

higher than pressure set in Menu and go to 2.4 Arm Speed (no auto switch)
controller OR 2.4a, 2.4b and 2.4c (with auto switch).
Decrease in increment of 2. Try Again.
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.

Menu and go to 2.4 Arm Speed (no auto switch)
OR 2.4a, 2.4b and 2.4c (with auto switch).
Decrease in increment of 2. Try Again.
Verify main lift switch is working. Look at LED

on switch or use service pendant and select
5 Diagnostics Menu. Choose 3 Test Switches.
Refer to Section 3.3-5.
6095127-R4 15
T ROUBLESHOOTING
3.4-5 Arm Movement

Problem Solution
Check for switched hydraulic hoses on

Arm clamps on load but will proportional pressure control valve (refer to
not open schematics in Installation Instructions).
Turn truck OFF & ON. Select 5 I/O Testing and

Arms move by themselves choose 1 Test Transducer. Check PT2 pressure
(open circuit pressure) values are reasonable
and appropriate. Replace PT2, located on
Proportional Valve, if required.
AFC system needs to be recalibrated. Refer to

Setup Instructions.

Arms move with a jerky
Settings and go to 4.3 Start P Diff. Decrease the
motion
start pressure differential by 50 psi (3.5 bar).
Try again.
Display’s arm position does Check auto switch mechanism inside long arm
not change for damage.

Menu and go to 2.1 Auto Switch. Verify that Yes
Auto Switch is selected. Go to 2.1a, 2.1b and 2.1c
to check trip point values.
Check cable continuity between auto switch

and junction box. Refer to Section 3.3-10.
16 6095127-R4
T ROUBLESHOOTING
3.4-6 Pressure Adjustment

Problem Solution
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.
Check priority flow valve for missing or split

O-ring or contamination.
Pressure drops steadily Check clamp cylinder check valves for

while AFC tries to increase contamination or damaged seals. Replace if
pressure required.

and choose 1 Test Transducer. Check PT1
No pressure increase on pressure (hoist pressure) is in a reasonable
hoisting loads range and appropriate. Replace PT1, located on
Drop/Stop Valve, if required.
Solenoid 2 is working. Verify polarity at

junction box. Use direct wire method.
Verify Attachment Factor (AF) is correct. Using

the service pendant, select 4 Advanced Settings
and got to 4.8 Attachment Fact. Increase Clamp
Force Factor (CFF) using the service pendant
submenu 2.2 CFF (no auto switch) OR 2.2a, 2.2b
and 2.2c (with auto switch)
Do a system hardware check and determine if

controller is operating correctly.
Relief valve squeals when Check priority flow valve for missing or split
lifting heavy load O-ring or contamination.
Clamping on load, pressure

remains the same while AFC
tries to increase pressure
6095127-R4 17
T ROUBLESHOOTING
3.4-7 Drop Stop (if equipped)

The drop stop forces the mast to return flow through
a priority flow cartridge, controlling the priority line.
Solenoids 1 and 4 are ‘off’ during initial clamping or after
arms are opened. Solenoid 1 will illuminate/activate when
start pressure is reached and the mast return flow is forced
through the priority cartridge. Solenoid 4 will illuminate/ Mast
activate when hoist pressure drops below the set drop stop Valve
activation pressure value. The priority flow will shut down
and the mast returns to normal flow. The system will reset Accumulator
about 2 seconds after Solenoid 1 and 4 are opened.
Hoist TRUCK ACCUM

Drop-Stop Priority
PT1
Valve Flow
Cartridge
SOL1
SOL4
Priority
Line
PUMP AC1969.eps
Problem Solution
Verify that AFC system is equipped with the

optional Drop Stop Valve (refer to Installation
Slack chain when lowering Instructions 6095124 or Parts Manual 6095129).
load If Drop Stop Valve is not included, the operator
is responsible to prevent slack chain.
Using the service pendant, select 3 Drop Stop

Menu and 3.0 Drop Stop? will appear. Verify that
Yes Drop Stop is selected.
Using the service pendant, select 3 Drop Stop

Menu and go to 3.2 Min Drop Stop Wt. Decrease
minimum weight in increments of 50. Try again.
WITH DROP/STOP SWITCH:

Check for broken or frayed wire to switch.
Verify Menu 3.4 Drop Stop Activation Pressure

value is greater then 50 psi.
18 6095127-R4
T ROUBLESHOOTING
3.4-7 Drop Stop (continued)

Use the following tree for troubleshooting situations where
the mast stops before the load is on the ground.
Troubleshooting Refer to Troubleshooting

Start Section 3.3-4
NO
Sol 1 & YES Orifice behind

NO Sol 1 NO
Sol 4 Sol 4 between Correct orifice
LED on
LEDs on .040-.060 in.
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
Verify valve and

cartridges are
Menu 3.4 working properly
value is 50 psi Change Menu 3.4
YES NO NO value by subtracting
OK greater than
lowering pressure 75 psi from lowering
(P1) value pressure value (P1)
YES
OK
YES
Change Menu 3.3 NO

value to 450 lbs.
Decrease Menu 3.4 Replace valve
value by 25 psi
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
System has YES NO

Any status
power, verify
light on
voltage
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
Trace power leads to

switched 12V source and
re-establish 12 VDC keyed
power. Voltage converter
and filter may be required.
Use kit 217932.
AC1702.ai
20 6095127-R4
T ROUBLESHOOTING
3.5-2 Hydraulic Schematic

Long Arm
Cylinders
LT1
PT3
Revolving Connection,
Slip Ring
OPEN CLAMP
Hose Reel
or IHR
Proportional
Pressure OPEN CLAMP
Control Valve
OPEN CLAMP
PT2
Mast PT4 SOL2

Valve Accumulator
Pressure
Transducer
Manifold
SOL3
PT1
TRUCK ACCUM
Hoist
Drop-Stop PT1
PT1
Valve
(optional)
To Mast
SOL 1
Valve PUMP TANK
SOL4
PUMP OR
Truck Main Truck Auxiliary

Valve (HOIST) Valve (CLAMP/OPEN)
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
3.5-3 Electrical Schematic

6 Conductor
Electric
Power Supply/
Truck
Maximum Freelift Communication
Pump
Lift Sensor Sensor Group 2 3
Switch
Switch Switch Relay
1 4
Switch Box
(optional) (Connected
Electric for electric
To Junction truck only)
Truck
Box Port 2
Pump
To Junction
Box Port 4
PT3 LT1 PT2 PT4

Light Tower
(optional) Clamp
Cylinder Proportional
Slip Ring Auto Switch Pressure
(optional) Control Valve
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
Fuse Power Bus/Relay

1 2 3 4
–+–+–+–+ -+ +-
Display
(optional)
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
IC Trucks – Use chassis ground.

Datalogger
Truck Electric Trucks – Use battery ground.
(optional)
Battery AC1968.eps
22 6095127-R4
T ROUBLESHOOTING
3.5-4 Junction Box Terminal Table

Junction Box Terminal/ Terminal/ Terminal/ Terminal/ Terminal/ Terminal/
Port Cable Wire Wire Wire Wire Wire Wire
3 6090897 Display B1 / RD C1 / GN + / WT - / BK
3 6092913 Light Box H3 / WH H3- / BK J3 / RD
6092972
2 F3 / BK F3+ / BN F3- / BU
Free/Main Lift
2 6092972 Max Lift F2 / BK F2+ / BN F2- / BU
6091024
2 G3+ / BK G3 / WH
Override
6079562
3 B1 / BK C1 / WH
Datalogger
6090962
2 A1 / GN A2 / OG B2 / BK A3 / RD E3 / WH
Pendant Cable
3 6090947 Power +/1 -/2
6092862
1 E2- / BU E2+ / OG E2 / GN E1- / BK E1+ / WH E1 / RD
Transducer PT2, PT4
4 6090961 SOL2 H2 / BU G2 / BN
4 6090961 SOL3 J2- / BU J2 / BN
6090959
1 D2- / BK D2+ / WH D2 / RD
Transducer PT1
4 6090961 SOL1 G1- / BU G1 / BN
4 6090961 SOL4 J1- / BU J1 / BN
6090924 Pressure Transducer Autoswitch
1
Mast Cable D1 / RD D1+ / WH D1- / BK E3 / GN F1 / OG F1- / BU
1 6098424 Relay ✖ J2- / BK J2 / WH
2 6804099 Switch Box F1-/RD F1/BK E3/WH
✖ Share terminals with Solenoid 3
Abbreviation Color Abbreviation Color
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+ C1 A2 A3 E3 E3 G1 G2 H3 J1 J2 J3 H1 H2 U2 U4 U6
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
AMERICAS
Fax: 888-329-8207 Fax: 905-629-7785 Tel: 55-13-2105-8800
Fax: 55-13-2105-8899
EUROPE-AFRICA
Italy South Africa
Tel: 39-045-8989111 Tel: 27-11-975-9240
Fax: 39-045-8989160 Fax: 27-11-394-1147
ASIA-PACIFIC
Fax: 86-592-651-2571 Phone: +91 020 2432 5490
Fax: +91 020 2433 0881
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
P ERIODIC MAINTENANCE
WARNING: After completing any

service procedure, always test the
clamp through five complete cycles.
First test the clamp empty, then test
with a load to make sure the clamp
operates correctly before returning it to
the job.
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
The Adaptive Force Control system uses a priority flow

valve and two solenoid operated hydraulic valves: WARNING: Before servicing any
hydraulic component, relieve pressure in
• Priority Flow Control Valve the attachment system. Turn the truck off
• Proportional Pressure Control Valve and move the truck auxiliary control lever
• Drop Stop Valve several times in both directions.
Mechanical components that may require service or For electro-hydraulic systems, pulse the attachment
replacement are the cartridge valves, solenoid coils, open to relieve pressure trapped in the CLAMP
transducers, limit switches, and wiring harnesses/ circuit before turning truck off.
connectors. All valves are serviced similarly. After completing any service procedure, always test
the attachment through several cycles. First test empty
Valve Removal and to bleed any air trapped in the system to the truck tank.
Then test with a load to make sure that the attachment
Installation operates correctly before returning to the job. Stay
clear of the load while testing. Do not raise the load
1 Disconnect the hoses from the valve. Plug the ends more than 4 in. (10 cm) off the floor while testing.
and tag for reassembly.
2 Disconnect the solenoid cable connections at the
solenoid coils. For reassembly, make sure that the
cable connector securing screws are properly installed.
3 Disconnect the pressure transducer cable connectors Priority Flow
from the pressure transducers. Cartridge
4 Remove the valve mounting capscrews. For reassembly,

tighten the capscrews to 15 ft.-lbs. (20 Nm).
Body
• Service the valve as described in Valve Service
section.
Valve Service AC0687.eps
IMPORTANT: Service the valve in a clean work area.

1 Remove the valve from the truck as described above.
2 Remove the solenoid coils, cartridges, pressure
transducers, fittings and plugs from the valve. For
reassembly, tighten cartridges to 30 ft.-lbs. (41 Nm). Priority Flow Control Valve
Solenoid coils are fastened to the cartridges as shown
on the next page.
3 Remove the O-rings and back-up rings from the
cartridges.
4 Clean all parts with clean solvent.
O-Rings (3)
• Replace O-rings and back-up rings as shown.
• Lubricate cartridges, fittings and plugs with
O-ring lube or petroleum jelly prior to installation.
• Make sure solenoid coils are properly installed and
fastened to their respective cartridge valves.
AC0684.eps
Back-Up Rings (4)
PRIORITY FLOW CONTROL CARTRIDGE
Cascade Corp.
File No. AU3546
6095128-R1 1
S ERVICE
NOTE: Service the Proportional

Pressure Valve using the procedures
in Valve Service. Refer to page 1.
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)
Proportional Pressure Control Valve
Solenoid Coil,
Plastic Retaining Nut
O-Rings (3) Tamperproof Cap O-Rings (2)
SOL3
Back-Up Rings (4) Back-Up Rings (2)
SOLENOID VALVE CARTRIDGE PO RELIEF CARTRIDGE
2 6095128-R1
S ERVICE
Solenoid Coil Coil

Solenoid-to-Cartridge
Retainer
O-Ring (1)
Plate
SOL2 O-Rings (2)

Manual Override O-Rings (2)
Screw, Locknut
Screws (4) Back-Up Ring (1) AC0683.eps

AC0680.eps
Back-Up Rings (2)
SOLENOID PROPORTIONAL PO CHECK CARTRIDGE

RELIEF CARTRIDGE
O-Rings (3)
O-Rings (3)
AC0681.eps
Back-Up Rings (3)
AC0682.eps
Back-Up Rings (4)
NC MODULATING CARTRIDGE PO CHECK CARTRIDGE
6095128-R1 3
S ERVICE
NOTE: Service the Drop-Stop Valve using the procedures in

Valve Service.
Coil securing Nut
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 (3) Solenoid Coil
O-Rings (2)
Nut SOL4
AC0684.eps
Back-Up Rings (4)

AC0715.eps
Back-Up
Rings (2)
PRIORITY FLOW CONTROL CARTRIDGE SOLENOID VALVE CARTRIDGE
Solenoid Coil
O-Rings (2) O-Rings (2)

Nut
SOL1
AC0717.eps
AC1687.eps
Back-Up Ring (1) Back-Up Ring (1) Back-Up Rings (2)
SOLENOID VALVE CARTRIDGE 2-POSITION 2-WAY VALVE CARTRIDGE
4 6095128-R1
S ERVICE
Auto Switch String Pot

3
Wiper
Replacement Cover
1 Remove auto switch assembly from the attachment. Dust Wiper

2 Remove the cover capscrews and cover.
3 Remove wiper cover with a flat head screwdriver and Cover
remove dust wipers. Discard dust wipers.
4 Loosen reel screw and remove broken string.
5 Feed new string through the two guide holes of the auto
switch assembly. Feed string through the reel’s surface
hole.
6 Pull the string through the reel slot.
Wrap the string
around the screw and tighten screw to 50 in.-oz.
(.35 Nm).
7 To retension the string, rotate reel clockwise until the
string’s end piece is flush with the outer guide hole. Do
2 AC1551.eps
not let the reel unwind.
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
Guide Outer Guide

Holes Hole
5
Reel
Surface
Hole
Screw
7
Reel Slot
Rotate Reel
Clockwise
6095128-R1 5
S ERVICE
Hydraulic Schematic – AFC

Long Arm
Cylinders
LT1
PT3
Revolving Connection,
Slip Ring
OPEN CLAMP
Hose Reel
or IHR
Proportional
Pressure OPEN CLAMP
Control Valve
OPEN CLAMP
PT2
Mast PT4 SOL2

Valve Accumulator
Pressure
Transducer
Manifold
SOL3
PT1
TRUCK ACCUM
Hoist
Drop-Stop PT1
PT1
Valve
(optional)
SOL 1
To Mast PUMP TANK
SOL4
PUMP
Truck Main Truck Auxiliary

Valve (HOIST) Valve (CLAMP/OPEN)
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
Electrical Connection Diagram – AFC

6 Conductor
Electric
Power Supply/
Truck
Maximum Freelift Communication
Pump
Lift Sensor Sensor Group 2 3
Switch
Switch Switch Relay
1 4
Switch Box
(optional) (Connected
Electric for electric
To Junction truck only)
Truck
Box Port 2
Pump
To Junction
Box Port 4
PT3 LT1 PT2 PT4

Light Tower
(optional) Clamp
Cylinder Proportional
Slip Ring Auto Switch Pressure
(optional) Control Valve
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
Fuse Power Bus/Relay

1 2 3 4
–+–+–+–+ -+ +-
Display
(optional)
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
IC Trucks – Use chassis ground.

Datalogger
Truck Electric Trucks – Use battery ground.
(optional)
Battery AC1968.eps
6095128-R1 7
AMERICAS
Fax: 888-329-8207 Fax: 905-629-7785 Tel: 55-13-2105-8800
Fax: 55-13-2105-8899
EUROPE-AFRICA
Italy South Africa
Tel: 39-045-8989111 Tel: 27-11-975-9240
Fax: 39-045-8989160 Fax: 27-11-394-1147
ASIA-PACIFIC
Fax: 86-592-651-2571 Phone: +91 020 2432 5490
Fax: +91 020 2433 0881
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
P ARTS MANUAL
Adaptive Force
Control
Manual Number 6095129-R4

Cascade Corp.
File No. AU3546
cascade
corporation
Adaptive Force Control Overview
(Refer to individual component pages for parts breakdown)
Power
Supply
Group
Service
Pendant
Display
Sensors Controller
F4
F3
Light Box F1
F2
3
YE
S
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
No Drop Hoist Drop AC2671.eps

or
Stop Kit Stop Valve
For Technical Assistance call: 800-227-2233, Fax: 888-329-8207

cascade To Order Parts call: 888-227-2233, Fax: 888-329-0234
Controller
AC1694.ai

1 1 6090514 Controller

Proportional Pressure Control Valve Group
1 2
AC1628.ai

6091348 Valve Group
1 1 6091349 Proportional Flow Valve u
2 1 6049389 Filter Fitting, 8-8
u See Valve Assembly page for parts breakdown.

0 1 8%
7#
4^
3
AC1641.ai
2&
3
@
5$
6
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
7 1 228738 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

Proportional Pressure Control Valve Group
Load Sensing
1 2
AC1646.ai

6091312 Valve Group
1 1 6091314 Proportional Flow Valve u
2 1 6049389 Filter Fitting, 8-8

Load Sensing
9 1 6#
5@ 4$
AC1645.ai
7 3
2%
8 3
!
5@

6091314 Proportional Pressure Control Valve
2 1 227785 Relief Cartridge
5 2 6059323 Plug
7 1 602580 Fitting, 8
8 1 604510 Fitting, 6
12 2 6024967 Seal Kit
13 1 6024968 Seal Kit
14 1 6024964 Seal Kit
15 1 6024969 Seal Kit

Display Assembly
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

Datalogger Kit
TM
3
86
75
60
r:
be
um
tN r
Pa
e
vic
De
3
86
75
60
r:
be
um
tN r
Pa
Kit
Q
1
2
!
TM
9
8
6
8
AC1836.eps
5 4

6078997 6078998 6803016 Datalogger Kit
1 1 6075863 6075863 6075863 AFC Datalogger
2 1 6078430 6078430 6078430 CD and Case
3 1 6078823 6078823 6078823 SD Card Reader
4 1 6075872 6075872 6075872 Ethernet Cross-over Cable
5 1 6078435 6078435 6078435 Ethernet Connector
6 1 6079618 — 6803026 Communication Cable
7 1 — 6079642 — Communication Cable
8 1 6079587 6079587 6079587 LED Cable q
9 2 6081781 6081781 6081781 Thumbscrew H
10 1 6081782 6081782 6081782 Access Cover H
11 1 6081614 6081614 6081614 Firmware Upgrade Cable n
q Included with Communication Cable.
H Included in Access Door Assembly 6082512.
n Not included in Datalogger Kit.

Scanner Kit
AC1662.ai
Long Short
Range Range

6082660 6082661 Scanner Kit
1 1 6082406 6082546 Scanner, Code Reader
2 1 6075871 6075871 Scanner/Datalogger Adaptor Cable u
u Not included in Scanner Kit.

9
8 7
0
!
@# fi
$
2 3
6
fl 5 4
) 1
› &
^
%
* (
‹
¤
⁄
AC2672.eps

Power Maximum
Supply Mast fork Conductors Supply
Group Height (in.) (No. @ AWG) Application
6844333 166 2 @ 18 ERC – Unswitched
1 Do not use 26 AWG for high voltage or high current applications; 26 AWG rated @ .25A,
20 AWG rated @ 5A.

6844333 6844335 Power Supply Group
1 1 6844356 6844366 Cable Assembly
2 1 6846006 6846008 Power Supply Kit Decal
Common Parts
5 1 6838404 Nut 1 206321 Capscrew, M6 x 16
18
7 1 6818146 Bracket 19 1 206323 Washer, M6
11 2 786881 Nut 23 1 6846510 Hose Clamp
13

9
8 7
0
!
@# fi
$
2 3
6
fl 5 4
) 1
› &
^
%
* (
‹
¤
⁄
AC2672.eps

Power Maximum
6844338 189 2 @ 18 ERC – Unswitched
20 AWG rated @ 5A.

1 1 6844357 6844367 Cable Assembly
Common Parts
5 1 6838404 Nut 1 206321 Capscrew, M6 x 16
18
7 1 6818146 Bracket 19 1 206323 Washer, M6
11 2 786881 Nut 23 1 6846510 Hose Clamp
13

9
8 7
0
!
@# fi
$
2 3
6
fl 5 4
) 1
› &
^
%
* (
‹
¤
⁄
AC2672.eps

Power Maximum
6844343 218 2 @ 18 ERC – Unswitched
20 AWG rated @ 5A.

1 1 6844358 6844368 Cable Assembly
Common Parts
5 1 6838404 Nut 1 206321 Capscrew, M6 x 16
18
7 1 6818146 Bracket 19 1 206323 Washer, M6
11 2 786881 Nut 23 1 6846510 Hose Clamp
13

9
8 7
0
!
@# fi
$
2 3
6
fl 5 4
) 1
› &
^
%
* (
‹
¤
⁄
AC2672.eps

Power Maximum
6844348 240 2 @ 18 ERC – Unswitched
20 AWG rated @ 5A.

1 1 6844359 6844369 Cable Assembly
Common Parts
5 1 6838404 Nut 1 206321 Capscrew, M6 x 16
18
7 1 6818146 Bracket 19 1 206323 Washer, M6
11 2 786881 Nut 23 1 6846510 Hose Clamp
13

9
8 7
0
!
@# fi
$
2 3
6
fl 5 4
) 1
› &
^
%
* (
‹
¤
⁄
AC2672.eps

Power Maximum
6844353 320 2 @ 18 ERC – Unswitched
20 AWG rated @ 5A.

1 1 6844360 6844370 Cable Assembly
Common Parts
5 1 6838404 Nut 1 206321 Capscrew, M6 x 16
18
7 1 6818146 Bracket 19 1 206323 Washer, M6
11 2 786881 Nut 23 1 6846510 Hose Clamp
13

ERC Wire Jumper Group
2
Junction Box
AC1721.ai

6094144 ERC Wire Jumper Group
1 1 6094111 Cable Assembly – Mast/ERC Clamp
2 1 6094042 Cable Assembly – Mast/ERC Power
Reference: SK-11333.

Stack Mounting Kit
2
1
AC2502.eps

6839378 Stack Mounting Kit
1 1 6845663 Divider Plate
2 2 6845680 Capscrew, M8 x 170
3 1 6845840 Conduit Anchor

Junction Box Wire Group
Power
Supply
Group
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

Junction Box Wire Group
1000 mm 400 mm
Cable Cable
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.

Switch Group
AC1667.ai

6091601 Switch Group
1 1 6091430 Mounting Bracket
2 1 6092966 Proximity Switch
3 1 6092972 Switch Cable

Hoist Drop Stop Valve
5
4 #
$
59 @
1 %
7
20 68
3!
AC1644.ai

6091606 Hoist Drop Stop Valve
2 1 211219 Priority Flow Control Cartridge
3 1 6004097 2-Position/2-Way Cartridge
8 1 6024966 Seal Kit
9 1 6009164 Seal Kit
10 1 6024964 Seal Kit
11 1 6024965 Seal Kit
15 1 6004138 Orifice, .060

Dual Drop Stop Kit
AC1714.ai

6093696 Dual Drop Stop Kit
1 2 6093681 Valve Assembly u
2 1 6093619 No Drop Stop Kit l
l See No Drop Stop Kit page for parts breakdown.

Hoist Drop Stop Valve – Dual
5
4
@
59
1 #
7
20 68
3!
AC1712.ai

6093681 Hoist Drop Stop Valve
2 1 211219 Priority Flow Control Cartridge
3 1 6004097 2-Position/2-Way Cartridge
8 1 6024966 Seal Kit
9 1 6009164 Seal Kit
10 1 6024964 Seal Kit
11 1 6024965 Seal Kit
13 1 6004138 Orifice, .060

No Drop Stop Kit
1
5
4
AC1707.ai 2

6093619 No Drop Stop Kit
1 1 6093579 Manifold
2 1 6025378 Fitting, 8-8
3 1 601377 Fitting, 8-8

Pendant Group
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

6095901 Pendant Group
1 1 6088597 Service Pendant
2 1 6090945 Pendant Ethernet Cable

DC to DC Voltage Converter Groups
4 2 7
8
I
N
P
U
T
O
U
T
P
6 U
T
9
1
AC2033.eps
24-36V 48-60V 72-96V

to 12 Volt to 12 Volt to 12 Volt
6009393 6007579 6009394 DC/DC Converter Group
1 1 6017868 6017869 6017870 DC/DC Converter
2 1 TT25A TT15A TT12A Fuse-Slow Blow (Buss/Littel Fuse)
3 1 6018819 6018819 6018819 Power Cord – Output
4 1 6811767 6811767 6811767 Power Cord – Input
5 1 6806701 6806701 6806701 Fuse, 2A
6 1 6811745 6811745 6811745 Plate
7 4 6405318 6405318 6405318 Capscrew, M5 x 25
8 4 685866 685866 685866 Lockwasher, M5
9 4 768202 768202 768202 Nut, M5
Cascade Corp.
File No. AU3546

Relay Kit
AC1804.ai

6098421 Relay Kit
1 1 6009853 Relay Group
2 1 6098424 Relay Cable

Relay Group
5
1
6
4
3
2
AC0325.ill

6009853 Relay Group
1 1 6006266 Relay
2 1 223696 Wedge
3 1 220895 Connector Receptacle
4 2 223673 Pin
5 2 6009859 Spade Connector
6 1 220908 Wire
䊛 For Technical Assistance call: 800-227-2233, Fax: 888-329-8207

cascade To Order Parts call: 888-227-2233, Fax: 888-329-0234
AFC Switch Kit
X
BO HIGH
H
ITC
SW M
ED
C
AF
LOW
AC2037.ai

6804099 AFC Switch Kit
1 1 6804017 Switch Box

AFC Truck Fitting Kit
Hyster H120FT-PRS
5
1 9
6
3
0
5 # 2
7 @
!
AC1527.eps
8
4

6068965 Truck Fitting Kit
2 1 214066 Connector Kit l
3 3 6028969 Fitting, 12-12
4 2 6029636 Fitting, 10-10
5 2 6049349 Fitting, 6-6
6 1 6063826 Fitting, 12-12
7 1 208728 Fitting, 6-6
8 2 6067596 Fitting, 10-10
9 1 6068966 Fitting, 12-12
10 1 200376 Fitting, 8-8
11 2 202350 Fitting, 6-8
12 1 601377 Fitting, 8-8
13 1 605761 Fitting, 8-8
u See Valve page for parts breakdown.
l See Kit page for parts breakdown.

Hyster E120XM
6
1 0
5
3
8
4
4
6 9 2
7 8
6
AC1532.eps
#
!
@

3 1 602580 Fitting, 8
4 3 6023531 Fitting, 16-12
5 1 6071511 Fitting, 16-12
6 4 604511 Fitting, 6-6
7 1 2680 Fitting, 6-6
8 2 601377 Fitting, 8-8
9 1 605761 Fitting, 8-8
10 1 643904 Fitting, 16-16
11 2 643919 Fitting, 14-14
12 2 643903 Fitting, 14-14
13 2 6071507 Reducer Fitting, 14-6

Hyster E120Z
6
1
4 5
5
0 4
6 9 2
7 8
6
AC1670.ai
#
!
@

3 1 602580 Fitting, 8
4 3 611293 Fitting, 12-12
5 2 611324 Fitting, 12-12
6 4 604511 Fitting, 6-6
7 1 2680 Fitting, 6-6
8 1 601377 Fitting, 8-8
9 1 605761 Fitting, 8-8
10 1 210342 Fitting, 12-12
11 2 611331 Fitting, 10-10
12 2 611323 Fitting, 10-10
l See Connector Kit page for parts breakdown.

Hyster S155FT-PRS
5
7 1 8
3
0 9 #
$
0
2 6
5 7 # %
@ 0
!
AC1528.eps
^
7
4

2 1 227202 Accumulator Kit l
3 1 6028969 Fitting, 12-12
4 2 6029635 Fitting, 8-8
5 2 6049349 Fitting, 6-6
6 1 6063826 Fitting, 12-12
7 4 6066414 Fitting, 8-8
8 1 6075586 Fitting, 16-16
9 1 6068966 Fitting, 12-12
10 3 200376 Fitting, 8-8
11 2 202350 Fitting, 6-8
12 1 208728 Fitting, 6-6
13 2 6075594 Fitting, 12-16
14 1 602580 Fitting, 8
16 1 6071703 Pigtail

Hyster S155XL
6
2 1
5 #
9
8
4
@
6 9 3
7 8
0
!
AC1529.eps
9

4 2 6034186 Fitting, 16-14
5 1 643903 Fitting, 14-14
6 2 604511 Fitting, 6-6
7 1 2680 Fitting, 6-6
8 2 601377 Fitting, 8-8
9 4 605761 Fitting, 8-8
10 2 662187 Fitting, 8-6
11 2 611330 Fitting, 8-8
12 2 611293 Fitting, 12-12
13 1 611324 Fitting, 12-12

Hyster H5.00DX
6
2 1
@
5 5
4
@
6 9 3
7 8
0
!
AC1530.eps

4 1 210342 Fitting, 12-12
5 2 611324 Fitting, 12-12
6 2 604511 Fitting, 6-6
7 1 2680 Fitting, 6-6
8 2 601377 Fitting, 8-8
9 1 605761 Fitting, 8-8
10 2 662187 Fitting, 8-6
11 2 611330 Fitting, 8-8
12 3 611293 Fitting, 12-12

Hyster E5.5XL
6
2 1
5
#
%
8
4
@
6 9 3
7 8
$
0
AC1531.eps

4 2 6032117 Fitting, 12-10
5 1 611324 Fitting, 12-12
6 2 604511 Fitting, 6-6
7 1 2680 Fitting, 6-6
8 2 601377 Fitting, 8-8
9 1 605761 Fitting, 8-8
10 1 662187 Fitting, 8-6
11 2 611330 Fitting, 8-8
12 2 611292 Fitting, 10-12
13 1 611323 Fitting, 10-10
14 1 605743 Fitting, 6-6
15 1 602580 Fitting, 8

Yale GLC060
1
2 5 6
#
9
4 0 8
6 9 3
7 8
6
!
7 AC1671.ai

4 2 611291 Fitting, 10-10
5 1 6013433 Fitting, 10-10
6 4 604511 Fitting, 6-6
7 3 2680 Fitting, 6-6
8 2 601377 Fitting, 8-8
9 2 605761 Fitting, 8-8
10 1 611299 Fitting, 10-10
11 2 611329 Fitting, 6-6
12 2 611293 Fitting, 12-12
13 1 611324 Fitting, 12-12

Yale GLC155VX
5
7 1 8
6
0 3
0
^
2 3
5 # %
9 @
!
AC1780.ai
$
7
4
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
16 1 6095556 Fitting, 12-10

Yale GLC120VX
5
7 1 8
6
0 3
0
%
2 3
5 # ^
9 @
!
AC1726.ai
$
7
4
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

Yale GLP70VX
5
7 1 8
6
0 3
0
2 3
5 # %
9 @
!
AC1672.ai
$
7
4
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

Toyota 7FGCU55
2 6
1
3 #
4
9
% 8
5
6 9 $
7 8
0
!
AC1525.eps
9

3 1 6034185 Fitting, 16-16
4 1 6034186 Fitting, 16-14
5 1 6082328 Fitting, 14-16
6 2 604511 Fitting, 6-6
7 1 2680 Fitting, 6-6
8 2 601377 Fitting, 8-8
9 4 605761 Fitting, 8-8
10 2 662187 Fitting, 8-6
11 2 611330 Fitting, 8-8
12 2 611293 Fitting, 12-12
13 1 611324 Fitting, 12-12
15 1 643904 Fitting, 16-16

Toyota 7FGCU70
2 6 %
1
3 OR #
4
9
8
5
6 9 $
7 8
0
!
AC1523.eps
9

3 1 6034185 Fitting, 16-16
4 1 6081783 Fitting, 16-16
5 1 6083809 Fitting, 14-16
6 2 604511 Fitting, 6-6
7 1 2680 Fitting, 6-6
8 2 601377 Fitting, 8-8
9 4 605761 Fitting, 8-8
10 2 662187 Fitting, 8-6
11 2 611330 Fitting, 8-8
12 2 611293 Fitting, 12-12
13 1 611324 Fitting, 12-12
15 1 6082328 Fitting, 14-16

Toyota 8FG45
2 6 5 #
1
3
4
6 9 $
7 8
0
AC1490.eps
!

3 1 6013433 Fitting, 10-10
4 1 6032117 Fitting, 12-10
5 1 6032113 Fitting, 12-10
6 2 604511 Fitting, 6-6
7 1 2680 Fitting, 6-6
8 2 601377 Fitting, 8-8
9 2 605761 Fitting, 8-8
10 2 662187 Fitting, 8-6
11 2 611330 Fitting, 8-8
12 1 611293 Fitting, 12-12
13 1 611291 Fitting, 10-10

Toyota 7FBMF50
2
1
AC1732.ai

6088228 Truck Fitting Kit s
s Installer feedback required for fitting information.

Kalmar EC75-600
2
1
AC1732.ai


Still RX60-30
1
5 5
4
@
0
2 6
8 3
4
! $
0 %
@
5
@
9
9
7
AC1526.eps

3 2 6209143 Fitting, Metric L
7 2 757346 Fitting, Metric S
10 2 601377 Fitting, 8-8
11 1 605761 Fitting, 8-8
12 4 755747 Fitting, SAE 6 – 12 mm S
13 1 6214659 Plug
14 1 6232601 Tube

Cat GP30N
5
7 1 9
6
0 3
0
2
3
5 $ %
@ #
!
AC1348.eps
8
4

3 3 6028969 Fitting, 12-12
4 2 6029636 Fitting, 10-10
5 2 6049349 Fitting, 6-6
6 1 6063826 Fitting, 12-12
7 1 6066414 Fitting, 8-8
8 2 6067596 Fitting, 10-10
9 1 6068966 Fitting, 12-12
10 2 200376 Fitting, 8-8
11 2 202350 Fitting, 6-8
12 1 208728 Fitting, 6-6
13 1 601377 Fitting, 8-8
14 1 605761 Fitting, 8-8

Linde H40D-394
1
5 5
4
@
0
2 6
8 3
4
! $
0 %
@
5
@
9
9
7
AC1526.eps

10 2 601377 Fitting, 8-8
11 1 605761 Fitting, 8-8
12 4 755747 Fitting, SAE 6 – 12 mm S
13 1 6214659 Plug
14 1 6232601 Tube

Linde H50D-394
1
5 5
4
@
0
2 6
8 3
4
! $
0 %
@
5
@
9
9
7
AC1526.eps

10 2 601377 Fitting, 8-8
11 1 605761 Fitting, 8-8
12 4 755747 Fitting, SAE 6 – 12 mm S
13 1 6214659 Plug
14 1 6232601 Tube

Linde H70D-353
1 5
4
#
0
2 6
5 3
4
# ! ^
0 &
@
$ 5
@
$
9
9 % AC1491.eps
7 8

10 2 601377 Fitting, 8-8
11 1 605761 Fitting, 8-8
12 2 662187 Fitting, 8-6
13 2 755747 Fitting, SAE 6 – 12 mm S
14 2 765642 Fitting
15 1 6214659 Plug
16 1 6232601 Tube

Komatsu FG45BCS-8
2 6
1
5 0
3
4 8
6 9 AC1675.ai
7 8 #
@
6
!
9

3 1 602580 Fitting, 8
4 2 611293 Fitting, 12-12
5 2 6074561 Fitting, 12-12
6 4 604511 Fitting, 6-6
7 1 2680 Fitting, 6-6
8 2 601377 Fitting, 8-8
9 3 605761 Fitting, 8-8
10 1 611324 Fitting, 12-12
11 2 611330 Fitting, 8-8
13 2 2618 Nut, 8

TCM FD70-28
2
1
AC1781.ai


Jungheinrich H45
1 5
4
#
0
2 6
5 3
4
# ! ^
0 &
@
$ 5
@
$
9
9 % AC1491.eps
7 8

10 2 601377 Fitting, 8-8
11 1 605761 Fitting, 8-8
12 2 662187 Fitting, 8-6
13 2 755747 Fitting, SAE 6 – 12 mm S
14 2 765642 Fitting
15 1 6214659 Plug
16 1 6232601 Tube

Semax P50HT-E
5
1
4 9
2
3 7
AC2038.ai
5 8
6 7 @
! #
5 $
%
^
0 &
8
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
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

Priority Flow Valve
23
1
WARNING
Do not block priority
port and start truck.
Decal 6011850
PRIORITY
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

Priority Flow Valve
46 5
1
2
WARNING
36 Decal 6011850
AC0885.eps

6027083 Priority Flow Valve
2 1 609234 Plug, 4
5 1 6011850 Warning Label
6 2 6024964 Seal Kit

Priority Flow Valve
46 5
1
2
WARNING
36 Decal 6011850
AC0884.eps

6034187 Priority Flow Valve
2 1 609234 Plug, 4
5 1 6011850 Warning Label
6 2 6026295 Seal Kit

Accumulator Kit
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
Mounting Clamps Shut-off Valve Charging Kit

227201 Accumulator Kit w/Mount (29 cu. in.) l
227202 Accumulator Kit w/Mount (58 cu. in.) l
1 227199 Accumulator (4000 psi, 29 cu. in.)
1
1 227197 Accumulator (4000 psi, 58 cu. in.)
2 1 601377 Fitting, 8-8 SAE 37°/O-Ring
3 2 227200 Mounting Clamps
4 1 227839 Shut-off Valve
5 1 227253 Seal Service Kit
6 1 228235 Charging Kit
l Includes items 1, 2 and 3.

Connector Kit
2
1
4 3
5
6 AC0281.eps

6807816 Connector Kit
2 1 211742 Hose Clamp, .38 ➔ .87 in.
2 211743 Hose Clamp – .50 ➔ 1.25 in.
3
2 213140 Hose Clamp – .75 ➔ 1.75 in.
4 1 211740 Hose, 72 in.
5 1 211741 Fitting, 8
6 1 601377 Fitting, 8-8

Recommended Spare Parts List
Adaptive Force Control

UNITS SERVICED
PART NUMBER DESCRIPTION
1-5 6-19
227835 Solenoid Coil – 12V 1 4
6091233 Pressure Transducer 1 4
211219 Priority Flow Control Cartridge 1 4
6009164 Seal Kit 1 4
6024964 Seal Kit 1 4
6024965 Seal Kit 1 4
6024966 Seal Kit 1 4
6024967 Seal Kit 1 4
6024970 Seal Kit 1 4
6024968 Seal Kit 1 4
6024969 Seal Kit 1 4
n Coil Cord – Communications Group 1 4
6092966 Proximity Switch 1 4
6092972 Proximity Switch Cable 1 4
6090961 Solenoid Cable Assembly 1 4
6090959 Pressure Transmitter Cable 1 4
6090945 Pendant Cable 1 4
n See Communications Group page for specific part number.

Blank
PARTS ORDERING LOG
PURCHASE SERIAL REF CASCADE CUSTOMER
DATE ORDER NUMBER PAGE NO. QTY PART NO. PART NO. DESCRIPTION PRICE
AMERICAS
Fax: 888-329-8207 Fax: 905-629-7785 Tel: 55-13-2105-8800
Fax: 55-13-2105-8899
EUROPE-AFRICA
Italy South Africa
Tel: 39-045-8989111 Tel: 27-11-975-9240
Fax: 39-045-8989160 Fax: 27-11-394-1147
ASIA-PACIFIC
Fax: 86-592-651-2571 Phone: +91 020 2432 5490
Fax: +91 020 2433 0881
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
G LOSSARY
Accumulator Dedicated Return to Tank Line

Absorbs load handling shocks reducing the clamp force Hydraulic line that returns excess oil flow back to tank.
required to handle the load. Provides smoother AFC
operation and better clamp force accuracy. Display
Visual component used to shows numeric values, load
Accumulator Precharge Pressure (or Accumulator range, pressure/force units, confirms that it is safe to hoist
Pressure) and informs the driver that there is an error.
The pressure change in the accumulator, typically is equal
to the pressure created in the hoist cylinder by the carriage Drop/Stop Valve
and clamp without a load. Protection against unwanted clamp movement due to slack
in chains and accumulator ‘jump’ when a load is set down
Adaptive Force Control (AFC) and unclamped.
Technology that enables Cascade lift truck attachments
to apply the minimum clamp force necessary to handle a Electronic Rotational Control (ERC)
specific load. Provides 90° and 180° stops during 360° clamp rotation.
Arm Speed Factor Free Lift

A value used to drive the arms during free closing. The Height range where the forks and carriage are raised
higher the value, the higher the speed and initial starting without extending the mast rails.
pressure.
Free Lift Sensor Switch
Attachment Factor Signals controller when the mast hoist level is in free lift or
A value that relates pressure in the cylinders to the main lift.
mechanical advantage of the clamp to determine the
calculated clamp force on the pads. Hoist Pressure Trigger Factor
Hoist circuit pressure at which the Datalogger starts and
Auto Switch stops the process of recording the clamp force, not starting
Allows parameter switch points based on arm position. pressure.
Auto Switch Linear Transducer Junction Box

Used to determine roll diameter by measuring how far the Provides all required connections for the controller and
arm has closed. AFC components.
Auto Switch Trip Points Status Light

Two points along long arm travel where clamp force Two indicator lights that inform the driver of the following:
switches from high to medium and medium to low. • Constant Green Light – OK to lift load
Calculated Clamp Force • Flashing Green Light – The system is in override. Driver
The calculated force that a clamp applies to a load. controls clamp pressure.
• Constant Red Light – Do not lift load
Calculated Clamp Pressure
The pressure required to handle the load based upon Load • Flashing Red Light – Error
Weight, Clamp Force Factor and Attachment Factor.
Load Weight
Calibration Load Weight The calculated weight of the load based upon pressure in
The weight of the load used during the calibration process. the hoist cylinder and the Calibration Load Weight.
Capture Time Maximum Clamp Pressure

A Datalogger time value setting in seconds to collect data. A value that sets the maximum AFC relief pressure. AFC
will not allow pressure to exceed this value.
Clamp Force Factor
Amount of clamp force applied as a multiple of load Maximum Lift Sensor Switch
weight. Signals the controller when the mast hoist level is at its
maximum.
Clamp Open Guard
Provides a safeguard against accidentally unclamping Main Lift
before the load is securely set down. Height range where the forks and carriage are raised after
extending the mast rails.
Controller
Mobile equipment controller that directs AFC systems Minimum Drop/Stop Weight
operation. Minimum load weight where drop/stop valve will function.
Effects Drop/Stop sensitivity.
Datalogger
A device that records clamp force values. Override Switch
Enables driver to override AFC features when maximum
DC to DC Converter pressure is required.
Steps down the truck’s power source voltage to provide 12v.
6095130-R1 1
G LOSSARY
Pilot Pressure
Minimum pressure required to allow AFC to function.
Power Bus/ Relay

Provides a common point to supply filtered 12V electrical
power to all Cascade electrical accessories.
Pressure Differential
Pressure difference between PT3 and PT4 indicating Arm
contact with the load.
Pressure Transducer
Provides pressure feedback to the controller.
Pressure Transducer 1 (PT1)

The transducer in the Hoist Circuit.

The transducer in the Open line on the AFC valve (not
checked pressure).

The transducer in the Clamp Cylinder indicating checked
pressure.

The transducer in the Close line on the AFC valve (not
checked pressure).
Pressure Transducer Factor (or Transducer Factor)

The value that relates transducer signal to pressure for
calculation in the controller.
Priority Flow Control Valve

Provides a constant priority flow required for AFC system
operation, typically at 1–2 GPM.

Proportions the correct pressure to the Clamp cylinders for
appropriate clamp force required to handle a specific load
weight.
Revolving Connection Slip Ring

Electrical connection through the center of the rotating
clamp.
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.
Starting Pressure/ Threshold Pressure

The minimum pressure that will be applied, even on small,
light loads.
Tilt Control
Stops the mast at true vertical.
2 6095130-R1
AMERICAS
Fax: 888-329-8207 Fax: 905-629-7785 Tel: 55-13-2105-8800
Fax: 55-13-2105-8899
EUROPE-AFRICA
Italy South Africa
Tel: 39-045-8989111 Tel: 27-11-975-9240
Fax: 39-045-8989160 Fax: 27-11-394-1147
ASIA-PACIFIC
Fax: 86-592-651-2571 Phone: +91 020 2432 5490
Fax: +91 020 2433 0881
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

Manual Service Clamp Cascade PDF

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ADAPTIVE FORCE CONTROL

Document Number 6093305-R6

ADAPTIVE FORCE CONTROL (AFC)

AFC SYSTEM BLOCK DIAGRAM

Maximum Free Lift Clamp

Truck Main Priority Truck

AFC System Components

Light Tower Junction Box

AFC System components shown in approximate locations

Spray-Metal Rubber Urethane Flexible Pad

Ribbed Tissue - Convex Tissue - Multiple Radii

AFC Operational Characteristics

Major components are shown below.

Scanner Power and

NOTE: Kits are UL Classified (File # AU3546) for safety in

cascade Cascade Corp.

For Technical Support . . . To Order Parts . . .

NOTE: Cascade provides many of the special fittings

2 Install the return to tank fitting in the tank line.

the hose ends and fitting for easy assembly. Refer to

3 If equipped, mount Hoist

4 Connect a hose (user supplied) from the hoist control valve to

3 Mount Hoist Drop Stop Valve

9 Install a low pressure hose from the proportional pressure

to attachment Plug side

Optional Hoist Drop Stop Valve Equipped – Connect

Accumulator Clamp Open

NOTE: UL Classified Kits require installation by qualified

The controller must be mounted near the junction box.

3 Mount the display (if equipped) on the truck overhead

display connector and route the free end cable wires to

5 Mount the status light on the mast or the truck overhead

guard in driver's view. Route the free end cable wires to

10 Route connector cable with free end cable wires (part

13 Mount the power bus (if equipped) in an easy access

2 19 4 6090961 SOL3 J2- / BU J2 / BN

Abbreviation Color Abbreviation Color Abbreviation Color

10 12 Wire Preparation and Installation

23 Connect the revolving connection cable end to the power

24 Apply SMARTCLAMP labels to the truck dashboard

The AFC control features can be temporarily disabled by Proportional

c be carefully followed to preserve

Instructions Power Supply/

AC2509.eps Power Wire Harness Part No. 6844330-R1

cascade W Cascade Corp.

WARNING: For UL Classified kits, to reduce

2 Determine a mounting location for the roller assembly on the

4 Grind the spacer mounting area on the mast to bare metal.

• Devcon Plastic Welder 14320

WARNING: If welding is used to attach

NOTE: If replacing an older supply/communication kit,

with old location of the roller hole, facing forward.

9 Clean area to be welded. Remove paint, oil, grease and

10 Install the cable junction block to the anchor plate. AC2485.eps

Tighten the left (driver's view) capscrew and washer to

11 Feed the cable up through the roller

IMPORTANT: If the cable end is released and gets stuck

C Tighten nut to 7 ft.-lbs. (10 Nm). Verify that no required)

Connect attachment Power

23 Connect the battery cable(s) to their proper terminals.

Coil Cord Maintenance

Cord Tension – The coil cord can be retensioned by pulling a

Attachment/Hydraulic Circuit Purpose Accumulator Pre-Charge