c Installation Instructions Clamp Open Guard Switch Activated Retrofit Kit 6048125 This manual provides installation instructions for Cascade Clamp Open Guard Retrofit Kit. The kit converts an existing Automatic Clamp Open Guard installation to a Switch Activated Version. The kit is designed for use with Cascade F and G-Series Paper Roll Clamps and D-Series Sliding Arm Clamps. WARNING: Do not use the Clamp Open Guard with any product other than a Pivot Arm Paper Roll Clamp and D-Series Sliding Arm Clamp. Display (Existing) Control Box (New) Switch to operate solenoid valve (New) Valve in Clamp Open Circuit (Existing) AC1014.eps Part No. 6048329-R3 cascade corporation For Technical Support... To Order Parts... Call: 1-800-227-2233 Fax: 1-888-329-8207 Call: 1-888-227-2233 Fax: 1-888-329-0234 Internet: www.cascorp.com Internet: www.cascorp.com Write: Cascade Corporation, PO Box 20187, Portland, OR 97294 Write: Cascade Corporation, 2501 Sheridan Ave., Springfield, OH 45505
Existing Components 1 Disconnect the cable from the positive battery terminal. 2 Disconnect the limit switch cable end from the cable harness. the limit switch mounted on the mast upright. 1 Disconnect positive cable 3 the hose connecting the hoist pressure switch valve to the mast hoist line. 4 the tee fitting from the hoist line and replace with a union fitting or cap the tee fitting with a metal cap included in the kit. AC0201.eps 7 switch 2 limit switch 6 cable harness 5 valve 3 hose AC1044.eps 4 tee fitting, replace with union or cap. 5 the hoist pressure switch valve. 6 the cable harness. 7 the switch from the auxiliary valve clamp control lever. 2
Installation Retrofit Kit 1 Install the Control Box on the truck cowl, under the dash or under the floor boards using the mounting plate or velcro provided. The mounting plate is drilled to match the old hoist pressure switch valve mounting. Connect 2 display Install 3 decal 1Install Control Box 2 Connect the Display cable end to the Control Box. Use a cable extension provided if necessary. 3 Install the new decal on the display. 4 Connect the Valve cable end to the Control Box. Use a cable extension provided if necessary. AC1015.eps Connect cable 4 end 5 Install the new Switch to the clamp control lever. the control knob. Position the switch on the handle in a location for comfortable thumb or index finger operation. Place the double sided tape under the switch to secure the switch in place. Place the heat shrink tubing over the handle and switch. Using a heat gun, heat the tubing to secure the switch to the handle. Reinstall the knob. Install cable ties as needed for the wires. Connect the cable end to the Control Box. 5 Install switch AC0402.eps Tape Cut tubing around button 3 in. for typical hand Shrink Tube Handle and Knob 3
CAUTION: Consult the Lift Truck OEM for proper + power source connection. 6 Connect cable ends to the Control Box as shown. 12V Systems Connect the fused positive wire from the cable harness to a 12V switched power source, and the ground wire to a chassis ground. 24V 48V Systems Connect the fused positive wire from the cable harness to a DC-to-DC converter positive output wire and the ground wire to the converter negative output wire. Connect a 24V 48V switched power source to the converter fused positve input wire and connect the converter input ground wire to a chassis ground. Check the cable routing for pinch points and clearance. Use wire ties as needed. Display Control Box System WARNING: The fused power cable is polarity sensitive. The positive wire must be connected to a positive power source. 6 Connect cable ends Output DC to DC Converter (24V-48V systems only) Valve 7 Reconnect the positive battery terminal to the battery. Switch Chassis Ground Truck Battery (or Power Bus) AC1012.eps Input Switched 7 Positive Truck Block Battery Terminal 8 Install Clamp Open Guard Decal 6048802 on the truck dash or overhead guard in an easy to read location for the driver. 8 Install decal 4 AC1035.eps
Test and Adjustment 1 Test the installation before putting the truck in service. When the truck key is turned ON, the green light will be lit for 10 seconds, then the amber light on the display should be on. Check the wiring if the lights on the display do not lite as described. 2 Press the button and observe that the green light comes on for approximately 10 seconds and then switches to amber. 3 Hoist a load 1 in. off the ground with the amber light on. Operate the clamp open handle, the clamp should not open. Lower the load to the ground, press and release the button to release the load. 4 The timer in the control box is set to 10 seconds for the open function. The timer can be adjusted to increase or decrease the length of time the open function is operational. Open the control box enclosure and locate the timer potentiometer. To decrease the open function time Turn the timer dial counterclockwise (CCW). To increase the open function time Turn the timer dial clockwise (CW). Test the setting to verify the desired time the green light is on (open function active). Reinstall the cover. Switch Display Control Box Valve AC1016.eps Operation The Clamp Open Guard prevents accidental opening of a clamp prior to the load being properly lowered. It prevents unintended activation of the truck s clamp open circuit. The clamp will not open until the safety switch is activated and the green light is active. Press and release the switch button, then operate the truck clamp open control lever to open the clamp. When the green light is on (timed for 10 seconds), the clamp will open normally. If additional time is needed to open the clamp, press and release the switch button again. If the clamp will not open when the button is pressed and released, set the load down, turn off the truck key and restart the truck. The clamp open guard will reset and function properly for the timed 10 seconds. See Test and Adjustment before returning to service. When the amber light is on, the clamp will not open. NOTE: The system does not work like a drop stop valve that prevents load drop or jump when the clamp is opened. The green light does not indicate that the load has been lowered to its optimal position. 5
System Disabling System The Clamp Open Guard can be disabled by performing the following steps: Disconnect the two hose ends to the normally-closed solenoid valve and connect them together with a union. the system power fuse in the cable harness. The truck and attachment will now operate normally. To enable the Clamp Open Guard, reverse the above procedure. Valve AC1030.eps 6
5 Clamp Open Guard Retrofit Kit 3 Switch 0! @ 8 9 6 fl ^$ 4 2 Display Control Box 1% Valve ( * fi ) System & 7 Switched Circuit 5A mini. # c This truck equipped with CASCADE Clamp Open Guard Press button to open clamp, green light shows ready to open for 10 seconds. If unable to open clamp: Lower roll, turn truck key off, then back on. OR Contact supervisor Decal Part No. 6048802 Wire connection WITHOUT converter Truck Block DC to DC Converter AC1045.eps Chassis Ground Battery REF QTY PART NO. DESCRIPTION 6048121 Clamp Open Guard Retrofit Kit 1 1 2645 Fitting, 6 2 1 6001641 Shrink Tube, 1 in. (25 mm) 3 1 6014987 Adhesive Tape 4 1 6026655 Decal 5 1 6029665 Velcro 6 1 6048115 Switch 7 1 6048139 Power Harness 8 1 6048225 Mounting Plate 9 1 6048330 Control Box 10 1 6048334 Extension Cable Switch 11 1 6048338 Extension Cable 12 1 6048340 Extension Cable Display 13 1 6048802 Decal 14 2 768505 Capscrew, M4 x 45 Reference only, included in original kit. 7 REF QTY PART NO. DESCRIPTION 15 1 2646 Fitting, 8 16 2 686454 Washer, M4 17 1 6008233, 10 Amp 18 1 6008301 Wire Harness 19 1 6020882 Valve, 12V 20 2 2618 Nut 21 2 2671 Reducer, 8-6 22 2 601377 Fitting, 8-8 23 1 6021069 DC-to-DC Converter 24 1 6048803 Spacer 25 1 6014287 Coil, 12V 26 1 6008231 Display 27 1 6004133 Lamp-Amber 28 1 6004132 Lamp-Green
Do you have questions you need answered right now? Call your nearest Cascade Service Department. Visit us online at www.cascorp.com AMERICAS Cascade Corporation U.S. Headquarters 2201 NE 201st Fairview, OR 97024-9718 Tel: 800-CASCADE (227-2233) Fax: 888-329-8207 Cascade Canada Inc. 5570 Timberlea Blvd. Mississauga, Ontario Canada L4W-4M6 Tel: 905-629-7777 Fax: 905-629-7785 Cascade do Brasil Rua João Guerra, 134 Macuco, Santos - SP Brasil 11015-130 Tel: 55-13-2105-8800 Fax: 55-13-2105-8899 EUROPE-AFRICA Cascade Italia S.R.L. European Headquarters Via Dell Artigianato 1 37030 Vago di Lavagno (VR) Italy Tel: 39-045-8989111 Fax: 39-045-8989160 Cascade (Africa) Pty. Ltd. PO Box 625, Isando 1600 60A Steel Road Sparton, Kempton Park South Africa Tel: 27-11-975-9240 Fax: 27-11-394-1147 ASIA-PACIFIC Cascade Japan Ltd. 2-23, 2-Chome, Kukuchi Nishimachi Amagasaki, Hyogo Japan, 661-0978 Tel: 81-6-6420-9771 Fax: 81-6-6420-9777 Cascade Australia Pty. Ltd. 1445 Ipswich Road Rocklea, QLD 4107 Australia Tel: 1-800-227-223 Fax: +61 7 3373-7333 Cascade Korea 121B 9L Namdong Ind. Complex, 691-8 Gojan-Dong Namdong-Ku Inchon, Korea Tel: +82-32-821-2051 Fax: +82-32-821-2055 Cascade New Zealand 15 Ra Ora Drive East Tamaki, Auckland New Zealand Tel: +64-9-273-9136 Fax: +64-9-273-9137 Cascade-Xiamen No. 668 Yangguang Rd. Xinyang Industrial Zone Haicang, Xiamen City Fujian Province P.R. China 361026 Tel: 86-592-651-2500 Fax: 86-592-651-2571 Sunstream Industries Pte. Ltd. 18 Tuas South Street 5 Singapore 637796 Tel: +65-6795-7555 Fax: +65-6863-1368 Cascade India Material Handling Private Limited No 34, Global Trade Centre 1/1 Rambaugh Colony Lal Bahadur Shastri Road, Navi Peth, Pune 411 030 (Maharashtra) India Phone: +91 020 2432 5490 Fax: +91 020 2433 0881 c Cascade Corporation 2012 05-2012 Part No. 6048329-R3