HFC - HYDRAULIC FORCE CONTROL

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1 HFC - HYDRAULIC FORCE CONTROL Prevent over clamping by controlling clamp force automatically. Control Clamp Force Automatically and Reduce Product Damage APPLICATIONS Excessive clamp force caused by too much hydraulic pressure is one of the most common causes of damage to paper rolls. Mechanical 3-position relief valves are under-utilized or primarily left on the high setting. HFC (Hydraulic Force Control) solves these issues by automatically adjusting clamp force. HFC is a hydraulically controlled automatic clamp force system that changes the clamp force proportional to the load weight. It works by continually sensing the hydraulic pressure necessary to lift the load and adjusts clamping pressure as the weight of the load increases or decreases. The system operates without any special actions on the part of the driver. BENEFITS No need to change driver habits. Driver can use normal operating procedure: Close clamp arms on load and then hoist load off ground. Hydraulics can be feathered to allow driver to control clamp force on extremely small, light loads. Quick Installation only requires tapping into the Hoist, Clamp and Open lines. Low maintenance system does not require an accumulator to charge the system (which can lose charge). FEATURES Conveniently sized hydraulic valves mount easily onto the cowl of lift truck. Infi nite adjustment of clamp force in the capacity range of the attachment. The system adjusts clamp force proportional to the roll weight. When installed with the equalizing valve, the clamp force remains constant between Freelift and Mainlift. Accomplished with the use of a switch that determines if the clamp is in Freelift or Mainlift. HFC is fl exible, allowing easy adjustment for: All clamp force settings Maximum pressure Balancing clamp force between Freelift and Mainlift Balancing clamp force when the size of the truck and clamp are not ideally matched. Compatible with Split and Solid Arm Clamps.

2 HFC - HYDRAULIC FORCE CONTROL HFC MODELS HFC KIT FOR FREE LIFT MAST APPLICATIONS Included voltage converter for 24V-48V kits HFC KIT FOR LIMITED FREE LIFT MAST APPLICATIONS For use on 2 Stage Limited Free Lift (Simplex) mast applications. For use on 2 Stage Full Free Lift (Duplex) and 3 Stage Full Free Lift (Triplex) mast applications. Includes equalization switch which equalizes system pressure for improved accuracy. OPTIONAL ARM SPEED OVERDRIVE System drives the arms to close at full speed (used in applications where very low clamping pressure is required, resulting in lower arm speed). Conveniently attaches to the main HFC valve for easy installation. This option also allows the operator to increase clamp force when needed on comprimised loads and in breakout situations. T OUT T IN FULL HEIGHT PRESSURE LIMITER Prevents excessive clamp force in applications where the mast is extended to full height on a regular basis while clamping a load. RECOMMENDED DAMAGE REDUCTION OPTIONS Load Cushion Hoist System Accumulator that absorbs shocks and reduces the clamp force required to handle the load. Available in one pint and one quart sizes. Wireless Pressure Monitor Wireless Pressure Monitor is a system to monitor the hydraulic pressure in the clamping cylinders of an attachment on a real time basis. Perfect for allowing drivers to see the actual pressure during the clamp cycle to determine if the load holding components are malfunctioning. Tilt Control Automatically controls the angle of the mast and attachment, aligning pad with the load. Electronic Rotational Control Provides 90 (bilge) and 180 stops during 360 clamp rotation, which automatically aligns pad to roll Cascade Corporation PO Box Portland, OR USA 800 CASCADE ( ) Tel Fax Fax Cascade Canada Ltd Timberlea Blvd. Mississauga, Ontario L4W 4M6 Canada Tel Fax Cascade is a registered trademark of Cascade Corporation. Cascade Corporation All rights reserved. Form r2 IH 10K 3/10

3 & Cable Reel Selection Guide

4 Attachments, NUMBER Dual Lift Masts Triple Lift Masts Quad Lift Masts OF (Overall Lowered Heights) Capacities ➀ (Overall Lowered Heights) ➀ (Overall Lowered Heights) ➀ Sideshifters FUNCTIONS 71" 83" 101" 120" 71" 83" 95" 110" 127" 137" 145" 152" 71" 83" 95" 107" ,000 lbs. 1 #4-11" THINLINE Reel #4-11" #6-13" #6-16" THINLINE Reel #6-16" THINLINE Reel 10,500+ lbs. 1 #6-13 THINLINE Reel #6-13" THINLINE #6-16" THINLINE Reel #6-16" THINLINE Reel Paper Roll Clamps Fixed Frame Clamps 2 ➂ #8-16" THINLINE Reel #8-16 THINLINE Reel" #8-16" Swing Frame Clamps 3 Load Push/Pulls #6-13" 4-Port THINLINE Reel #6-13' 4-Port 6-16" 4-Port THINLINE Consult #8-16 THINLINE Reel #8-16 THINLINE Reel Cascade lbs. 1 or 2 ➁ #6-13" THINLINE Reel #6-13" THINLINE #6-16" THINLINE Reel #6-16" THINLINE Reel Solenoid Equipped 2 or 3 ➃ HC2 R/L Cable- HC8 R/L Cable- HC8 R/L Cable- Reel HC6 R/L Cable- Reel HC8 R/L HC6 R/LCable- Reel 5,500-8,000 lbs. 1 or 2 ➁ #8-16" THINLINE Reel #8-16" THINLINE Reel #8-16" Solenoid Equipped 2 or 3 ➃ #8-16" THINLINE Reel & #8-16" THINLINE Reel & Consult H2R/L Cable Reel H2R/L Cable Reel Cascade Carton Clamps 2,000-4,000 lbs. 2 #6-13" THINLINE Reel #6-13" THINLINE #6-16" THINLINE Reel #6-16" THINLINE Reel Solenoid Equipped 2 ➄ HC2 R/L Cable- HC8 R/L Cable- HC8 R/L Cable- Reel HC6 R/L Cable- Reel HC8 R/L HC6 R/LCable- Reel 4,500-6,000 lbs. 2 #8-16" THINLINE Reel #8-16" THINLINE #8-16" Solenoid Equipped 2 ➄ #8-16" THINLINE Reel & #8-16" THINLINE Reel & Consult H2R/L Cable Reel H2R/L Cable Reel Cascade Rotators 4,000-20,000 lbs. 1 #8-16" THINLINE Reel #8-16" THINLINE Reel #8-16" Clamps 2,000-3,500 lbs. 1 or 2 #6-13" THINLINE Reel #6-13" THINLINE #6-16" THINLINE Reel #6-16" THINLINE Reel 4,000-20,000 lbs. 1 or 2 #8-16" THINLINE Reel #8-16" THINLINE Reel #8-16" Clamps Rotating 2,000-20,000 lbs. 2 ➄ #8-16" THINLINE Reel #8-16" THINLINE Reel #8-16" Notes ➀ The recommendations in this Selection Chart are based on the assumption that the reel is mounted on the upper portion of the mast. If you plan to mount the reel in a different location, such as the truck cowl, you should calculate the exact usable hose and/or cable length required and order from the appropriate specification brochure, Cascade Product Price List, or contact Cascade's Customer Service Department for assistance 888 CASCADE ( ) ➁ For increased visibility and reduced cost, a 4-Port #6-13 or #6-16 THINLINE Reel can be used in place of two 2-Port Reels. ➂ If your truck is equipped with internal hose reeving, it should be used to supply the clamp function, and not the rotation function. ➃ Most three-function solenoid equipped push/pulls, including all Cascade models, only require a single-function hydraulic supply. For "non-cascade", three function, solenoid equipped push/pulls, refer to the manufacturer's specifications to determine whether a single, or double-function hydraulic supply should be ordered. ➄ Solenoid equipped carton clamps use a single-function hydraulic supply in conjunction with the electrical supply.

5 Order Numbers THINLINE Hydraulic Supply Groups Attachment DUAL LIFT TRIPLE LIFT QUAD LIFT Models Functions MASTS MASTS MASTS THINLINE Reel Hydraulic Supply Group: 1 R.H R.H #4-11 R.H R.H L.H L.H R.H R.H R.H #6-13 R.H R.H R.H L.H L.H L.H N/A R.H R.H #6-16 N/A R.H R.H N/A L.H L.H R.H R.H R.H #8-13 R.H R.H R.H L.H L.H L.H THINLINE 4-Port Reel Hydraulic Supply Group: #6-13 #6-16 The numbers listed below represent complete THINLINE Reel hydraulic supply groups. They contain all the components necessary to plumb your truck from the auxiliary valve, over the mast, to the carriage. THINLINE 2-Port Single Function Hydraulic Supply Groups contain a reel, mounting bracket, hose terminal, header hoses, supply hoses and fittings. THINLINE 4-Port Hydraulic Supply Groups contain a reel, mounting bracket, hose terminal, header hoses, supply hoses and fittings. Individual Reels and Components may be ordered from your Cascade Product Price List. 2-R.H N/A 2-L.H N/A 2-R.H. N/A L.H. N/A N-1 Cable- Reels & Cable Reels Listed below are individual order numbers for 6-N-1 Cable- Reels, Cable Reels and related components. All components required for a complete installation are included with the exception of the truck-to-reel header hoses and cables. Because of wide variations in the type and location of lift truck electrical terminals, components for the truck-toreel connection should be selected at the time of installation. MOUNTING BRACKETS REEL CABLE/HOSE JUNCTION All Masts FITTING Model Right Left #5 #6 BLOCK (including Dual Lift) GROUP 6-N-1 Cable- Reel HC2/RL HC8/RL HC6/RL N-1 Cable- Reel Cold Storage Materials* HC2/RL HC8/RL HC6/RL Cable Reel-6 Conductor # # # # H2/RL Included with Reel N/A *Ambient temperature range: STANDARD MODEL +20 F/-7 C TO +100 F/+38 C COLD STORAGE MODEL -20 F/-29 C TO +80 F/ +27 C

6 THINLINE Reel THINLINE Reels are general purpose 2-port reels that offer the thinnest mounting available. The THIN- LINE Reel design enhances driver visibility and protects the reel from damage. It also provides excellent durability and performance standards. THINLINE 4-Port Reel The Cascade THINLINE 4-Port Reel is used for 2-function installations where only one hose reel is desired, or in 3-function installations in conjunction with a 2-Port THINLINE Reel. The THIN- LINE 4-Port Reel carries two twin bonded thermoplastic hoses. 6-N-1 Cable Reel 6-N-1 Cable Reels are recommended for applications with solenoid equipped attachments. 6-N-1 Cable Reels transmit both the electrical and hydraulic power through a single reel. Up to six hydraulic functions may be controlled with one reel depending upon the solenoid arrangement. Single Line Reel Single Line Reels should be specified for applications where SAE 100-R1, R2 or R5 type hose is desired. Single Line Reels are available in narrow, medium and wide models.

7 Cable Reel Cable Reels are recommended for installations with a solenoid equipped attachment and a separate hydraulic supply. Cable Reels may also be used in conjunction with hydraulic hose reels. Separate Cable Reel and Reel arrangements are recommended for installations requiring #8 hose (10+ GPM). Order Reels Online: just go to the Parts Order Form (Dealers only) PO Box Portland, OR CASCADE ( ) Tel Fax Fax Cascade is a registered trademark of Cascade Corporation. Cascade Corporation All rights reserved. Form R1 10M PG 6/00.

8 THINLINE HOSE REEL The thinnest mounting profile available. Narrow mounting profile for better visibility & less damage. APPLICATIONS The THINLINE Reel is a general purpose 2-port reel that offers the thinnest mounting profile available on the market. The reel design enhances driver visibility and protects the reel from damage. THINLINE Reels may be used for both new and replacement installations on most two, three or four stage masts. FEATURES Narrow Profile Achieved through a unique design in combination with SAE 100-R7 thermoplastic twin bonded hose. A general purpose weld-on mounting bracket is used for most masts allowing a narrow mounting profile to be achieved from a number of different mounting positions. bracket provides the flexibility to compensate for interference from lift cylinders, tilt anchors, overhead guards and crossmembers. Simplicity of design and construction make the THINLINE Reel exceptionally easy to service. OPTIONS Twinline Bonded Brackets All Masts Terminal Down Terminal Up Connection Fitting Group

9 THINLINE HOSE REEL Contents Thinline Reel Reel Terminal Down Fittings Reel Group Package Reel Right Hand Left Hand #4 ➀ 11" 154" 136" 20 Right Hand Left Hand #6 ➀ 13" 180" 152" 28 Right Hand Left Hand #6 ➀ 16" 300" 272" 32 Right Hand Left Hand #8 ➀ 16" 228" 194" 38 Group Package Right Hand Left Hand #4 11" 154" 136" 25 Right Hand Left Hand #6 13" 180" 152" 34 Right Hand Left Hand #6 16" 300" 272" 41 Right Hand Left Hand #8 16" 228" 194" 47 ➀ not included. Thinline Reel Group Packages are a practical and economical choice for both new and replacement installations. Replacing existing reels with a Thinline Group Package will allow you to achieve the Thinline Reel s extremely narrow mounting profile. Contents Thinline Reel(s) Reel Header s ➁ Terminals Down Terminals Up Fittings Reel Hydraulic Supply Groups Brackets for Reel and Terminals (Weld-On) Size Maximum Mast Down Height ➀ Reel Diameter Attachment Functions Package Weight (Lbs.) Size Flange Size Total Length Usable Length Weight (Lbs.) 2 Stage Masts 3 Stage Masts 4 Stage Masts Right Hand Left Hand #4➂ 120" 11" RH/1 LH/2 35 Right Hand Left Hand #6 120" 13" 1 46 Right Hand Left Hand #8 120" 16" RH/1 LH/2 62 Right Hand Left Hand #4➂ 83" 11" RH/1 LH/2 46 Right Hand Left Hand #6 95" 13" 1 46 Right Hand Left Hand #6 152" 16" 1 53 Right Hand Left Hand #8 127" 16" RH/1 LH/2 62 Right Hand Left Hand #6 71" 13" 1 46 Right Hand Left Hand #6 107" 16" 1 53 Right Hand Left Hand #8 83" 16" 1 62 ➀ For down heights greater than shown, contact Cascade. Normally the reel is mounted on upper top part of mast channel. If mounted elsewhere, check usable hose length. Thinline Reel Hydraulic Supply Groups contain all necessary components to plumb from the auxiliary valve bulkhead to the mast carriage. ➁ ➂ Header hoses may require shortening for best fit. Additional fittings may be required for auxiliary valve connection. Terminal Up connection not included. Separately priced Installation Kit is needed to complete normal hydraulic system installation. One or two required depending upon hydraulic functions. PO Box Portland, OR CASCADE ( ) Tel Fax Fax Cascade is a registered trademark of Cascade Corporation. Cascade Corporation All rights reserved. Form M PG 6/00.

10 THINLINE 4-PORT HOSE REEL Increased visibility for two-function attachment installations. A single hose reel provides hook-up for two-function attachments. NOW YOU HAVE AN OPTION Cascade s THINLINE 4-Port Reel gives you the option of using a single reel to supply a two-function attachment. The THINLINE 4-Port Reel can be used instead of two standard hose reels, one reel and internal reeving, or one reel an a solenoid. The benefits: Lower initial purchase price, less installation time and unobstructed visibility on one side of the mast (right hand mounting recommended for most attachments). FEATURES THINLINE 4-Port Reels have the same features as THINLINE 2-Port Reels, which include thin profile, seals in the hub, reversible spring and no center divider has full ID dimension with minimum OD dimension, allowing more hose to be stored on a smaller reel terminal makes a positive hose-to-hose connection without a rotary joint junction block terminal eliminates a potential leak point and has far less restriction because there are no internal check valves Flexible strain relief secures the hose to the carriage terminal and maintains hose within its recommended bend radius brackets allow reel to be mounted with extremely narrow profile Group Package includes: Thinline 4-Port Reel Two Reel Sets Terminal Down Hydraulic Supply Groups include: Thinline 4-Port Reel Two Reel Sets Terminal Down Four Header s ➂ Fittings Brackets for Reel and Terminals (Weld-On) ➃

11 THINLINE 4-PORT HOSE REEL Size ➀ Flange Size Total Length Usable Length Package Weight (Lbs.) Reel Right Hand # Left Hand # Right Hand # Left Hand # Group Package Right Hand # Left Hand # Right Hand # Left Hand # Size Maximum Mast Down Height ➁ Hydraulic Supply Groups 2 Stage Masts Right Hand #6 120" ➄ 13" Stage Masts Left Hand #6 120" " Stage Masts Right Hand #6 95" ➄ 13" Stage Masts Left Hand #6 95" " Stage Masts Right Hand #6 152" ➄ 16" Stage Masts Left Hand #6 152" " Stage Masts Right Hand #6 107" ➄ 16" Stage Masts Left Hand #6 107" " 2 73 Reel Diameter Attachment Functions Package Weight (Lbs.) ➀ ➁ ➂ ➃ ➄ not included. For down heights greater than shown, contact Cascade. Normally the reel is mounted on upper top part of mast channel. If mounted elsewhere, check usable hose length. Header hoses may require shortening for best fit. Additional fittings may be required for auxiliary valve connection. Interference with overhead guard, crossmembers, tilt anchors, etc. may necessitate relocating reels. Includes Terminal Up connection. Fitting Group Contains Standard 37 JIC adapter fittings to connect the hoses to the Thinline Reel. Fitting/ Size # # # Twinline Bonded Provides the maximum length twinline thermoplastic hose (SAE 100-R1) for each Thinline Reel size. Thinline 4-Port Model Length #6-13" 172" #6-16" 280" Bracket All Masts Provides the bracket and hardware for mounting the Thinline Reel on virtually any mast. Thinline 4-Port Model #6-13" & 16" Terminal Down Provides a non-rotary joint hose termination point on the mast carriage. Connections to valves and cylinders between the carriage bars are made directly to the Terminal Down. Thinline 4-Port Model #6-13" & 16" Terminal Up Connection Terminal Up Connection tubes are added to the Terminal Down for connections above the top carriage bar, such as motors and top mounted valves. Includes mounting bracket. Thinline 4-Port Model #6-13" & 16" PO Box Portland, OR CASCADE ( ) Tel Fax Fax Cascade is a registered trademark of Cascade Corporation. Cascade Corporation All rights reserved. Form M PG 8/01

12 6-N-1 CABLE-HOSE REEL Control up to six hydraulic functions with a single reel. APPLICATIONS An efficient way to transmit both electrical and hydraulic supply over the mast. Cascade's 6-N-1 Cable- Reel can control up to six hydraulic functions when used in conjunction with the proper solenoid arrangement. The 6-N-1 Reel is an efficient, economical and space-saving method of transmitting both the electrical and hydraulic supply over the truck's mast on a single reel. Using one 6-N-1 Reel eliminates the need for multiple reel installations, resulting in reduced cost and an improved mounting configuration. FEATURES Well sealed rotary joint and durable seals Excellent hydraulic flow Rugged, durable construction Fully contoured metal flanges protect cable-hose line from chafing Unique hose guide design prevents hose kinking Non-rotary joint carriage terminal eliminates need for joint Brushless connections are completely enclosed fittings and electrical connections are readily accessible

13 6-N-1 CABLE-HOSE REEL Model Mast Type Diameter Weight (Lbs.) 6-N-1 Cable Reel ➀ Standard to +20 F Right Hand HC2R Dual Standard to +20 F Left Hand HC2L Dual Standard to +20 F Right Hand HC8R Triple Standard to +20 F Left Hand HC8L Triple Standard to +20 F Right Hand HC6R Quad Standard to +20 F Left Hand HC6L Quad Cold Storage to 20 F Right Hand HC2R Dual Cold Storage to 20 F Left Hand HC2L Dual Cold Storage to 20 F Right Hand HC8R Triple Cold Storage to 20 F Left Hand HC8L Triple Cold Storage to 20 F Right Hand HC6R Quad Cold Storage to 20 F Left Hand HC6L Quad Six conductor reel with junction block. ➀ Cable sold separately. REEL MOUNTING BRACKET for 6-N-1 Cable Reels Mast Type All Masts REEL FITTINGS for 6-N-1 Cable Size # JUNCTION BLOCK for 6-N-1 Cable Model J CABLE HOSE ASSEMBLY for 6-N-1 Cable Recommended Reel Model Size HC2R&L #5/128" HC8R&L #5/231" HC6R&L #5/316" HC2R&L #6/118" HC8R&L #6/212" HC6R&L #6/239" N/A HC6R&L #6/284" PO Box Portland, OR CASCADE ( ) Tel Fax Fax Cascade is a registered trademark of Cascade Corporation. Cascade Corporation All rights reserved. Form M PG 3/02

14 SINGLE LINE HOSE REELS Single function hydraulic supply for a wide variety of mobile applications

15 SINGLE LINE HOSE REELS Features Dramatically Improved Sealing O-rings and continuous back-up rings, located in the hub, provide a well sealed rotary joint with dramatically improved seal life. Interchangeability Cascade Single Line reels are directly interchangeable with older Cascade metal and plastic flange reels. The reels mount in exactly the same location. When supplied with fittings, they can be connected directly to existing hoses or tubing. Center Divider A center divider prevents hose cross-over winding. Patented Accessibility fittings are readily accessible, permitting hoses to be easily installed or removed without the need to disassemble the reel. Full Support Fully contoured metal flanges, hub and center divider provide support and protect the hoses from chafing. An exclusive hose guide supports the hose at the minimum bend radius to prevent hose kinking. Excellent Performance Good spring torque and low friction seals result in excellent hose wind and rewind capability. Automatic Spring Declutching A Spring declutching device eliminates spring damage when the spring is wound backwards. The spring is wound about a large diameter shaft, resulting in lower spring stresses and longer life. Low Pressure Loss Large, unrestricted passages minimize pressure loss through the reel.

16 SINGLE LINE HOSE REELS Direction of Wrap.5 dia UNF 0-ring Ports Direction of Wrap UNF 0-ring Ports Inboard Spring Reel dia. 1.2 Outboard Spring Reel 1.8 Inboard Spring Reels Model Narrow Width RH H2R LH H2L RH H8R LH H8L RH H6R LH H6L Medium Width RH H4R LH H4L Wide Width RH H1R LH H1L Diameter Usable Length ➀ SAE SAE SAE SAE 100-R1 100-R2 100-R5 100-R7 Weight without hoses #5 #6 #8 #6 #5 #6 #8 #5 #6 lbs. kg " " Outboard Spring Reels Model Diameter Usable Length ➀ SAE SAE SAE SAE 100-R1 100-R2 100-R5 100-R7 Weight Medium Width RH H3R LH H3L Wide Width RH H5R LH H5L #5 #6 #8 #6 #5 #6 #8 #5 #6 lbs. kg. 11.5" " Notes: ➀ Add 20 inches to usable length for prewrap. HOSE TYPES: SAE 100-R1 Rubber covered single wire braid hose. SAE 100-R5 Cloth covered single wire braid hose. SAE 100-R2 Rubber covered double wire braid hose. SAE 100-R7 Thermoplastic hydraulic hose. HYDRAULICS: Pressure 3000 PSI Maximum Flow Dependent on hose (refer to hose manufacturer for specs) Temp Ambient temperature range -20 F (-7 C) to +100 F (+38 C)

17 SINGLE LINE HOSE REELS UNF O-ring ports Dia Dia Standard Size With Check Valves UNF O-ring ports Junction Blocks Dia Dia Dia UNF O-ring ports Standard Size Without Check Valves 1.5 Dia UNF O-ring ports Shaft Junction Blocks (continued) Outboard Spring Reel Bracket Dia. 3.0 Brackets Mast Type Inboard Spring All Masts Outboard Spring All Masts Reel Fitting Group Compact Size Size Model # Inboard # Spring # # Outboard # Spring # UNC x 1.0 long.5-13 UNC x 5.8 long UNF O-ring ports UNF O-ring ports Inboard Spring Reel Bracket Dia Junction Blocks reel junction blocks provide a hose swivel connection at the truck carriage. Type Model Shaft Size Without J3R Right Check J3L Left Standard Valves J3C Center J1C Center Compact With Check Valves Junction Block Fittings J2R Right J2L Left J2C Center Size Model # #6 J # # #6 J2 & J # To Calculate Lengths H = Total lift height D = Distance from centerline of reel to junction block 1. When H is equal to, or greater than, 2 x D then line length = H D + 20 inches. 2. When H is less than 2 x D then line length = D + 32 inches. H D Example: H = 288 D = = 212 reel hose or cable length. Standard Note: It is essential that 20 inches of hose be prewrapped on the reel at all times. This amount is included when using this formula for calculating line length. PO Box Portland, OR CASCADE ( ) Tel Fax Fax Cascade is a registered trademark of Cascade Corporation. Cascade Corporation All rights reserved. Form M PG 11/04

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