6806956R7 iForks User Manual
Contents
1. e lf the inside teeth of the caliper pass over the fork freely the fork must be taken out of service The fork has 10 wear and 20 reduction in capacity FP0832 eps Fork Arm Blade Sasca Cross Section 100 se OK E Fork Arm Blade Cross Section 90 A ee 2 in 50 mm A Repair or Remove Replace Fork Shoe FK0088 eps 6806956 R7 27 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 EUROPE AFRICA Cascade ltalia S R L European Headquarters Via Dell Artigianato 1 37030 Vago di Lavagno VR Italy Tel 39 045 89891 11 Fax 39 045 8989160 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 CI CITM Cascade Corporation 2014 Cascade Canada Inc 5570 Timberlea Blvd Mississauga Ontario Canada L4W 4M6 Tel 905 629 7777 Fax 905 629 7785 Cascade Africa Pty Ltd PO Box 625 Isando 1600 60A Steel Road Sparton Kempton Park South Africa Tel 27 11 975 9240 Fax 27 11 394 1147 Cascade K2. When appears Short Button Press Zero Setting Manually zeros the display Automatic Tare Allows the tare weights to be reset to zero automatically Added and subtracted weights can be determined Weighed load is added to total weight If printer is installed a printout is made Sampling a piece weight Determined an unknown piece weight by sampling a certain number of pieces Standard sampling amount is 10 pieces On Off Middle of Display 1 Weight shown is in 44 Ib 2 kg steps only for weight that ranges 0 441 Ib 0 200 kg e2 Weight shown is in 1 1 Ib 5 kg steps only for weight that ranges 441 1102 Ib 200 500 kg 3 Weight shown is in 2 2 lb 1 kg steps only for weight that ranges 1102 4850 Ib 500 2200 kg F1 Fork 1 relay setpoint 1 is activated F2 Fork 2 relay setpoint 2 is activated NOTE Smaller loads are weighed with higher accuracy Example If an original load with e2 range selected is removed and a smaller load qualified for e1 range the e2 range will remain selected until the forks are zeroed ID CODE kg 3 Second Button Press Code Entry A 5 digit code useful for a weighing system connected to peripheral equipment for later processing Manual Tare An entered tare weight at any moment Check subtotal and print total Enter a piece weight The last used piece weight or an entered value Toggle Units Right of Display When the following
3. J SER manva Q IMPORTANT iForks system forks and display are paired and calibrated as a set Do not separate Consult Cascade Service department with any questions CAUTION This is a precise weighing system treat with care Environment and application will affect the system and its components Conditions with mud grime water corrosive chemicals and abrasive substances can damage or effect performance of the iForks Manual Number 6806956 R7 RAVAS CI CITM Cascade is a Registered Trademark of Cascade Corporation CO ONTENTS V g Q D OVERVIEW WARNINGS amp SAFETY MEASURES INSTALLATION USING DISPLAY Functions Other Features Error Codes USING iFORKS Dos and Don ts Weighing Load Basic Weighing a Load Net Tare Gross Weight Weighing a Load Add to the Total amp Reset Piece Counting AUTO SHUT OFF BATTERIES iForks Indication Changing iFork Battery Packs Changing Display Batteries DISPLAY OPTIONS User Settings 4 md med A L i mah OIDIOIDIAIGIBRININIO OITO ISIN IDINIIN User Settings Submenus 20 PRINTER OPTION 23 PERIODIC MAINTENANCE 25 i 6806956 R7 O VERVIEW This manual describes the installation and use of the iForks Read this manual carefully The installer must be informed of the contents of this manual Follow the contents of the manual precisely Always do things in the correct order This manual should be kept on a safe an
4. FK0035 eps IMPORTANT If installing on fork positioner contact Cascade FK0036 eps Install battery packs into the iForks A Lift up battery holder locking clip B Position battery pack C Click into the battery holders D Secure the locking clips down 6806956 R7 NSTALLATION Locate and mount the display Find a suitable location for readout and easy access to display NOTE If required install batteries into display r Refer to Batteries Section Changing Display Cabin Roof Batteries page 17 La OR Side Rail OR a FK0038 eps Install display bracket and support if required A Install bracket to display B Install bracket display to the support FK0039 eps S5 If equipped with regulator or converter wire display to truck Refer to installation instructions 6814336 for connection the display to truck power 4 6806956 R7 U SING DISPLAY Functions Left of Display When lt appears The weighing system including load is stable gt 0 lt NET The display is showing The weight shown is within the zero range the net weight When mm appears the weight shown is negative 6806956 R7 Button Names Zero
5. printed and total is reset A KG LB Total is reset CLR NOTE If no button is pressed during the flashing the subtotal stays in memory and the system returns to the weighing mode FK0058 eps 6806956 R7 6806956 R7 SING iFORKS Piece Counting Piece Counting To determine an unknown weight by sampling a number of pieces The number of pieces taken from or placed on the iForks determines the accuracy of the sampling The standard sampling amount is 10 pieces 95 pieces maximum NOTE Piece counting is not NTEP approved Press Piece Count Change digit Press Zero button button if necessary NOTE Press the On Off button for 3 seconds to return to basic weighing mode The piece total will be lost Add or take away counted pieces FK0059 eps Enter a Piece Weight known weight Selected digit flashes Hold Piece Count Press the Zero 1 button for three 2 cad diait white ich 3 button to accept seconds gaigit aigit le value NOTE Press the On Off button for 3 seconds to return to basic weighing mode The piece total will be lost FK0060 eps SING iFORKS Powering Off iForks Press and hold the blue button on each battery pack for 10 seconds or until the blinking blue light turns solid Release hold on blue button fA VTO SHUT OFF After 2 minutes of no action On the display Count
6. appears Weight shown is in kilograms Weight shown is in pounds Amount displayed is the number of pieces on the scale EX Display low battery Entry Mode Enter accept value Decrease the value of the digit flashing Increase the value of the digit flashing Shift to the next digit on the left cLR Clear entry FK0186 eps 5 SING DISPLAY Other Features Display Menus Weigh Mode Options Net Tare Gross Auto Manual Tare Add weight Subtotal weight Total weight Piece weight Toggle units Manual zero On off User Settings Auto shut off time Light intensity Deactivate Activate Com Port 1 Deactivate Activate Com Port 2 Alibi Memory FK0041 eps Select Weight Type The value will appear for 5 seconds 3 The original unit format will resume FK0042 eps 1 Hold for 3 seconds 6806956 R7 U SING DISPLAY Error Messages FK0085 eps Display Error Message Out of error mode Err10 Calibration count o point lower than count Automatic 1st 2nd point usoceisoramegamo uiupiicionsiommegana 6806956 R7 7 SING iFORKS Dos amp Don ts PRIOR TO WEIGHING Verify iForks are free of obstacles prior to zeroing a Position to vertical For legal trade l NTEP 5 3 Horizontal OIML 5 Horizontal Verify the display shows zero If necessary press
7. Development of a periodic schedule will prevent faulty readings Cascade recommends a minimum interval of every 12 months or 2000 hours whichever comes first 100 Hour Every time the lift truck is serviced or every 100 hours of truck operation whichever comes first complete the following maintenance procedures e Check for debris between fork and fork shoe ie wood chips e Inspect the bottom of the forks for debris that might be wedged between the fork and the fork shoe Remove any debris found e Check for pinched wires at bottom of batteries e Tighten fork shoe capscrews after initial 100 hours of service Tighten to a torque of 80 ft lbs 108 Nm As necessary replace the cover spool fork shoe capscrews and nuts e Every 100 hours or when the battery packs are changed inspect the battery holders for damage and debris Remove any debris found and check to make sure that the capscrews are tight and contact tabs are not damaged or bent If required tighten the contact point capscrews Cleaning iForks As required use a mild cleanser and wipe down the forks with a towel Rinse the fork with a non pressurized stream of water CAUTION Do not rinse display Battery Holders Check capscrews contact tabs and contact point capscrews 6806956 R7 P ERIODIC MAINTENANCE 2000 Hour After 2000 hours of truck operation forks in use shall be inspected at intervals of not more than 12 m
8. for Gross weight will show 5 seconds Press Zero button to move onto next information menu Net shows for 5 seconds Net_C shows for Net Weight is measured 5 seconds Net_C Weight is calculated Press Zero button to move onto next information menu Tare shows for 5 seconds Ptare shows for 5 seconds Tare Weight is measured Ptare Weight is keyed in Press Zero button to move onto next information menu Code shows for 5 seconds Code will show If no Press the Press the On Off FKOOBO eps code was used 0 will Zero button button to return show Press the Zero to search to the normal button for another weighing mode weighing 22 6806956 R7 P RINTER OPTION NOTE For troubleshooting refer to iForks service manual Print Weight B G 250 0 kg T 25 0 kg N 275 0 kg Nr 1 10 15 09 17 45 Printer will print out load weight Short press Total button to print NOTE This will add the weight to the total weight FK0081 eps Tot B G 2000 0 kg Tot T 50 0 kg Tot N 1950 0 kg Tot Nr 5 10 15 09 17 55 FK0082 eps Hold Total button Press Tare Printer will print for 3 seconds button to print out load weight 6806956 R7 23 a pP RINTER OPTION Change Time amp Date Printout mode guide To accept current settings 2 Change current settings shown in entry press the enter button Time Setting Hour Hold for 6 sec
9. the Zero button Optimal Temperature Range 15 F 10 C minimum 105 F 40 C maximum FK0043 eps HANDLING LOADS Center load on forks and Tidl I pallet load must be flat i FK0044 eps FK0046 eps FK0045 eps 6806956 R7 SING iFORKS Weighing a Load Basic To weigh a load button Wait 5 seconds 2 Press the On Off Display will zero 3 If necessary zero manually Weigh load Before next weighing check zero point 6806956 R7 IMPORTANT e At initial daily start up allow 3 5 minutes for iForks system to warm up before weighing loads e If front face or bottom of iForks touches the load or pallet it will not weigh correctly e Unstable weight readings indicate debris ie wood chips between fork and fork shoe If weighing liquids more time is needed for display to show a steady weight Press the blue button on each battery pack FK0047 eps IMPORTANT The display will show weight in graduations as follows iFork Capacity Display Graduation 5000 lb 2268 kg NTEP 5 Ib kg not available 5000 Ib 2268 kg Non NTEP 2 Ib 1 kg 6000 Ib 2722 kg Non NTEP 2 Ib 1 kg 10 000 Ib 4536 kg Non NTEP 2 Ib 1 kg For example on 5000 Ib fork capacity iForks with a 35 5 Ib load the display will show 36 Ib Non NTEP or 35 Ib NTEP NOTE Custom product may have a differe
10. atteries on iForks perform the following Remove batteries A Unlock batteries Apply pressure on the latch by hand on the bottom side of the cap until the latch is free CAUTION Do not use a hammer or pry open with a screwdriver B Remove battery packs FK0064 eps Remove D Cells from battery packs A Remove the capscrews B Remove top housing of battery pack C Remove batteries OU AU QU ANN FK0065 eps 16 6806956 R7 B ATTERIES Changing iFork Battery Packs Continued Install battery packs in iForks CAUTION When installing battery packs place batteries into casing Shoving or hitting battery into the packs will A Install four batteries in each battery pack cause damage to the casing B Replace the top housing of the battery pack C Install capscrews finger tight D install battery packs into the iForks IMPORTANT Every time the battery pack is removed and replaced inspect battery pack and holder connections for debris Check that the contact points are not loose Tighten the contact point capscrews as required Do not leave the battery holders exposed WARNING Alkaline batteries are A not rechargeable Alkaline battery packs are not c
11. d dry place In case of damage or loss the user may request a new copy of the manual from Cascade U SER MANUAL iForks Read through Review parts Install iForks user manual system on truck Install batteries Use system Recharge or NOTE The iForks are ehangeDalgnee calibrated and ready for use at the factory non NTEP only FK0034 eps Perform Periodic Maintenance 6806956 R7 1 ARNINGS amp SAFETY MEASURES When using iForks carefully read the instructions and guidelines contained in this manual Follow the steps shown to install the iForks system onto the truck If any of the instructions are not clear please contact Cascade No riders No reaching through mast IMPORTANT Field alterations may impair performance or capability and could result in loss of warranty Consult Cascade for any required modifications No standing under load FKO112 eps CAUTION Do not use iForks display in a moist environment for an extensive period g No Stand Zone WARNING Cascade is not responsible for any physical harm done to the operator due to the presence of the display in the truck cabin WARNING Do not operate iForks unless you are a trained and authorized lift truck driver A IMPORTANT If display and or iForks are i
12. down After 20 seconds off screen Screen Shows will appear Press any button to cancel auto shut off and return to weighing mode After 2 hours of no weighing the iForks will turn off m gt NOTE To turn on refer to Weighing a Load Basic Page 9 FK0061 eps Display screen will be blank 14 6806956 R7 ATTERIES el iForks Display FUNCTIONALITY BLUE LED S DURING POWERING ON ON for 5 sec FULL BATTERY Blink Time Interval Working Mode Once every 1 5 sec Sleep Mode Once every 4 sec LOW BATTERY Working Mode Twice every 10 sec Sleep Mode Twice every 10 sec Arrows for fork will blink F1 Fork 1 F2 Fork 2 F1 amp F2 Fork 1 amp Fork 2 6806956 R7 The display will show when there is a low battery on the iforks Low Battery Display FK0062 eps IMPORTANT For three shift applications change batteries every morning NOTE Battery life will last up to 80 hours if the system is set at factory settings IMPORTANT If display and or iForks are indicating low battery iForks weighing accuracy and communication to the display can be affected Fork Low Battery The blue LED on the related fork will start blinking 2 times every 10 seconds FK0063 eps NOTE The battery packs will switch off automatically after 10 minutes of low battery 15 B ATTERIES Changing iFork Battery Packs To change b
13. e button for 3 seconds 2 Unladen load Example Pallet weight 25kg t 1 Lift pallet and load FK0052 eps NET arrow will show NET weight will show 4 NOTE Pressing the Tare button again will show the gross weight FK0054 eps When no load is on the pallet tare weight entered No load the value is zero Pallet only 6806956 R7 FK0055 eps Enter in TARE weight weight must be known For flashing digit while in entry mode pressing buttons Vv AN Decrease the value o oo ooo oo0oo0oo0o Shift to the next digit on the left Increase the value Accept the value FK0053 eps When no load and pallet on forks tare weight entered No pallet and load the value will be negative Forks only 11 FK0056 eps SING iFORKS Weighing a Load Add to the Total amp Reset To add a series of load weights and total Display will return to weighing mode Press the Total button Display will show to add to total Added NOTE For each load to be weighed and added repeat No weight can be recorded twice while adding until the display returns to weighing mode FK0057 eps During the next 3 seconds the following flashes Hold the Tare button Number of items Subtotal weighed for 3 seconds If one of the buttons is pressed during flashing TOTAL For printer option total is
14. e down Move up intensity menu Value through list through list Intensity options 0 Backlight Off 25 50 75 100 Com Port 1 Menu Bluetooth Board Com Port 1 can not be de activated FK0077 eps YH Enter Com Port 1 menu Com Port 2 Menu Printer Board When value is accepted the display will Sena return to User Settings Mode ins Menu Enter Com Port Accept Move down Move up 2 menu Value through list through list Options C20ff De activate Com Port 2 20 C2_on Activate Com Port 2 6806956 R7 ISPLAY OPTIONS User Settings Submenus Continued Alibi Memory This option is only active for forks that require NTEP or OIML certification The memory 1 Mb capacity stores every weight date time and an Alibi reference number This data can be used for dispute Once memory is full Use Entry Mode to the oldest data will be overwritten first look up alibi number information Enter alibi number based on printout or PC data Date Setting Day Date Setting Month For flashing digit while in entry mode pressing buttons A Gr on B Vv A Decrease Increase R em ue Aut Nem Date Setting Year the Value the Value E O e lt LY Shift to the next digit on the left Accept the value FKOO79 eps Time Setting Hour Time Setting Minute 6806956 R7 Continue to next page 21 ISPLAY OPTIONS User Settings Submenus Continued Alibi Memory Continued Gross shows
15. n wrench batteries NUL FK0069 eps FK0070 eps Install new batteries Install display lid and tighten NOTE Check the position and polarity of Capscrews batteries AM Saat FK0072 eps FK0071 eps 6806956 R7 ISPLAY OPTIONS mo User Settings Enter user settings 2 Choose a menu option Multiple screens User Settings will flash Menu Mode Continue to desired submenu see next page FK0073 eps Hold for 10 seconds Select menu scroll through option menu options Auto Shut Off Time Display Light Intensity Deactivate Activate Com Port 1 Bluetooth board Deactivate Activate Com Port 2 Printer board Alibi Memor 4 Exit menu Exit amp Save Changes are being saved Hold for 3 seconds Weigh Mode OR Exit without Saving FK0074 eps i Weigh Mode Press On Off button 6806956 R7 ISPLAY OPTIONS User Settings Submenus Auto Shut Off Menu Display NOTE Auto shut off is set to zero only when the Selected digit display is hardwired to the truck power minutes flashes 3 gt When value is accepted the display will FKOO75 eps return to User Settings Mode e Menu Enter auto Accept Move over shut off menu Value 4 x digit left Decrease Increase digit value digit value Backlight Intensity Menu 3 When value is accepted the display will return to User ee Settings Mode Menu Enter backlight Accept Mov
16. ndicating low battery iForks weighing accuracy and communication to the display can be affected IMPORTANT Cascade is not responsible for errors that occur due to incorrect weighing or inaccurate scales It is the responsibility of the purchaser to train their employees and to properly maintenance iForks IMPORTANT All safety regulations that apply to the truck remain valid and unchanged Always follow the operating maintenance and repair instructions for the truck CAUTION High humidity and liquid applications will damage iForks Conditions with mud grime waiter corrosive chemicals and abrasive substances can damage or effect performance of the iForks Verify iForks are pretreated with a coating to help prevent rust and corrosion CAUTION Environment and application can affect the iForks and how the system weighs Verify that iForks suit proper conditions IMPORTANT Tampering or removing iForks NTEP Security wire or label will void NTEP Certification No Pressure Wash Steam FK0113 eps Optimal Temperature Range 15 F 10 C minimum 105 F 40 C maximum 6806956 R7 NSTALLATION CAUTION Install an electrostatic discharge strap to the truck chassis to prevent electrostatic discharge damage to the iForks system 1 Install iForks IMPORTANT Truck mast must be vertical A Remove standard forks B Unlock iForks C Install iForks
17. nt display graduation setting To determine with a load watch the display numbers increment For example a display with a 5 Ib 2 kg graduation the display will show 5 Ib 2 kg 10 Ib 5 kg 15 Ib 7 kg etc A 28 Ib 13 kg load will show 30 Ib 14 kg Position load on forks raise forks FK0048 eps SING iFORKS Weighing a Load Net Tare Gross Weight FK0049 eps Net A Tare B Gross C NET The weight of the load to weigh TARE The weight of an unladen load that is not included pallet bin etc GROSS The weight of the load and unladen load weights combined Net Weighing Automatic Tare To weigh a load but disregard part of the load with an unknown weight example pallet NOTE Display must be in basic weighing mode prior to performing the following steps press on off button for 3 seconds Weight of pallet Arrow will appear next NET and display will set to zero t 1 Lift pallet FK0050 eps Gross Weight Pallet Load Weight Net value will show Load weight only Press the Tare button 10 TKO TES 6806956 R7 SING iFORKS Weighing a Load Net Tare Gross Weight Net Weighing Manual Tare To weigh a load but disregard part of the load with a known weight example pallet NOTE Display must be in basic weighing mode prior to performing the following steps press power button for 3 seconds Gross weight Hold Tar
18. ompatible with the charger Tampering with Alkaline battery packs can cause damage to the charger and battery packs FK0066 eps Charge battery packs if equipped with rechargeable batteries E Plug the charger s into 110V source The red NOTE Rechargeable batteries are NiMH with a LED s on charger s will light charge capacity of 10 000 mAh F If using single chargers charge for 8 hours Red A Lift up locking clips of charger module LED will stay on after batteries are fully charged B Position the battery packs into charger IMPORTANT When using single charger do not charge for more then 8 hours The charger does not shut off and will damage the charger The red D Push locking clips down LEDs will remain illuminated C Click batteries into charger Single Charger TTT TTT Ir J TTT IL renina J Tr 4 Timm Charging A Charge 8 Hours Maximum Smart Charger FK0109 eps FK0110 eps 6806956 R7 17 ATTERIES Changing Display Batteries if equipped Display Low battery will flash NOTE Based on usage display battery life is variable FK0068 eps The display is equipped with four AA batteries 1 Remove capscrews from display Open display and remove old lid using M5 alle
19. onds Time Setting Minute Entry Mode Guide ISSS 0 Ul I kg TIL LILI Date Setting Day For flashing digit while in entry mode pressing buttons A rs on v AN Decrease Increase go ut teon Date Setting Month the value the value oe E o oo ooo 2000 Shift to the next digit on the left Accept the value FK0083 eps Date Setting Year 24 6806956 R7 D AILY INSPECTION Check the following items below each day Refer to Service Manual 6823346 for troubleshooting maintenance and repair procedures Check upper hook engagement Inspect battery packs before battery holders Make sure that the contact points are not loose Tighten screws as required Inspect battery holders for debris or bent tabs T Remove any debris found Check that the tabs are not bent if required straighten tabs IMPORTANT The battery holder should not be left exposed Check lower hook FK0187 eps engagement Inspect bottom of forks for debris wedged between the fork and fork shoe Remove any debris found 6806956 R7 25 P ERIODIC MAINTENANCE 26 IMPORTANT Only trained and authorized personnel are allowed to service iForks Other maintenance procedures are the sole responsibility of the purchaser IMPORTANT To prevent weighing inaccuracies the end user is responsible to check accuracy on a regular basis at intervals that best fit their application and requirements
20. onths for single shift operations or whenever any defect or permanent deformation is detected Severe applications will require more frequent inspection FORK LOWER HOOKS CARRIAGE Inspect fork hooks and carriage bar clearance NOTE Use go no go Wear Gauge Part No 209560 Class ll or 209561 Class III A Inspect the fork lower hooks and carriage bar If the gauge fits between the carriage bar and lower hook repair or replacement is needed B nspect the upper carriage bar If the gauge arrow UPPER CARRIAGE BAR touches the carriage bar repair or replacement is needed oF EO C spect the fork upper hooks If the gauge arrow OK G 45 touches the hook repair or replacement is needed j 5 Inspect forks NOTE Use fork calipers on forks up to and including 4 in 100 mm thick Fork calipers indicate a 10 wear factor if the calipers can pass over the blade cross section FORK UPPER HOOKS A Remove fork shoe from forks For reassembly tighten capscrews to a torque of 80 ft lbs 108 Nm B Measure the fork shank thickness with the caliper outer teeth approximately 2 in 50 mm above top of blade Hold this setting for step C A C Position the caliper inner teeth on the fork arm blade approximately 2 in 50 mm out from the face of the shank e Ifthe inside teeth of the caliper hit the fork it has less than 10 wear and requires no replacement
21. orea 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 RAVAS 11 2014 Cascade do Brasil Pra a Salvador Rosa 131 141 Jordan polis S o Bernardo do Campo SP CEP 09891 430 Tel 55 13 2105 8800 Fax 55 13 2105 8899 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 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 Part Number 6806956 R7
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