iForks Order Picker User Manual
Contents
1. Fork 6182775 3 NSTALLATION Locate and mount the display Find a suitable location for readout and easy access to display Cabin Roof Side Rail er OR Dashboard ce Display Li FK0038 eps Install display bracket and support if required A Install bracket to display B Install bracket display to the support 4 6182775 NSTALLATION Connect cables A Connect the sensor connectors to each sensor receptacle B Connect cable end from the display to the junction box C Connect the RS232 cable to a laptop handheld device or separate inventory control system D Cut the provided fuse wire E Connect the fuse inline with the positive wire red US brown EU to the display cable F Connect the display negative wire black US blue EU to the negative battery terminal G Connect the detached end of the fuse to a switched positive power source oe D Sensor Sensor A Receptacle Connector FKO197 eps Sensor Connectors To Fork 1 To Fork 2 Red US T nase E Brown EU onnection Black US Blue EU E Fuse 3 15A Cascade Part No 6167147 G Ground 6182775 SING DISPLAY U Functions Left of Display When lt appears The weighing system wn including load is stable gt 0 lt The weight2. J SEP manva Q Order Picker 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 6162775 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 Display Messages USING iFORKS Prior To Weighing Handling Loads To Weigh A Load Normal Weighing Mode Obtaining Net Tare Gross Weight Adding and Totaling A Group of Load Weights Sampling Weight Sampling Quantity AUTO SHUT OFF DISPLAY OPTIONS User Settings PRINTER EQUIPPED Print Weight Print Total Weight Change Time amp Date Printout PERIODIC MAINTENANCE L pes L 4 i mh eh L OI OICINIDILI OlLOLOIDIOINIDIG IG IN NININININ OUR ion ere re i 6182775 O VERVIEW This manual describes the installation and use of the Order Picker iForks Read this manual thoroughly prior to installation and operation Be sure to know and understand all installation processes operating procedures and safety operations Perform installation and operation in the order shown in this manual This manual should be kept in a safe and dry place In case of damage or loss request a new copy of the m
3. i i a a enter the menu option s NOTE Multiple screens will A off Auto Shut Off Time Display STERIC flash while button is held Light Light Intensity Conn1 Deactivate Activate Com Port 1 Bluetooth board Conn2 Deactivate Activate Com Port 2 Printer board NOTE Communication Port 1 can not be deactivated Exit User Settings To Save and Exit To Exit without Saving Press and or hold the Zero button for three seconds 1 Press On pa Off button 2 2 A screen The display will will show as return to normal changes are weighing mode saved 3 The display will return to normal weighing mode FK0224 eps 6182775 19 D ISPLAY OPTIONS User Settings Continued Change Submenu Settings NOTE To access User Setting Submenus refer to the previous page Enter User Settings Menu to select the appropriate submenu Auto Shut Off Menu Display NOTE Auto shut off is set to zero only when Change time and the display is hardwired to the truck power accept the value ressing th Selected digit py pressing the minutes flashes Zero button When value is accepted the display will return to the User Settings FK0075 eps Menu previous A page s performed on the previous Accept Move left to section the Zero button is Value next digit pressed to enter the submenu Decrease Increase digit value digit value Backli
4. Daily Inspection Check the following items below each day 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 Inspect fork pin connections 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 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 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 6182775 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
5. o oo 200 o000 Shift to the next digit on the left 6182775 C gt 0 lt K d Accept the value 17 J sinsirorks Sampling Quantity Continued 6 Press and hold the Zero button for two seconds 7 The display will show the quantity of items currently being weighed Press the On Off button to return to normal weighing mode NOTE If a printer is installed item weight print label PcWt sampled and quantity print label Qty will be printed Refer to Printer Equipped section page 23 UTO SHUT OFF gt 0 lt ner pes ot 2 ed gt 0 lt H gt T lt FK0229 eps a After 2 minutes of no action 1 Onthe display a countdown screen shows Press any button to cancel auto shut off and return to normal weighing mode 2 After 20 seconds of no further action off will appear on the screen The display will turn off 3 After 2 hours of no weighing the iForks will turn off NOTE To turn on refer to To Weigh A Load section page 10 FK0232 eps 18 6182775 D ISPLAY OPTIONS User Settings Enter User Setting Menu User Settings Menu Option Name Continue to selected gt submenu go to next page FK0223 eps To enter user settings hold Choose a user setting menu Press the Zero button to the Total button for ten option by scrolling through the list confirm the selected user seconds Options available are as follows setting menu option and
6. example pallet NOTE The display must be in basic weighing mode prior to performing the following procedure 5 6182775 Position a pallet or bin Tare weight and load Net weight on the iForks and raise the iForks The Gross weight will show on the display Press and hold the Tare button for three seconds Enter the known Tare weight value of the pallet or bin Use the Entry Mode Guide below as an aide to enter the value Tare Weight FK0235 eps Entry Mode Guide Current digit to change will flash The display will show the Net weight and the Net arrow willappear The arrow indicates only Net values will show e If the load is removed from the pallet or bin the display will show zero e Ifthe pallet or bin and load are removed a negative weight Tare weight will show NOTE Pressing the Tare button will show the Gross weight Use the following buttons to enter the value The current digit to change will flash Vv a Decrease the value Increase the value lt pam Shift to the next Accept the value digit on the left Net Arrow will appear 5 Net Weight FK0231 eps 13 J SING irorKs 14 Adding And Totaling A Group Of Load Weights 1 If required position a pallet or bin on forks Raise iForks and pallet or bin 2 Zero the display 3 Add a load to weigh to the iForks 4 Press the Total button This will be
7. Button NOTE If no button is pressed while the display screen flashes the total weight and counter value stays in the display s memory The system will return to FK0222 eps normal weighing mode 6182775 15 J SING irorKs Sampling Weight Perform the following procedure to determine an unknown item weight by sampling the weight of the number of the same kind of items The number of items placed on the iForks determines the accuracy of the sampling The greater the weight difference the greater accuracy The standard sampling amount is 10 items 95 items maximum A display equipped with a printer is recommended for this section NOTE The total weight of items must be greater than 22 Ib 10 kg 1 Position a pallet or bin on forks Raise iForks and pallet 1 or bin 2 If required zero the display FKO238 eps 3 Press Sampling button on the display 4 The display will show Add 10 and pcs 5 Choose a quantity of items to weigh Add 10 is the standard To change the number to another quantity use the Tare up and Total down buttons to scroll through the list The following quantity options are available 10 20 50 95 1 2 and 5 6 Add the number of items based on the quantity entered into the display onto the pallet or into the bin 7 Press and hold the Zero button for two seconds NOTE If the error message Err05 appears the total sampling weight is too lo
8. 65 6795 7555 Fax 65 6863 1368 Part Number 6182775
9. 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 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 RAVAS 09 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
10. anual from Cascade Manuals are available at www cascorp com under the support tab Technical Support Manual link NOTE For troubleshooting refer to iForks Service Manual U SER MANUAL iForks Oo wt tis Read through Review parts Install Order Picker this manual iForks system to an operator compartment FK0189 eps Use system Perform Periodic Maintenance 6182775 1 ARNINGS amp SAFETY MEASURES When using iForks carefully read the instructions and IMPORTANT Field alterations may impair performance guidelines contained in this manual Follow the steps or capability and could result in loss of warranty Consult shown to install the iForks system onto the truck If any of Cascade for any required modifications the instructions are not clear please contact Cascade CAUTION Do not use iForks display in a moist environment for No riders No standing under load an extensive period OO WARNING Cascade A is not responsible for e any physical harm done to the operator due to the presence of the display in the truck cabin No Stand Zone WARNING Do not operate iForks unless you are a trained and authorized lift truck driver IMPORTANT Cascade is not responsible for errors that occur due to incorrect weighing or inaccurate scales Itis the responsibility of the purchaser to train their employees and to properly mai
11. econds 6182775 7 a U SING DISPLAY Display Messages FK0085 eps Error Messages Display Shows Meaning To Exit Error Mode ErrO1 Load cell signal is unstable Automatic Err02 iForks are overloaded Automatic after removing weight Err03 Gross weight is negative This action is not allowed Automatic Err04 Out of zero range Press any button Err05 Sampling accuracy too low Press any button Err06 Input signal too high Automatic after correcting input Err08 Calibration out of range negative Automatic Err09 Calibration out of range signal too low Automatic Err10 as count 2nd 3rd point is lower than count 1st 2nd Automati Err14 Calibration setpoint value 2 lt setpoint value 1 This is not allowed Automatic Err98 a all calibration must be higher than Automatic Err99 Button pressed or another action is performed while toggling Wait for display to return to original unit between units format Ib or kg format Ib or kg ErrF1 Problem with iFork 1 no communication Restart display Restart iForks amp display ErrF2 Problem with iFork 2 no communication Restart display Restart iForks amp display Load cell signal negative Lift up the forks from the ground ErrCS Problem with correction sensor Contact the Cascade Service department 6182775 SING iFORKS Prior To Weighing Verify the display shows zero If necessary press the Z
12. ero button Verify iForks are free of obstacles prior to zeroing Optimal Temperature Range SE 15 F 10 C minimum 105 F 40 C maximum FK0208 eps Handling Loads Center load on forks and pallet load must be flat FK0209 eps x XxX FK0210 eps FK0211 eps 6182775 J sinsirorks To Weigh A Load Normal Weighing Mode IMPORTANT e Atinitial daily start up allow 3 5 minutes for iForks system to warm up before weighing loads e The system will not weigh correctly if front face or bottom of iForks touches the load or pallet e Unstable weight readings indicate debris ie wood chips between fork and fork shoe e When weighing liquids more time is needed for display to show a steady weight 1 On the display press the On Off button Wait five seconds If required press 2 Display will zero If necessary zero manually by the Zero button pressing the Zero button to manually zero the display 3 Position the load on the iForks and raise the iForks FK0212 eps 4 The display will show the weight of the load If needed the display may need more time to show a steady weight Before next weighing verify that the display is zeroed 10 6182775 _ U SING iFORKS Obtaining Net Tare Gross Weight Net A Tare B Gross C Net The weight of the load being weighed Tare The weight of an unladen load that is no
13. f the digit flashing Manual Tare An entered tare weight at any moment Increase the value of the digit flashing Add To Total Weighed load is added to total weight If printer is installed a printout is made Check subtotal and print total Sampling item weight s Determine an unknown item weight by sampling a set quantity of the same kind of items Standard sampling amount is 10 items Sampling Determine a quantity of the same items sampled with an known item weight Shift to the next digit on the left Sampling On Turn the display on OR Toggle Units Change the units on the display between kg and Ib 6 6182775 On Off Off Turn the display off Clear entry U SING DISPLAY Other Features Display Menus The following menu options are available Weigh Mode Options Manual zero Net Tare Gross Auto Manual Tare Add and total a group of load weights Sampling weight On off or Toggle units User Settings Auto shut off time Light intensity Deactivate Activate Com Port 1 Deactivate Activate Com Port 2 Alibi Memory 4 Refer to Display Options User ROOF I Eps Settings Section page 19 Toggle Units Ib and kg To view a displayed value in another unit format kg or lb perform the following The toggled value will appear for five seconds The original unit format will resume FK0042 eps 1 Hold for three s
14. ght Intensity Menu Scroll through the list of intensity 1 options and accept the value by pressing the Zero button When value is accepted the display will return to the User Settings FKOO76 eps Menu previous As performed on the previous Accept Move down Move up page section the Zero button is Value through list through list pressed to enter the submenu Intensity options percentage O Backlight Off 25 50 75 100 and accept the value by pressing Com Port 2 Menu Printer Board 1 Scroll through the list of options the Zero button FK0078 eps As performed on the previous Accept Move down Move up section the Zero button is Value through list through list pressed to enter the submenu Options C20ff De activate Com Port 2 C2_on Activate Com Port 2 20 When value is accepted the display will return to the User Settings Menu previous page 6182775 P RINTER EQUIPPED Print Weight 1 if required zero the display 2 Position load on iForks and raise iForks 3 Weigh the load FK0241 eps B G 250 0 Ib T 25 0 Ib N 275 0 Ib 4 Press the Total button to print Nr 1 10 15 09 17 45 5 Printer will print out load weight NOTE This will add the weight to the total weight Print Total Weight 1 Press and hold the Total button for three seconds 2 Press the Tare button to print IMPORTANT The load must be removed from the iFor
15. gin an adding sequence of the group to be weighed 5 The display will show Added and return to normal weighing mode 6 Add the next load to the pallet with previous load s 7 Press the Total button to add the weighed load to the total NOTE If a printer is installed the Gross Net and Tare weights will be printed 8 The display will show Added and return to weighing mode 9 Repeat Steps 6 8 until all loads to be weighed are on the pallet and added to the total Procedure continued on next page FK0236 eps 6 Additional Load s FK0237 eps NOTE At any time during weighing and adding the subtotal can be viewed by pressing and holding the Tare button for three seconds The counter number of loads weighed and subtotal will flash for three seconds 6182775 _ U SING iFORKS Adding And Totaling A Group Of Load Weights Continued 10 When all loads are weighed remove the loads from the iForks and pallet or bin 11 Press and hold the Tare button for three seconds to view the total weight 12 The counter number of loads weighed and total weight will flash for three seconds 13 While the display screen flashes the following can be performed e Press the Total button to print the total and reset the total weight to zero and the counter to zero e Press the On Off button to reset the total weight to zero and the counter to zero Total Button On Off
16. ks before pressing the Tare button 3 Printer will print out the total load weight Tot B G 2000 0 Ib Tot T 50 0 Ib Tot N 1950 0 lb Tot Nr 5 10 15 09 17 55 FK0082 eps 6182775 21 a pP RINTER EQUIPPED Change Time amp Date Printout NOTE For Steps 2 6 refer to the Entry Mode Guide below to change the time and date values 2 Enter the hour Press and hold the Sampling button for 8 seconds 3 Enter the minute Entry Mode Guide 4 Enter the day Use the following buttons to change the value The current digit to change will flash Vv a MM Enter the month Decrease Increase en Someta the value the value o oo ooo 0000 Shift to the next Accept the value digit on the left FK0083 eps 6 Enter the year The display will return to normal weighing mode NOTE If a printer is installed the date and time will print with weight information 22 6182775 P ERIODIC MAINTENANCE 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 Development of a periodic schedule will prevent faulty readings Cascade recommends a minimum interval of every 12 months or 2000 hours whichever comes first
17. ntain iForks No Pressure Wash Steam 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 water 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 Optimal Temperature Range iForks and how the system weighs Verify that iForks 15 F 10 C minimum suit proper conditions 105 F 40 C maximum 6182775 NSTALLATION CAUTION Install an electrostatic discharge strap to the truck chassis to prevent electrostatic discharge damage to the Order Picker iForks system Locate and mount bracket and junction box underneath the operator compartment NOTE The junction box and bracket should be close enough to the iForks so that each sensor connector can reach the junction box and each sensor receptacle Operator Compartment Junction Box Bracket Install iForks underneath the front operator compartment A Install user supplied pin into the horizontal holes located on the block on the fork B Secure the pin for each fork If required secure the back of the fork at the vertical hole User Supplied Pin A User Supplied Pin
18. shown is within the zero range NET The display is showing the net weight When Y appears e1 e2 e3 F1 F2 M Weight shown weight that ran Weight shown weight that ran Weight shown weight that ran iddle of Display is in 44 Ib 2 kg steps only for ges 0 441 Ib 0 200 kg is in 1 1 Ib 5 kg steps only for ges 441 1102 Ib 200 500 kg is in 2 2 lb 1 kg steps only for ges 1102 4850 Ib 500 2200 kg Fork 1 relay setpoint 1 is activated Fork 2 relay setpoint 2 is activated Right of Display When the following appears kg Ib Weight shown is in pounds Weight shown is in kilograms Quantity displayed pcs is the number of items on the scale When mm appears the weight shown is negative 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 FK0207 eps Button Names 3 Second Button Press Code Entry A 5 digit code useful for a weighing system connected to peripheral equipment for later processing Short Button Press Entry Mode Enter accept value Zero Zero Setting Manually ID CODE zeros the display Automatic Tare Allows the tare weights to be reset to zero automatically Added and subtracted weights can be determined Decrease the value o
19. t included pallet bin etc Gross The combined weight of the load and unladen load Obtain Net Weight Using Automatic Tare To weigh a load Net weight but disregard part of the load Tare weight with an unknown weight example pallet perform the following procedure NOTE The display must be in normal weighing mode prior to performing the following procedure 1 If required zero the display a 2 Position a pallet or bin Tare weight on forks and raise t 2 forks The weight of the pallet or bin will show on the T display FK0213 eps 3 Press the Tare button 4 The display will be set to zero and the Net arrow will appear The arrow indicates only Net weight values will show on the display NET Arrow 4 Procedure continued on next page 6182775 11 12 U SING iFORKS Obtaining Net Tare Gross Weight Continued Obtain Net Weight Using Automatic Tare Continued 5 Add a load to weigh onto the iForks 6 The display will show the Net weight only the load s weight FK0214 eps View Gross weight Tare weight Net weight Press the Tare button to view the Gross weight Gross Weight Example Pallet weight Load weight FK0217 eps Net Arrow will Tare button disappear 6182775 _ U SING iFORKS Obtaining Net Tare Gross Weight Continued Obtain Net Weight Using Manual Tare To weigh a load but disregard part of the load with a known weight
20. w Press any key to return normal weighing mode Remove the items being weighed Repeat Steps 3 7 Adjust the quantity in Step 4 to a higher quantity KO 89S 8 Sampling is complete The display will show the total number quantity of pieces on the forks Press the On Off button return to normal weighing mode NOTE If a printer is installed item weight print label PcWt sampled and quantity print label Qty will be printed Refer to Printer Equipped section page 23 16 6182775 _ U SING iFORKS Sampling Quantity Perform the following procedure to determine the quantity of the same items in a sampling using a known weight of one item The items are placed on the iForks and weighed prior to entering the known weight 1 Position a pallet or bin on iForks Raise fork and pallet or bin 2 If required zero the display 3 Place the items onto the pallet or into the bin 1 FK0240 eps 4 After the weight shows on the display press and hold Sampling button for three seconds 5 A previous item weight will show on the display Press the Zero button to accept the value or change the value using the Entry Mode Guide below as an aide to enter the weight value Entry Mode Guide Current digit to change will flash flash Bi v Use the following buttons to enter the value The current digit to change will AN Decrease Increase the value the value
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