Ravas iForks Service Manual
  1. Manuals
  2. Brands
  3. Ravas Manuals
  4. Forklifts
  5. iForks
  6. Service manual

Ravas iForks Service Manual

Hide thumbs Also See for iForks:
Table of Contents

Advertisement

Quick Links

S
ERVICE MANUAL
&
IMPORTANT: Tampering or removing iForks
NTEP Security wire or label will void
NTEP Certification. If NTEP iForks require
service, the forks will need to be recertified.
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 6823346-R3

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the iForks and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Ravas iForks

Summary of Contents for Ravas iForks

  • Page 1 & IMPORTANT: Tampering or removing iForks NTEP Security wire or label will void NTEP Certification. If NTEP iForks require service, the forks will need to be recertified. IMPORTANT: iForks system (forks and display) are paired and calibrated as a set.

  • Page 2: Table Of Contents

    Reset Current Parameter and Calibration Settings To Default (Factory) Settings Three Part Calibration Calibration Introduction Prior To Calibration Zero Calibration Corner Calibration Weight Calibration Display Pairing The Display To iForks Wire Harness Wire Harness Removal New Wire Harness Installation 6823346-R3...

  • Page 3: Introduction

    This manual provides Periodic Maintenance, Troubleshooting and Service for Cascade-Ravas iForks. In any communication about the iForks, refer to the product catalog and serial numbers stamped on the side of the fork shank. Refer to the back cover for Cascade contact Stamped Catalog Number information.

  • Page 4: Periodic Maintenance

    FK0176.eps the capscrews are tight and contact tabs 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.
  • Page 5 ERIODIC MAINTENANCE 2000-Hour Maintenance FORK LOWER HOOKS, CARRIAGE After 2000 hours of truck operation, forks in use shall be inspected at intervals of not more than 12 months Wear (for single shift operations) or whenever any defect or Gauge permanent deformation is detected. Severe applications will require more frequent inspection.

  • Page 6: Preparation

    Preparation Tool Required 2.1-1 Digital Multimeter Kit 213867 In addition to a normal selection of technician's hand tools, the following are needed to troubleshoot the iForks system: • Digital Multimeter, test leads and adapter (Service Kit 213867) AC0311.eps Before Starting 2.1-2...

  • Page 7: Error Messages

    Wait for display to return to original unit between units format (lb or kg). format (lb or kg). ErrF1 Problem with iFork 1 (no communication). Restart display. Restart iForks & display. ErrF2 Problem with iFork 2 (no communication). Restart display. Restart iForks & display. ----- Load cell signal negative.

  • Page 8: Basic Troubleshooting

    • Moisture in the electronics or load cells. • Low Battery – iForks indicating low battery can affect weighing accuracy and communication to the display. Solution Problem Nothing works.
  • Page 9 ROUBLESHOOTING Basic Troubleshooting (continued) Problem Solution System is inaccurate but Calibrate the system. Refer to Section 3.2. linear. Display shows a positive or negative, weight and the display wont zero. Calibrate the system. Refer to Section 3.2. The scale reacts normal when a load is placed on the scale.

  • Page 10: Check Display Power

    ROUBLESHOOTING Check Display Power 2.3-1 - Check fuses Start - Check power to power supply Power Supply 6 or Check voltage going Equipped voltage 12 VDC into the display with Battery With the batteries installed into the display, check the voltage Output Problem Troubleshoot display,...

  • Page 11: Check Weight Readout At Each Load Cell

    ROUBLESHOOTING Check Weight Readout At 2.3-2 Each Load Cell Use this procedure to determine if the display is showing instability problems (weight changes). NOTE: For this procedure, a weight of at least 50 lb. (23 kg) is required. If required, turn on display. Verify that the display is zeroed.
  • Page 12 ROUBLESHOOTING Check Weight Readout At 2.3-2 Each Load Cell (continued) Position C Move the weight to position C, as shown. Note the weight shown on the display. Position D Move the weight to position D, as shown. Note the weight shown on the display. If the any of weights are not within weight ±A (chart FK0256.eps below) of each other, the load cell may require further...

  • Page 13: Display Debug Mode

    ROUBLESHOOTING Debug Mode 2.3-3 Load Cell Layout and Corresponding Display Arrow NOTE: This procedure is recommended for scale technicians. Debug mode is a useful service tool for dealing with display instability problems or when calibration is lost. Each iFork assembly transmitter module has two AD (analog-to-digital converter) chips and each load cell has one AD chip.
  • Page 14 ROUBLESHOOTING Debug Mode (Continued) 2.3-2 The display will show the AD count for Corner A. An arrow over e1 will show. Press the "Total" button to view the next AD count. The display will show the AD count for Corner B. An arrow over e2 will show.

  • Page 15: Hardware

    ROUBLESHOOTING Hardware Fork Assembly 2.4-1 Start Place a weight on each of the bolts of the iForks assemblies Display Display Weigh a normal to heavy load. shows weight shows weight Press the "tare" button to reset identical on all identical on all the display to zero.

  • Page 16: Wire Harness

    ROUBLESHOOTING Wire Harness 2.4-2 Start With fully charged batteries and the iFork assemblies switched on, check the voltage of battery holder. Check cables, especially where the Voltage cable enters the load cell connector. 6 VDC Move the cable and observe the display. Battery holder is faulty, Cable or connector Display...

  • Page 17: Load Cells

    ROUBLESHOOTING Load Cells 2.4-3 NOTE: Cascade recommends using Debug Mode first. If further troubleshooting is required, follow this flow chart. Testing Individual Load Cells – With a load cell disconnected from the iFork system: Start • Measure resistance. The resistance between the power + (red) and signal + (green) should be equal, within 2 ohms, of the resistance between power - (black) and signal - (white).

  • Page 18: Display

    ROUBLESHOOTING Display 2.4-4 Solution Problem Disconnect the display from the system. • If the display remains unstable or does not react to being disconnected, the board is The display is unstable and faulty. does not react to weights. • If not, there may be a problem with the load cell.
  • Page 19 ROUBLESHOOTING Display (continued) 2.4-4 Solution Problem Verify that the parameter setting, parameter 60 is set correctly: Display shows low battery • If equipped with power supply, parameter 60 indication and remains on should be set to 12V. • If equipped with batteries, parameter 60 should be set to 6V.

  • Page 20: Printer

    ROUBLESHOOTING Printer 2.4-5 Problem Solution External Power Supply: • Check voltage output. If voltage is below Low battery indication on 11.8 VDC, check converter or fuse for damage. or unstable while printing • With printer installed, check amperage to and from convertor.

  • Page 21: Parameter Settings

    ERVICE Parameters IMPORTANT: Parameters should only be changed when calibrating (Section 3.2), advised by Cascade or as a last option. Contact Cascade before making changes to the parameters. Accessing The Parameters 3.1-1 Menu If required, turn on display. Press and hold the "On/Off" button for 30 seconds. The display will show "P_ _00".

  • Page 22: Changing A Parameter

    ERVICE Changing A Parameter's Setting 3.1-2 NOTE: Refer to the Parameter Table (Section 3.1-3) on the following pages to determine the parameter number. Access the Parameters Menu as described in Section 3.1-1. Enter the parameter number of the parameter setting to change.
  • Page 23 ERVICE Changing A Parameter's 3.1-2 Setting (continued) If required, change the parameters value. Refer to the Entry Mode Guide (below) to scroll or change the values (A and B). Always accept the value by pressing the "Zero" button, C. Entry Mode Guide Example: Parameter 61 Example: Parameter 66 Selected value will flash...

  • Page 24: Parameter Table

    ERVICE Parameter Table 3.1-3 Default Settings Parameter Software Number Function Version Available Setting Options 1 = kg Weight units 2 = lb Smallest graduation step for multirange 0.1, 0.2, 0.5, 1, 2, 5, 10, 20, 50 Biggest graduation step for multirange 0.1, 0.2, 0.5, 1, 2, 5, 10, 20, 50 Number of divisions for every range 1000...
  • Page 25 ERVICE Parameter Table (continued) 3.1-3 Default Settings Parameter Software Number Function Version Available Setting Options Printout format for com1 and com2 2.15 & before stnd stnd stnd, total, confi 2.18 Printout format for com2.1 Header lines added 0 – 3 Baudrate com2 2.15 &...
  • Page 26 Compensation factor digital corner D 1.000 1.000 are calibrated (corner calibration). NOTE: Only enter this parameter to Pairing iForks to the display via establish a complete new bluetooth bluetooth connection (Refer to Section connection. Enter last 6 characters 3.3-1) of MAC address of Fork 1 and Fork 2 or cancel by pressing "CLR"...
  • Page 27 ERVICE Parameter Table (continued) 3.1-3 Default Settings Parameter Software Number Function Version Available Setting Options Default settings without changing 2.15 & before calibration Reset current parameter settings to default (factory) settings. 2.18 NOTE: Calibration settings will not change. Default settings with changing 2.15 &...

  • Page 28: View Current Calibration Settings

    ERVICE View Current Calibration 3.1-4 Settings NOTE: Some software versions may not offer this parameter. Access the Parameters Menu as described in Section 3.1-1. Verify that Parameters 1 through 5 are correct according to US (EU) values found on the sticker on the display. Refer to "Changing A Parameter's Setting", Section 3.1-2, Steps 2, 3 and 4.
  • Page 29 ERVICE View Current Calibration 3.1-4 Settings (continued) The following values will show on the display in sequence: Unit type used for calibration Gravity value Zero calibration value and AD value. Weight calibration value(s) and AD values. NOTE: If one weight was used for weight calibration, "Weight 2"...

  • Page 30: Change Units

    (lb or kg). CAUTION: Verify that the display is version 2.13 or greater. Earlier versions before 2.13 will require recalibrating the iForks. Contact Cascade. Access the Parameters Menu as described in Section 3.1-1. Change the current parameter menu number to "01".
  • Page 31 Update Parameters 2 through 5 referencing the chart below. Refer to "Changing A Parameter's Settings", Section 3.1-2 to update the parameters. NOTE: The following changes are for standard iForks. If the iForks system is customized, contact Cascade on updating Parameters 2 through 5. Parameter 2 Parameter 3...

  • Page 32: Reset Current Parameter And Calibration Settings To Default (Factory) Settings

    ERVICE Reset Current Parameter 3.1-6 and Calibration Settings To Default (Factory) Settings IMPORTANT: Initial parameter settings are backed up at the factory. The following procedure recovers factory parameter settings. Access the Parameters Menu as described in Section 3.1-1. Change the current parameter menu number to "91". Refer to "Changing A Parameter's Settings", Section 3.1-2, Steps 2 and 3.

  • Page 33: Three Part Calibration

    • Corner Calibration – Takes any inconsistency between the load cells (corners) and equalizes them with each other. • Weight Calibration – Determines and sets the weight range for the iForks system by using a sample of known weight(s). When to Calibrate ■ Calibration Procedures ◆...

  • Page 34: Prior To Calibration

    Fork 2 Position C (toward fork tip) Position C Position A FK0346.eps Position B • Logistics iForks – Locate hidden load cells. NOTE: Load cell positions are the same as the standard iForks. Mark locations with removable ink or similar Flex Joint FK0347.eps...

  • Page 35: Zero Calibration

    This calibration procedure defines the zero point of the system. If required, turn on display. Slide an empty pallet on the iForks (and/or if desired, use a protective cover). Raise the iForks so that the pallet/cover is not touching the ground.
  • Page 36 ERVICE Zero Calibration (continued) 3.2-3 After the system has zeroed, the display will show "AP" or "AP 0". FK0363.eps Software Versions 2.13 or newer – Then the display will show "done". • While "done" shows, press and hold the "Zero" button for three seconds.

  • Page 37: Corner Calibration

    ERVICE Corner Calibration 3.2-4 Corner Calibration is the second procedure of the Three Part Calibration. This calibration procedure takes a reading of a weight's electrical output signal at each load cell (corner) location. The four readings are then adjusted to be equalized for accuracy of weight. IMPORTANT: This procedure is set up where Fork 1 is the left fork and corner positions are as shown on page 32.
  • Page 38 ERVICE Corner Calibration (continued) 3.2-4 "Corn A" will show on the display. Place a weight on pallet, position A. Position A Press the "Zero" button, to accept the weight (load cell output) value. A new value will show on the display (example 45144). Then "Corn B"...
  • Page 39 Move the same weight to position B. NOTE: To locate Position B on a Logistics iFork, refer to the illustration shown under "Logistics iForks – Locate hidden load cells", page 32. Press the "Zero" button, to accept the weight (load cell output) value.
  • Page 40 Move the same weight to position C. NOTE: To locate Position C on a Logistics iFork, refer to the illustration shown under "Logistics iForks – Locate hidden load cells", page 32. Press the "Zero" button, to accept the weight (load cell output) value.
  • Page 41 ERVICE Corner Calibration (continued) 3.2-4 Position D Move the same weight to position D Press the "Zero" button, to accept the weight (load cell output) value. A new value will show on the display (example 45582). Then "Done" will show on the display. FK0368.eps 6823346-R3...
  • Page 42 The display will return to normal weighing mode. NOTE: If the display has a negative weight, perform the Zero Calibration, Section 3.2-2, with the pallet/cover remaining on the iForks. Then continue to the next procedure, "Weight Calibration", Section 3.2-5. FK0406.eps...

  • Page 43: Weight Calibration

    Weight Calibration 3.2-5 Weight Calibration is the third procedure of the Three Part CAUTION: The iForks system tolerance can be Calibration. This procedure uses the sample of weights to achieved using three known weights (0.1%). If the determine the curve of how the system measures weight handled product weight range is very consistent, 1 or 2 based on three known weights.
  • Page 44 ERVICE Weight Calibration (continued) 3.2-5 Software Versions 2.13 and newer – Press the "Zero" button to accept the unit. An arrow above "e1" will show on the screen. Press the e1 arrow will flash "Zero" button to begin calibration for the first (known) weight, Weight 1.
  • Page 45 ERVICE Weight Calibration (continued) 3.2-5 Allow the load to rest for 5 seconds on the iForks. Press and hold the "Zero" button for three seconds. The screen will show "Adj08" and then will count down from 8 while the display records the weight. The screen will return to showing the weight and an arrow flashing over "e1".
  • Page 46 Place a Weight 2 on the pallet/cover so that the weight is centered evenly between the four corner positions. Weight 2 Allow the load rest for 5 seconds on the iForks. Press and hold the "Zero" button for three seconds. The screen will show "Adj08" and then will count down from 8 while the display records the weight.
  • Page 47 Place a Weight 3 on the pallet/cover so that the weight is centered evenly with between four corner positions. Allow the load to rest for 5 seconds on the iForks. Press and hold the "Zero" button for three seconds. The screen will show "Adj08" and then will count down from 8 while the display records the weight.
  • Page 48 To Store Zero Calibration Value: display will show "Set" while storing Press and information in the memory. hold the "Zero" button for three seconds The display will return to normal weighing mode, showing the current weight on the iForks. FK0261.eps 6823346-R3...
  • Page 49 ERVICE Weight Calibration (continued) 3.2-5 Remove the weight from the iForks. In the following order confirm that each weight shown on the display matches the rated weight value: No weight Weight 1 Weight 2 Weight 3 Cycle through the order listed above one to five times.

  • Page 50: Display

    For situations where the dual Bluetooth pc board has been ® replaced or the complete display is replaced, it is necessary to pair the display to each of the iForks Bluetooth receivers. ® Option 1 Determine the MAC address for each iFork receiver.
  • Page 51 ERVICE Pairing The Display To iForks (continued) 3.3-1 On the display, access the Parameters Menu, as described in Section 3.1-1. FK0274.eps Change the current parameter menu number to "85". Refer to "Changing A Parameter", Section 3.1-2, Steps 2 and 3.
  • Page 52 ERVICE Pairing The Display To iForks (continued) 3.3-1 The display will show "F2Adr". Perform one of the following: • To change the MAC address for Fork 2, press the "Zero" button. • To skip changing the MAC address for Fork 2, press the "On/Off"...
  • Page 53 ERVICE Pairing The Display To iForks (continued) 3.3-1 The display will return to the parameter menu, showing the next available parameter. Press the "On/Off" button times to save and return to normal weighing mode. Power off the display by pressing and holding the "On/ Off"...

  • Page 54: Wire Harness

    ERVICE Wire Harness Wire Harness Removal 3.4-1 The following procedure can be performed with the iForks mounted on the truck carriage. Remove fork shoe from fork arm: Standard iForks Standard iForks – Remove capscrew and nut from fork shoe. Slide fork shoe from fork arm. Keep track of cover spool, capscrew and nut.
  • Page 55 Standard iForks – Remove capscrews and tolerance ring from load cells. If equipped with level sensor, remove capscrews. Logistic iForks – Remove capscrews from load cells. Level If equipped with level sensor, remove capscrews. Sensor...

  • Page 56: New Wire Harness Installation

    Remove old wire harness as described in Section 3.4-1. Place new double-sided tape in the fork arm wire channels and shank cut out. Standard iForks – Install two tolerance rings to each load cell. Install load cells and level sensor (if equipped) into fork arm.
  • Page 57 Cover Plate Mount the battery carrier to the cover plate and tighten Capscrew capscrews to 7 ft.-lbs. (9.5 Nm). Standard iForks – Install cover spools to the load cells. iFork Shoe Capscrew Cover Spool FK0137.eps Install fork shoe: Standard iForks –...
  • Page 58 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 5570 Timberlea Blvd. Praça Salvador Rosa, U.S. Headquarters 2201 NE 201st Mississauga, Ontario 131/141-Jordanópolis, Fairview, OR 97024-9718...

This manual is also suitable for:

Iforks pro

Table of Contents