Cascade KOOI ROLLERFORKS User manual

Manual Number 6921954
Cascade KOOI is a Registered Trademark of Cascade Corporation
SER MANUAL
ROLLERFORKS®
U

16921954
Table of Contents
Denitions ............................................................................... 2
Note.......................................................................................... 2
Quality standards, norms and directives .......................... 2
Introduction............................................................................. 2
Safety....................................................................................... 3
Type plate ................................................................................ 4
Type Indication – Explanatory Notes.................................. 4
Load Capacity ........................................................................ 5
Putting the ROLLERFORKS® into service ......................... 6
Mounting the ROLLERFORKS® ........................................... 7
Instructions for equalising.................................................... 7
Picking up a load with the ROLLERFORKS® .................... 8
Dividing 2 packages with the ROLLERFORKS® ................ 9
Inspection and Maintenance............................................... 10
Instructions for replacing the cartridges........................... 11
Instructions for replacing the tip ........................................ 11
Instructions for replacing the support rollers................... 12
Torques .................................................................................... 12
Ordering Components ........................................................... 12
Appendices............................................................................. 13
Appendix 1...............................................................................
Spare Parts for ROLLERFORKS© RFC10-D1 ...................... 14
Appendix 2...............................................................................
Spare Parts for ROLLERFORKS© RFC15-D1 ...................... 15
Appendix 3...............................................................................
Spare Parts for ROLLERFORKS© RFC20-D1 ...................... 16
Appendix 4...............................................................................
Spare Parts for ROLLERFORKS© RFC24-D1 ...................... 17
Appendix 5...............................................................................
Spare Parts for ROLLERFORKS© RFC30-D1 ...................... 18
Appendix 6...............................................................................
Spare Parts for ROLLERFORKS© RFCC10-D1.................... 19
Appendix 7...............................................................................
Spare Parts for ROLLERFORKS© RFCC20-D1.................... 20
Appendix 8...............................................................................
Spare Parts for ROLLERFORKS© RFCC24-D1.................... 21
Appendix 9...............................................................................
Spare Parts for ROLLERFORKS© Suspension .................. 22
User Manual & Components Book
Article No.: MAN01022017-03 Language: ENG
Publication date: 01-02-2017 Revision: 03
ROLLERFORKS®
RFC10-D1, RFCC10-D1
RFC15-D1
RFC20-D1, RFCC20-D1
RFC24-D1, RFCC24-D1
RFC30-D1

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• ISO 9001
The ROLLERFORKS® comply with the following norms/directives:
• CE (2006/42/EC) – Machine Directive
• ISO 2328 – Fork-lift trucks – Hook-on type fork arms and fork arm carriages – Mounting dimensions
• ISO 3834-2 Quality requirements for fusion welding of metallic materials – Part 2: Comprehensive quality requirements
Warning:
Blocks of text accompanied by a “Warning” icon (as shown on the left) and starting with the text “Warning: ” provide
information about actions that can result in (serious) personal injury.
Caution:
Text blocks accompanied by a “Caution” icon (as shown on the left) and starting with the text “Caution:” provide informa-
tion about actions which may result in damage to the ROLLERFORKS®, components of the ROLLERFORKS® or goods.
Note
© Copyright 2019, Cascade KOOI. All rights reserved.
Information provided in this manual, including but not limited to illustrations and text, may not be reproduced without the prior writ-
ten permission of Cascade KOOI.
The information in this manual is provided without any form of guarantee. Under no circumstances shall Cascade KOOI be held
liable for accidents or instances of damage arising from the use of this manual.
Please note that the information in this manual may be changed at any time without prior notice and that it may contain technical
inaccuracies and typing errors. Cascade KOOI makes every effort to avoid errors in this manual, but cannot guarantee this. If you
encounter any typing errors or technical inaccuracies, or if you have any suggestions, you can contact the supplier.
Other trademarks or product names that are used in this manual but not mentioned here are the trademarks of their respective hold-
ers.
Quality Standards, Norms and Directives
Cascade KOOI complies with the following quality standard:
Introduction
The ROLLERFORKS® are forklift truck forks made for palletless retrieval and lifting of goods, whether or not the goods are placed
on a slipsheet. In addition, the ROLLERFORKS® can be used as replacements for standard forklift truck forks, for use with standard
pallets.
ISO 2328 suspension for attachment to these machines. The ROLLERFORKS® do not incorporate any electrical or hydraulic compo-
nents and are driven by the manoeuvring back and forth of the machine on which they are mounted.
ROLLERFORKS® can be used both in dry or wet environments and at temperatures between -20°C and +50°C.

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Safety
Warning:
Never exceed the forklift truck’s maximum load capac-
ity, regardless of the stated load capacity of the
ROLLERFORKS®.
Warning:
Never exceed the maximum load capacity of the ROL-
LERFORKS®.
Warning:
Never walk under the ROLLERFORKS®.
Warning:
Do NOT use the ROLLERFORKS® in an environment
where the temperature is lower than -20°C / -22°F or
higher than 50°C / 122°F.
Warning:
The ROLLERFORKS® may not be operated by a minor.
Warning:
Do NOT use the ROLLERFORKS® to move people or
animals.
Warning:
Do NOT weld anything to the ROLLERFORKS® with-
out specic permission from the supplier. If anything
is welded to the ROLLERFORKS® without permission
from the supplier, all guarantee provisions become
null and void.
Warning:
If the ROLLERFORKS® have a defect, do NOT use
them until they have been expertly repaired.
Warning:
While driving with a load, contact between the ROLL-
ERFORKS® and the ground must be avoided. As soon
as the ROLLERFORKS® touch the ground the load
will roll off the forks, which can lead to damage and
dangerous situations.
Warning:
Do NOT lift or move a load using the tips of the ROL-
LERFORKS® alone.
Caution:
Before use, always equalise the length of the ROLLER-
FORKS® using the adjusting screw on the heel side.
(See Instructions for equalising the ROLLERFORKS®)
Caution:
Do not use a side-shift system when the ROLLER-
FORKS® are on the ground. This is in order to prevent
damage to the ROLLERFORKS®.
Caution:
To prevent damage to the rollers, always lower the
ROLLERFORKS® (and carriage plate) in a controlled
manner.
Caution:
Always use the widened ROLLERFORKS® (RFCC) for
the loading and unloading of refrigerated containers
with special circulation grooves on the underside.
The rollers of the standard ROLLERFORKS® could get
into the grooves.

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Nameplate
Type Indication – Explanatory Notes
Type Description
Serial No.
Centre of gravity
Max. capacity at loaded centre of gravity
Loaded centre of gravity
Build Year
Tare weight
Additional information
WARNING: Never exceed the capacity indicated on the forklift truck’s type plate.
The capacity of the combination of forklift truck and extension is the responsibility of
the forklift truck manufacturer, and may be lower than the capacity as indicated on
the extension’s type plate.
R F C * 2 4 1 1 0 0 2 A
Type
Capacity x 100 Kg
Fork Length (mm)
Mounting (Class ISO 2328)
* C = Wider rolls for use in refrigerated containers (optional).

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Among other things, the type plate shows the maximum load capacity per set of ROLLERFORKS®. Using the loading diagram shown
below, one can determine the load-bearing capacity per ROLLERFORK® or per pair of ROLLERFORKS® for every load centre distance.
Correction factors are shown vertically and load centre distances are shown horizontally, measured in millimetres from the front edge
of the fork’s back.
Warning:
The above diagram is only applicable to the ROLLERFORKS®
The forklift truck’s residual load capacity with the ROLLERFORKS® must be provided by
Load Capacity
0
0,1
0,2
0,3
0,4
0,5
0,6
0,7
0,8
0,9
1
1,1
6008001000120014001600180020002200
Load center (mm)
correction factor

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1. Check the ROLLERFORKS® for any (transport) damage.
2. Loosen the ROLLERFORKS® from the pallet by snipping or cutting through the tensioning straps.
Putting the ROLLERFORKS® into service
3. Lift up the fork back of the ROLLERFORKS®.
4. Secure the fork back in its upright position by placing the supplied clamping bush into the hole. (see following image)
Possibly, use a plastic hammer in order to place the clamping bush in the hole.
5. The ROLLERFORKS® can now be mounted onto the carriage plate

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1. Move the ROLLERFORKS® to eye level, then tilt the mast forwards or backwards until the two ROLLERFORKS®
are virtually horizontal.
2. Unscrew the rear adjusting bolt M20 from the heel.
3. Using the foremost adjusting bolt M20, adjust the ROLLERFORKS® until the tips of the 2 forks are
at the same level.
4. Secure the front adjusting bolt with the rear adjusting bolt (torque 170 Nm)
Instructions for Equalizing
+
-
+
-
Adjusting bolt M20 (for securing)
Adjusting bolt M20 (for sets)
Mounting the ROLLERFORKS®
1. Tilt the mast forwards and hang the ROLLERFORKS® onto the carriage plate in accordance with the following image.
2. Slide the ROLLERFORKS® left or right over the carriage plate. Make sure that the locking pin (1) of each Rollerfork drops
into one of the notches (2) of the carriage plate.
1
2

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Picking up a load with the ROLLERFORKS®
A1
A2
A3
A4
A5
A1.
Check whether the slipsheet projects out on the side
where the package is to be picked up.
Tilt the ROLLERFORKS® forward and allow them to
contact the ground at their tips.
A2.
Drive towards the package until the tips of the
ROLLERFORKS® are under the slipsheet
A3.
Lower the forward-tilting mast until the
ROLLERFORKS® are standing at on the ground. (All
the rollers of the ROLLERFORKS® should now touch
the ground)
Thanks to the hinging heel, the rollers come to touch
the ground.
A4.
Drive forward so that the ROLLERFORKS® roll under
the
package.
A5.
Continue driving forward until the entire package is
sitting on the ROLLERFORKS®.
Tilt the mast backwards. The package can now be
lifted

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Dividing 2 packages with the ROLLERFORKS®
B1.
Tilt the ROLLERFORKS® downward and bring the tips
approximately to the height of the underside of the
upper package.
B2.
Drive forwards and manoeuvre the tips of the ROL-
LERFORKS® between the projecting parts of the two
slipsheets separating the packages.
B3.
Lower the ROLLERFORKS® until the heels are at
roughly the same height as the tips of the
ROLLERFORKS® and are parallel with the lower
slipsheet.
B4.
Drive forwards until the entire upper package is rest-
ing on the ROLLERFORKS®.
B5.
Tilt the mast back. The package can now
be lifted
B1
B2
B3
B4
B5

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Consult the maintenance schedule for additional inspection work.
At least once a year, the ROLLERFORKS® must be tested again by a specialist in accordance with
ISO5057 standards. The results of this test should be recorded in a logbook. Other checks are shown in the table below.
Inspection and Maintenance
Nº Description Daily Monthly Annually or
every
2,000 hours
1.
Check wear and tear on tip
Reject if tip is no longer functional or is worn down to
inner fork or side plate.
2.
Check wear and tear on the side plates
Reject if side plate is no longer functional or is worn
down to bolt heads.
3.
Check wear and tear on the rollers
Reject if rollers no longer extend above or below fork
when the ROLLERFORKS® are resting on the ground.
4. Check for broken rollers
Reject if roller is broken.
5.
Check cartridges
fork blade
6. Check inner fork in accordance with ISO5057 standards
Rejection: in accordance with ISO 5057.
Maintenance items
1.
2.
3/4/5
5.

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1. Set the ROLLERFORKS® to hip height and switch off the forklift truck.
2. Unscrew the 2nd, 4th, 6th, 8th, etc. bolts (starting from the front of the tip), whichever is relevant to the
cartridge.
3. Now change the cartridge which is to be replaced, in accordance with the image below.
4. Remove the old Loctite and clean the screw threads of the bolts using Loctite 7063 cleaner.
5. Apply Loctite 2701 to the bolts and tighten the bolts in accordance with the torque table.
1. Set the ROLLERFORKS® to hip height and switch off the forklift truck.
2. Remove the tip in accordance with the image below. (possibly, use a plastic hammer in order to (dis-)mount the tip
3. Clean the surfaces and remove any sharp edges.
4.
5. Remove the old Loctite, clean the screw thread using Loctite 7063 cleaner, and apply new Loctite 2701 to the bolts.
6. Tighten the bolts in accordance with the torque table.
Instructions for Replacing the Cartridges
Instructions for Replacing the Tip

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Table of Torques for ROLLERFORKS®
When ordering components, you are advised to not only look up the product numbers in the appendices but also
to check the measurements of the relevant components yourself. This is because a special version may be involved, in which some
components may vary from the standard version.
Ordering Components
Torques
1. Set the ROLLERFORKS® to hip height and switch off the forklift truck.
2. Remove the components in accordance with the image below.
3. Remove the old Loctite and clean the screw thread of the bolt using Loctite 7063 cleaner.
4. Now apply Loctite 2701 to the bolt.
5. Fit the new support roller and accompanying parts, and tighten the bolt in accordance with the table Torques for
ROLLERFORKS®.
Instructions for Replacing the Support Rollers
Item Recommended torque (Nm)
Bolt M8 class 12.9 37
Bolt M10 class 12.9 70
Bolt M16 class 8.8 180

c
Cascade Corporation 2019 04-2019 Part No. 6921954
Do you have questions you need
answered right now? Call your nearest
Cascade KOOI Service Department.
Visit us online at www.cascorp.com
AMERICAS
Cascade KOOI
U.S. Headquarters
2201 NE 201st
Fairview, OR 97024-9718
Tel: 800-CASCADE (227-2233)
Fax: [phone]
Cascade KOOI Canada Inc.
5570 Timberlea Blvd.
Mississauga, Ontario
Canada L4W-4M6
Tel: [phone]
Fax: [phone]
Cascade KOOI do Brasil
Praça Salvador Rosa,
131/141-Jordanópolis,
São Bernardo do Campo - SP
CEP 09891-430
Tel: [phone]
Fax: [phone]