Cascade KOOL Reachforks User manual

Manual Number 6928035-R1
Cascade KOOI is a Registered Trademark of Cascade Corporation
SER MANUAL
Manual ReachforksW
U

16928035-R1
Table of Contents
..................................................................... 2
Note
Definitions
.............................................................................. 2
Quality Standards, Norms and Directives ..................... 2
Safety ............................................................................ 3
................................................................. 4
Assembly....................................................................... 5
Extending ...................................................................... 5
Working with Manual Reachforks ................................. 6
Maintenance Schedule ................................................. 6
Wear.............................................................................. 7
Instructions for Replacement of Sleeve ........................ 8
Troubleshooting ............................................................ 8
Identification

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6928035-R1
Warning:
Text blocks marked by a “Warning” icon (as shown on the left) and starting with the text “ Warning:” provide
information on actions which may result in (serious) personal injury.
Caution:
Text blocks marked by a “Caution” icon (as shown on the left) and starting with the text “ Caution:” provide
information on actions which may result in damage to the Manual Extension Forks, parts of the Manual Extension
Forks or goods.
Denitions
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 written 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 damages arising from the use of this manual.
Please note that 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. Please let us know if you encounter any typing errors or technical inaccuracies, or if you have any suggestions.
Other trade or product names used in this manual, but not mentioned here, are the trademarks of their respective holders.
Quality Standards, Norms and Directives
Cascade KOOI complies with the following quality standards: ISO 9001
Manual Reachforks comply with the following norms/directives:
• ISO 13284 - Fork-arm extensions and telescopic fork arms.
• ISO 2328 - Fork-lift trucks - Hook-on type fork arms and fork arm carriages.
• CE (2006/42/EC) – Machinery Directive.
• ISO-FDIS-ISO 3834-2 - Quality requirements for fusion welding of metallic materials - Part 2: Comprehensive
quality requirements.
The Manual Reachforks are randomly subjected to dynamic testing in accordance with ISO 2330.

36928035-R1
Safety
Warning:
Do not ride on the Manual Reachforks or on the
load.
Warning:
Do not walk or stand under the Manual
Reachforks.
Warning:
Do not load the Manual Reachforks beyond the
limits of the lifting capacities and load center
stipulated by the manufacturer.
Warning:
Do not weld anything onto the Manual
Reachforks without the express permission of the
supplier. Welding carried out without permission
shall void any warranty.
Warning:
Do not use faulty Manual Reachforks before they
have been either professionally repaired or
replaced.
Warning:
Do not use the Manual Reachforks in areas where
the temperature is below -30ºC (-22ºF) unless
otherwise agreed with the manufacturer.
Caution:
When leaving the forklift truck, the engine must
be switched off and the handbrake applied.
Caution:
Bear in mind the space above and below the
Manual Reachforks.
Caution:
The load on the Manual Reachforks must be
distributed as evenly as possible.
Caution:
Retract the (loaded) Manual Reachforks as soon
as possible.
Caution:
If possible, retract the Manual Reachforks before
driving.
Caution:
Always drive with the Manual Reachforks in the
lowest possible position.
Caution:
Move hands outside outer sleeves after
disengaging locking pin and before sliding
outer sleeve inwards.

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Type plate legend:
Structure of Manual Reachforks type description
Identication
Type Description Weight
Max. Capacity on Retracted Load Center
Max. Capacity on Extended Load Center
Production Year
Extra Information
Serial Number
Retracted Center of Gravity
Extended Center of Gravity
Retracted Load Center
Extended Load Center
Warning: Never exceed the maximum truck capacity as seen on the truck type plate.
Rated capacity of both truck and attachment is the responsability of the original truck
manufacturer and may be less then the capacity shown on the attachments type plate.
type
capacity X 100 kg
mounting
stroke (mm)
retracted length (mm)

56928035-R1
1 2
2
3
Assembly
Make sure that locking pin (2) of each Manual
Reachfork drops into one of the notches on the carriage
plate. Use catch (1) before operating.
Slide the Manual Reachforks onto the carriage plate.
Extending
1
Unlock the fork by moving the catch to the right. Keep the catch in the right position and pull the fork out
a few centimetres. Let go of the catch and pull the sleeve
to the next position, where it is secured by the spring
mechanism.
Caution! check whether the sleeve is properly secured by
pulling/pushing the sleeve once.

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3
1
4
2
Working with Manual Reachforks
To minimise wear, avoid as much as possible allowing the Manual Reachforks to come into contact with the ground
during operation. In order to reduce wear:
• The chains in the mast of the forklift truck can be shortened so that the Manual Reachforks cannot reach the
ground.
Maintenance Schedule
Nº Description Weekly Monthly 6 months or
every 1000
hours
Annually or
every 2000
hours
1. Grease the underside and topside of the inner fork
2. Check sleeve for signs of wear, especially the heel
side*
3. Check for and remove any dirt in the sleeve
4. Check inner forks in accordance with ISO 5057*
standards
*See chapter on ‘Wear’.
Notes on ‘Maintenance Schedule’
• Recommended lubricating grease: Novatex
EP2 (point 1).
• If defects are detected, first solve the
problem/replace parts before proceeding
to work with the Manual Reachforks.
• See chapter on ‘Instructions for Replacement
of Sleeve’ for further explanation
about replacing the sleeve.

76928035-R1
1
2
A
B
100mm 100mm
S1 S2
Instructions for Replacement of Sleeve
1
2
Wear
replaced when S1 is 5% thinner than S2. See point 4 of the
The inner fork is declared unfit for use and must be
Maintenance Schedule.
Caution:
The sleeves must be removed from the Manual
Reachforks before welding work on the
sleeves can proceed.
When surface A (dark grey) is worn to the extent that it is
level with or below surface B (light grey), then the wear
plate (2) must be replaced. If there are signs of wear
on the lower side of the sleeve (2) then it must also be
replaced. See point 4 of the Maintenance Schedule.
Wear Plate Welding Data:
• Process: MAG (135), 210A, 28 VDC
Weld type: fillet weld a4, 1 layer
•
• Cleaning: brush
• Wire: 1 mm, EN 12534 / Mn3Ni1CrMo
• Shielding gas: 80% Ar / 20% CO2, 15-16 L/min
• Weld in wear plate notches
Position the Manual Reachforks at hip height,
tilt the mast of the forklift truck slightly
forward. Remove the stop using the three clamping bushes that
connect it to the inner fork.

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3 4
Troubleshooting
Observation Symptom Possible Cause Possible Solution
Difference in height be -
tween forks
One fork point is hanging
lower than the other
One of the Manual Exten -
sion Forks has been perma-
nently deformed as a result
of overloading
Remove the forks from the
carriage plate immediately
and contact the supplier
One of the Manual Exten -
sion Forks is not hanging
properly on the carriage
plate
Hang the Manual Extension
Forks properly onto the car-
riage plate (check locking
mechanism)
Carriage plate is not com -
pletely horizontal
Please contact your forklift
truck supplier
The forks do not match
(forks belong to different
sets)
Check the serial numbers
Wear strips on one Manual
Extension Fork are more
worn than the other Replace wear strips
Excessive play between
fork blade and sleeve
Wear strips worn out
Sleeves worn out Replace sleeves
Slide the catch to the right, similar to the unlocking pro -
cedure. Slide the sleeve back around the fork and replace
the stop.
Unlock the fork by moving the catch to the right and slide
the sleeve off the fork.

c
Cascade Corporation 2020 03-2020 Part No. 6928035-R1
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]