Ravas iForks User manual

ERVICE MANUAL
S
Manual Number 6823346-R3
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.
&

6823346-R3i
ONTENTS
C
Page
INTRODUCTION
Introduction 1
Special Definitions 1
PERIODIC MAINTENANCE
100-Hour Maintenance 2
2000-Hour Maintenance 2
TROUBLESHOOTING
Preparation 4
Tools Required 4
Before Starting 4
Error Messages 5
Basic Troubleshooting 6
Check Display Power 8
Check Weight Readout At Each Load Cell 9
Display Debug Mode 11
Hardware 13
Fork Assembly 13
Wire Harness 14
Load Cells 15
Display 16
Printer 18
SERVICE
Parameter Settings 19
Accessing The Parameters Menu 19
Changing A Parameter 20
Parameter Table 22
View Current Calibration Settings 26
Change Units 28
Reset Current Parameter and Calibration Settings To
Default (Factory) Settings 30
Three Part Calibration 31
Calibration Introduction 31
Prior To Calibration 32
Zero Calibration 33
Corner Calibration 35
Weight Calibration 41
Display 48
Pairing The Display To iForks 48
Wire Harness 52
Wire Harness Removal 52
New Wire Harness Installation 64

16823346-R3
INTRODUCTION
1. 2 Special Definitions
The statements shown appear throughout this manual
where special emphasis is required. Read all WARNINGS
and CAUTIONS before proceeding with any work.
Statements labeled IMPORTANT and NOTE are provided
as additional information of special significance or to make
your job easier.
WARNING - A statement preceded by
WARNING is information that should be
acted upon to prevent bodily injury. A
WARNING is always inside a ruled box.
CAUTION - A statement preceded by CAUTION is
information that should be acted upon to prevent
machine damage.
IMPORTANT - A statement preceded by IMPORTANT is
information that possesses special significance.
NOTE - A statement preceded by NOTE is information that
is handy to know and may make your job easier.
FK0138.eps
Stamped Catalog Number
and Serial Number
1.1 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
information.
NOTE: Specifications are shown in both US and (Metric)
units. All fasteners have a torque valve range of ±10% of
stated value.

26823346-R3
PERIODIC MAINTENANCE
IMPORTANT: Only trained and authorized personnel are
allowed to service iFork assemblies. 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.
1.1 100-Hour Maintenance
Every time the lift truck is serviced or every 100 hours
of truck operation, whichever comes first, complete the
following maintenance procedures:
• Check for debris between fork and fork shoe (e.g. wood
chips).
• Inspect the bottom of the forks for debris that might be
wedged between the fork and the fork shoe. Remove
any debris found.
• Check for pinched wires at bottom of batteries.
• Tighten fork shoe capscrews after initial 100 hours of
service. Tighten to a torque of 80 ft.-lbs. (112 Nm).
As necessary, replace a cover spool, fork shoe
capscrews and nuts.
• 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 not damaged
or bent. If required, tighten the contact point capscrews.
FK0176.eps
Battery Holders
Check capscrews, contact
tabs and 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.

36823346-R3
PERIODIC MAINTENANCE
FK0088.eps
2 in. (50 mm)
Fork Arm Blade
Cross Section
100 %
Fork Arm Blade
Cross Section
90 %
OK
Repair or
Replace
Remove
Fork Shoe
B
C
A
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.
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.
C Position the caliper inner teeth on the fork arm blade
approximately 2 in. (50 mm) out from the face of the
shank.
• If the inside teeth of the caliper hit the fork, it has
less than 10% wear and requires no replacement.
• If 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.
Inspect fork hooks and carriage bar
clearance
NOTE: Use go/no-go Wear Gauge Part No. 209560
(Class II) or 209561 (Class III).
AInspect the fork lower hooks and carriage bar. If the
gauge fits between the carriage bar and lower hook,
repair or replacement is needed.
B Inspect the upper carriage bar. If the gauge arrow
touches the carriage bar, repair or replacement is
needed.
CInspect the fork upper hooks. If the gauge arrow
touches the hook, repair or replacement is needed.
FP0832.eps
OK
OK
OK
FORK LOWER HOOKS, CARRIAGE
UPPER CARRIAGE BAR
FORK UPPER HOOKS
Wear
Gauge
1.2 2000-Hour Maintenance
After 2000 hours of truck operation, forks in use shall
be inspected at intervals of not more than 12 months
(for single shift operations) or whenever any defect or
permanent deformation is detected. Severe applications
will require more frequent inspection.

ROUBLESHOOTING
T
46823346-R3
2.1 Preparation
2.1-1 Tool Required
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)
2.1-2 Before Starting
iForks system problems and solutions are listed on the
following pages, under one of the categories shown below:
Determine All The Facts –It is important to gather all the
facts about the problem before beginning any service
procedures. The first step is to talk to the equipment
operator and ask for a complete description of the
malfunction or problem.
!
AC0311.eps
Digital Multimeter Kit 213867
iForks System
2.2 Error Messages
2.3 Basic Troubleshooting
2.3-1 Check Display Power
2.3-2 Display Debug Mode
2.4 Hardware
2.4-1 Fork Assembly
2.4-2 Wire Harness
2.4-3 Load Cells
2.4-4 Display
2.4-5 Printer

56823346-R3
ROUBLESHOOTING
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Error Messages
Low Battery Messages
Display Shows: Meaning:
BltF1 Successful connection with Fork 1
BltF2 Successful connection with Fork 2
Other Display Messages
FK0085.eps
FK0086.eps
Low Battery
Indicators
2.2 Display Messages
Display
Shows: Meaning: To Exit Error Mode:
Err01 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 Calibration count 2nd (3rd) point is lower than count 1st (2nd)
point. Automatic
Err14 Calibration setpoint value 2 < setpoint value 1. This is not allowed. Automatic
Err97 NTEP (OIML) only: Calibration not allowed. Press "On/Off" button two times. Contact
Cascade Service if calibration is required.
Err98 Entered weight used for weight calibration must be higher than
previous entered weight. Automatic
Err99 Button pressed or another action is performed while toggling
between units format (lb or kg).
Wait for display to return to original unit
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. Lift up the forks from the ground
L - _ Forks are out of level (only legal for trade version) Put the forks into horizontal position
ErrCS Problem with correction sensor Contact the Cascade Service department
Display
Shows: Meaning: To Exit Error Mode:
Battery of display is low Replace or recharrge the 4 AA batteries
+F1 Fork 1 battery is low Recharge battery packs or replace the
D cells in both battery packs.
+F2 Fork 2 battery is low Recharge battery packs or replace the
D cells in both battery packs.
▼
▼

ROUBLESHOOTING
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66823346-R3
2.3 Basic Troubleshooting
There are seven potential problem areas that can affect the
function of iForks:
• Power supply – Worn out battery, broken fuse, or power supply.
• Bad or broken contacts.
• Pinched or worn out cabling.
• Loose screws or bolts.
• Mechanical problems – Weighing part interferes with a
non-weighing parts of the system due to deformation or
accumulated dirt or debris in between components.
• Moisture in the electronics or load cells.
• Low Battery – iForks indicating low battery can affect weighing
accuracy and communication to the display.
Problem Solution
Check power supply or battery. Refer to
Section 2.3-1.
Check the display for bad contact. Refer to
Section 2.4-4 for further diagnosis.
Check the display for moisture or loose
contacts. Refer to Section 2.4-4 for further
diagnosis.
Check load cell cables and load cell. Refer to
Section 2.3-2 (or 2.3-3) & 2.4-3.
Check the iForks assembly. Verify the
capscrews are properly tightened. Refer to
2.4-1 for further diagnosis.
Make sure the weight is centered on the iForks
and iForks are level.
Check the iForks assembly. Refer to Section
2.4-1 for further diagnosis.
Check the load cells by verifying that the parts
do not interfere with fixed, non-weighing parts.
Nothing works.
The display is dead, even
when pressing the keys.
With the same load,
different weights show on
the display
The display is unstable;
values change
Check the iForks assembly. Refer to Section
2.4-1 for further diagnosis.
Smaller weights are
accurate but inaccurate
with heavy weights
Section Continued On The Next Page

76823346-R3
ROUBLESHOOTING
T
Problem Solution
Calibrate the system. Refer to Section 3.2.
Check the display. Refer to Section 2.4-4 for
further diagnosis.
Check the display. Refer to Section 2.4-4 for
further diagnosis.
Calibrate the system. Refer to Section 3.2.
Calibrate the system. Refer to Section 3.2.
Check load cell cables and load cell. Refer to
Section 2.3-2 (or 2.3-3) & 2.4-3.
Check the display. Refer to Section 2.4-4 for
further diagnosis.
Check load cell cables and load cell. Refer to
Section 2.3-2 (or 2.3-3) & 2.4-3.
System is inaccurate but
linear.
The buttons on the display
does not work
Segments fail on the
display
Display shows a positive
or negative, weight and the
display wont zero.
The scale reacts normal
when a load is placed on
the scale.
With or without a load, the
display shows an over or
underload error message
(Err02)
The display does not react
to loads being weighed
2.3 Basic Troubleshooting (continued)

ROUBLESHOOTING
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86823346-R3
FK0117.eps
2.3-1 Check Display Power
Start
Complete
Equipped
with
Power
Supply
Battery
With the batteries
installed into the display,
check the voltage
Output
6V
Replace battery
Check voltage going
into the display
No
voltage
YES
YES
YES
YES
NO
NO
NO
NO
- Check fuses
- Check power to power supply
6 or
12 VDC
Troubleshoot display,
refer to Section 2.4-4
Problem
with
power

96823346-R3
ROUBLESHOOTING
T
FK0255.eps
2.3-2 Check Weight Readout At
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.
1 If required, turn on display. Verify that the display is
zeroed.
2 Place a known weight on position A, as shown.
3 Note the weight shown on the display.
4 Move the weight to position B, as shown.
5 Note the weight shown on the display.
Procedure continued on next page
1
2
4
3
5
Position A
Position B

ROUBLESHOOTING
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10 6823346-R3
6 Move the weight to position C, as shown.
7 Note the weight shown on the display.
8 Move the weight to position D, as shown.
9 Note the weight shown on the display.
10 If the any of weights are not within weight ±A(chart
below) of each other, the load cell may require further
troubleshooting or service. Contact Cascade Service
department. Refer to the back cover of this manual.
iFork Capacity Weight 'A'
5000 lb. (2268 kg) 2 lb. (1 kg)
6000 lb. (2722 kg) 2 lb. (1 kg)
10,000 lb. (4536 kg) 2 lb. (1 kg) 1
5 lb. (2 kg) 2
1Use this value if the weight used for the procedure is less
than 1000 lb (543.6 kg).
2Use this value if the weight used for the procedure is
greater than 1000 lb (543.6 kg).
2.3-2 Check Weight Readout At
Each Load Cell (continued)
FK0256.eps
6
7
9
8
Position C
Position D

116823346-R3
ROUBLESHOOTING
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FK0118.eps
2.3-3 Debug Mode
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.
When the display is in debug mode, the number of counts
received from each AD chip is shown, individually. This
helps isolate which load cell could be the problem.
NOTE: The AD values shown on the display should be
close to each other for calibration.
NOTE: Both iFork assemblies must be turned on.
A
B
C D
Corner
(load cell
location) Display Arrow
A
B
C
D
e1
e2
e3
F1
Load Cell Layout and Corresponding Display Arrow
1 If required, turn on display.
2 Press and hold the "Tare" button for 25 seconds.
3 Press "Total" button until "DEBUG" shows.
4 Press the "Zero" button to enter debug mode.
Procedure continued on next page FK0242.eps
1
4
2
3

ROUBLESHOOTING
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12 6823346-R3
FK0243.eps
FK0244.eps
2.3-2 Debug Mode (Continued)
12 To exit Debug mode, press "On/Off" button to leave
debug mode. The display will go back to weighing
mode.
5 The display will show the AD count for Corner A.
An arrow over e1 will show.
7 The display will show the AD count for Corner B.
An arrow over e2 will show.
9 The display will show the AD count for Corner C.
An arrow over e3 will show.
11 The display will show the AD count for Corner D.
An arrow over F1 will show.
6 Press the "Total" button to view the next AD count.
8 Press the "Total" button to view the next AD count.
10 Press the "Total" button to view the next AD count.
7
10
12
11
5
8
6
9
To View Digital Corner Calibration Values:
Typically, parameter 80 (digital corner calibration) is
enabled and parameters 81-84 (a compensation factor for
each corner) can range from 0.98 to 1.020. Original AD
counts are multiplied by a compensation factor (one of
parameters 81-84) after a corner calibration is performed.
Example of a load cell:
AD Count: 2319
Compensation Factor: 1.0026
Calibrated AD Count: 2325
To view the calibrated AD count perform the following:
1 During Steps 5, 7, 9, and/or 11, in the previous section,
press the "Sampling" button to view the calibrated AD
count.
2 An arrow appears next to the tilde symbol (~) on
the display. This indicates that the AD count has a
compensation factor applied.
NOTE: To view parameter values, refer to Section 3.1 for
accessing parameters.
1
2

136823346-R3
ROUBLESHOOTING
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FK0120.eps
2.4 Hardware
2.4-1 Fork Assembly
Start
Complete
Display
shows weight
identical on all
corners
Display
shows weight
identical on all
corners
Any sign of
interference
Dismantle the system
and look for interference
between weighing and
non-weighing components
Weigh a normal to heavy load.
Press the "tare" button to reset
the display to zero. Load each
extreme corner of the iForks.
Assemble the weighing system
with paper between the weighing
and non-weighing parts. Load the
iForks to full capacity and move
the load sideways.
Check load cell capscrews are
firmly tightened. For further
troubleshooting, refer to Section
2.3-2 (or 2.3-3) and 2.4-3.
Check that the fork shoes are
mounted correctly and do not
interfere with the frame at the
sides. Look for debris between
weighing and non-weighing parts.
Place a weight on each
of the bolts of the iForks
assemblies
Load cell
capscrews
tightened
correctly
YES
YES
YES
YES
YES
NO
NO
NO
NO
NO
Fix areas of friction.
Example: Align the
platform, clean the
inside, align the forks.
Paper shows
friction

ROUBLESHOOTING
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14 6823346-R3
FK0121.eps
2.4-2 Wire Harness
Complete
Voltage
6 VDC
Display
reacts
Display
reacts
Check load cell calibration board.
Without touching contact points,
move board or cables.
Battery holder is faulty,
replace wire harness Cable or connector
is damaged or has
oxidized
Contact is bad
Check cables, especially where the
cable enters the load cell connector.
Move the cable and observe the display.
With fully charged batteries
and the iFork assemblies
switched on, check the
voltage of battery holder.
YES
YES
YES
NO
NO
NO
Start

156823346-R3
ROUBLESHOOTING
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FK0122.eps
2.4-3 Load Cells
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:
• 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). The
resistance between the wires and load cells should
be infinite.
OR
• To determine if one load cell is the problem,
connect each load cell to the display (using it as
a voltmeter) and compare the values shown for
each load cell. The separate values should be
close in value. If one value differs from the other
by a considerable amount, the load cell should be
replaced. Verify that the cables are not damaged.
Complete
Display
still shows
an error
Display
still shows
an error
Display is
instable
With or
without a load
display show over
or underload error message
and system will not
reset to zero
The difference
is larger then 1/2
graduation
Each load
cell gives the
same weight
The difference
between each
cell is large
Verify display is not creating
the problem. Replace the
touch panel and then
calibrate.
Check load cells separately.
Refer to "Testing Individual
Load Cells".
Place a weight on each
of the bolts of the iFork
assemblies
Calibrate load cells.
Refer to Service
Section 3.1.
Calibrate load cells.
Refer to Service
Section 3.1.
Load cell is not the
problem
Dismantle the iFork assembly.
Place capscrews in the
assembly holes of the load
cells. Balance a test weight that
is 1% of their capacity of each
load cell on the capscrews.
Check display, refer
to Section 2.4-4
Check iFork assembly,
refer to Section 2.4-1.
YES
YES
YES
YES
YES
YES
YES
NO
NO
NO
NO
NO
NO
NO
Start

ROUBLESHOOTING
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16 6823346-R3
2.4-4 Display
Problem Solution
Disconnect the display from the system.
• If the display remains unstable or does not
react to being disconnected, the board is
faulty.
• If not, there may be a problem with the load
cell. Contact Cascade.
Check for moisture. Look for condensation or
water drops. Contact Cascade.
To determine if the display is faulty:
• Change does not show on the display when
the load cells are disconnected.
• The display remains unstable, even when not
load cell is connected
• The display reacts when going over bumps
or other kinds of shock.
The display is unstable and
does not react to weights.
External Power Supply Equipped:
• Check fuse and verify that an extra fuse is not
installed.
Battery Supply (equipped with four AA):
• Check batteries. Replace with new batteries
(6 VDC) or rechargeable (4.8 VDC).
Display does not turn on
External Power Supply Equipped:
• Check voltage. If voltage is below 11.8 VDC,
the converter or fuse may be damaged.
Replace the fuse.
• If the fuse is not damage, contact Cascade.
Battery Supply (equipped with four AA):
• Replace with new batteries (6 VDC) or
rechargeable (4.8 VDC)
• Check parameter setting, parameter 62.
NOTE:The display may be set to shut off after
2 minutes from the factory.
Display automatically shuts
off after 2 minutes

176823346-R3
ROUBLESHOOTING
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Verify that the parameter setting, parameter 60
is set correctly:
• If equipped with power supply, parameter 60
should be set to 12V.
• If equipped with batteries, parameter 60
should be set to 6V.
Display shows low battery
indication and remains on
Problem Solution
Disconnect additional features (printer). Then
check if display buttons work. If the buttons
still don't work, contact Cascade. The touch
panel may need to be replaced.
If equipped with printer, verify LED on printer is
on.
Buttons on display have no
reaction
2.4-4 Display (continued)
Disconnect additional features (printer). Then
check if display buttons work. If the buttons
still don't work, contact Cascade. The touch
panel may need to be replaced.
Touch panel connector may need to be
replaced, contact Cascade.
Verify scale is unloaded before accepting new
print.
Check power supply. Refer to Section 2.3-1.
Check wiring to printer.
Restart display.
Motion detection parameter needs to be
checked. Contact Cascade.
Display does not react
when buttons pressed and
weights change
Totaling button (also printer
function) does not function

ROUBLESHOOTING
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18 6823346-R3
2.4-5 Printer
Problem Solution
External Power Supply:
• Check voltage output. If voltage is below
11.8 VDC, check converter or fuse for damage.
• With printer installed, check amperage to and
from convertor. Amperage should be 3 Amps.
Battery Supply (equipped with four AA):
• Replace with new batteries (6 VDC) or
rechargeable (4.8 VDC).
Contact Cascade to check parameter P35.
Wrong COM port selected (user settings
submenu on display).
Wrong parameter setting. Contact Cascade.
CTS wire may be damaged. Contact Cascade.
Wiring to display may be wrong. Contact
Cascade.
Check printer cable is installed.
Action not allowed because system is NTEP
approved. Unload scale then perform next
weighing and printing action. NTEP regulations
allow for weight to be recorded once.
Low battery indication on
or unstable while printing
No printout while printer is
on – Display shows subtotal
and sequence number on
the display but the display
does not show "added"
No printout while printer is
on – Display shows subtotal
and sequence number on
the display and the display
does show "added"
No printout while printer is
off – Display shows subtotal
and sequence number on
the display and the display
does show "added"
No printout – Display shows
"NTEP"