Camera system on Forklifts

Installation manual
No. IM0993600 R2-0

August/2013
English
 Installation manual

Camera system on Forklifts

Installation Manual
No. IM0993600 R2-0

Safety
In order to guarantee safe operation, these safety
instructions must be read before you start using the
Orlaco camera sytems.

• Do not open the enclosures. This can cause damage,

short-circuiting or electrical shocks.
• Do not expose any equipment to extreme
temperatures. This can cause deformation of the
enclosures or damage to internal components.
• Repairs may only be undertaken by the
manufacturer.
• The Orlaco camera sytems must be assembled as
shown in this manual.

Before you start using the Orlaco camera sytems, please read
this manual carefully and follow all instructions. This installation
manual describes the functions of the equipment, outlines the
connection options and explains how to put the equipment into
operation. We recommend that you keep this manual in a safe
place for reference purposes.

If you have any questions or issues concerning the operation

of this equipment, consult the relevant section in the manual or
contact the Orlaco Products BV Service department.

The camera/display systems from Orlaco comply with the latest

CE, ADR, EMC and mirror-directive regulations. All products are
manufactured in accordance with the ISO 9001 quality manage-
ment system, ISO/TS16949 quality automotive and ISO 14001
environmental management systems.

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Contents
page
1. Introduction 3
2. Camera and monitor installatioin 4
3. Mastcable installation 4
4. Sideshift, Forkpositioner 10
5. Disposal 11
6. General terms and conditions 11
7. Revisions 11

Available documentation
Datasheet DS0403330 Pulley for cable 1220600
Datasheet DS0403340 Spring set mast cable forklift
Datasheet DS0304370 Mastcable 0,5m 4p
Datasheet DS1220600 Mastcable 1 x coax, 5 x wire PUR FL
Datasheet DS1221000 Mastcable 1 x coax, 11 x wire PUR
Datasheet DS1221100 Mastcable coax + 14 leads 9mm

1. Introduction
The Orlaco camera system for forklift trucks is suitable for after-
market installations on a wide variety of forklift truck models.

When the camera is used for rear-view, or for other functions

where it is installed on the frame of the truck, the cabling will be
guided over the frame and fixed in place permanently.

Most often however the camera is placed in mid-mast mounting, or

on the carriage of the forklift, or on an attachment mounted to the
forklift. In these cases, the cable will have to be mounted in such a
way that the normal movement of the mast is not hindered.

The model of forklift truck may vary from Reachtruck to

Counterbalance truck, Sideloader or Containerhandler. These may
employ 2-, 3- or 4-stage masts, with or without freelift cylinder(s).
Chains and hydraulic hoses will typically be included on the inside
or the outside of the mast, and these will be guided over their own
pulleys.

Due to this wide variety of truck- and mast-models it is impossible

to give a detailed overview of installation possibilities for each and
every forklift truck.
For some specific models with special mast configurations, Orlaco
manuals are available.
This manual aims to give general guidance to the technician on
installing the Orlaco mastcable.

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2. Camera and monitor installation WARNING:

The camera(s) and monitor(s) are to be installed on the forklift
Prior to installation of the
truck as described in their respective manuals. Guidance on the
mastcable in the mast, the
physical placement and the electric connections are described in
coiled-up cable needs to be unwound
these manuals, also the proceedings and connections in case of
completely to remove kinks.
multiple camera’s are explained there.

In general, the monitor is placed within the field of vision for

normal operation.
On a Reachtruck, the monitor is most often hung from the
overhead guard while on Counterbalance trucks it is often placed
on the dashboard to the right of the steering column. The monitors
are supplied with brackets that match these installations – the
monitors of Reachtruck sets come with a clamp bracket that
can be clamped on the overhead guard, while the monitors for
Counterbalance trucks come with a bolt-on bracket.

The connection between camera(s) and monitor is provided by an

Orlaco mastcable.
The Orlaco mastcables are specifically designed for Forklift
applications; They withstand the continuous bending, torque and
pull associated with such use – even in coldstore conditions.
The difference between the Orlaco mastcable types lies in the
amount of additional wires that are available within the cable
– these additional wires can be used for low-power auxiliary
functions.
Figure 1A: Two-stage mast,
3. Mastcable installation Hydraulics inside mast.
When reviewing the operation of a mast, it will be clear that the
movement of hydraulic cylinders causes the mast to move. Chains
are used to move other mast sections, and also hydraulic hoses
may be installed in the mast.

The general rule to install an extra cable in the mast of a forklift

truck is, to have the cable run parallel to the existing chains and
hydraulic hoses.
The mastcable should never cross the hydraulic hoses or chains.
Also, the cable needs to be installed in such a way that normal
operation of the mast is not hindered.

On a traditional 2-stage mast, one mast section is fixed to the

truck’s frame, while the second mast section is pushed up by
cylinders.
As the second mast section moves up, the carriage is pulled up
by chains that run over their own pulleys, placed at the top of the
second mast section (see figure 1A and 1B).The system comes
down due to gravity.
Figure 1B: Two-stage mast,
Hydraulics outside of mast.

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As can be seen in the pictures, the chains and hydraulics form a

loop over the pulleys.
Typically, the hydraulic hoses will be either on the inside or on the
outside of the mast, as shown in the pictures of figure 1A and1B.

On a 3-stage mast with freelift cylinder, the principle mast

movement with hydraulic cylinders and chains remains the same,
but now there are two loops instead of one – the first loop goes
from the forkcarriage, over the freelift cylinder, to the bottom of
the third (inner) mast-section; The second loop goes from there,
over the top of the second mast-section, to the outer (non-moving)
mast-section. power power

The Orlaco mastcable will follow the same route.

Each loop is fixed on both ends – one end is fixed in place by an
anchoring block, the other end is fixed by a springset, which also
keeps some tension on the cable to prevent it from slacking.

In case of a mid-mast installation (which most often occurs on a

Reachtruck with a 3-stage mast and freelift cylinder), the cable is
run from the camera (near the top of the third mast-section) to the
bottom of the third mast-section. 2-stage 3-stage mid-mast
From there it goes over the top of the second mast-section, to the
outer (non-moving) mast-section. Figure 2: Mastcable routing

For 4-stage masts, the configurations are quite diverse.

Although the operation becomes more complicated when more
mastsections are involved, the principal movement of cylinders and
chains remains the same.
However, with the 4-stage mast the available space within the
mast-sections can be so limited that it becomes impossible to
install extra pulleys to run a mastcable.

For most 4-stage masts however goes that an extra mastcable

can be installed in much the same manner as on a 3-stage mast;
On some 4-stage masts an extra cable assistance loop may be
required to cover movement of the extra mastsection – this may be
formed by a hollow chain section, often referred to as a ‘flex-track’
or ‘energy-chain’.
For all mast configurations, be it 2-, 3- or 4-stage masts, goes that
the cable needs to be guided over pulleys to accommodate for the
movement of the mast-sections.

In figure 2 some mastcable routings are shown. Also the placement

of a pulley, springset and anchoring block is shown. It should be
noted that the anchoring block, spring and clamp are all included
in Orlaco’s 0403340 Springset, which is specifically designed to fit
the Orlaco mastcables.

The placement of the anchoring block and spring can be reversed

– sometimes it can be advantageous to install these parts on the
other side of the loop.

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As for the pulleys, quite often there will be free pulleys available in
the mast from un-used hydraulic groups as shown in figure 3.
The Orlaco mastcable can be guided over these pulleys, provided
that:
• The mastcable is bent over a diameter of at least 80mm (3 1/8 ”)
• The Pulley groove can accommodate the Mastcable’s diameter of
9mm (3/8 ”)

Sometimes, extra OEM pulleys can easily be installed on the truck -

eg on the existing pulley axle as shown in figure 4.
Figure 3: Free hydraulic group pulleys
If it is not possible to use either of these methods, then 0403330
Orlaco universal pulleys can be installed in the mast. When
installing the pulleys, welding should be avoided at all times. Also,
drilling in structural parts of the truck is to be avoided.

During the installation of the pulleys and springsets, care must be

taken that these do not come in contact with other parts when the
mast is being extended.
Once the installation is finalized, the mast should be slowly and
carefully extended and collapsed several times so that it can be Figure 4: Installing extra OEM Pulley
inspected for proper functioning.
The truck should only be put back in normal use when the mast
functions properly and the mastcable, pulleys and springsets do
not interfere with normal mast movement.

The Orlaco pulleys come with a stainless steel mounting bracket

that allows installation in a variety of ways. The pulleys are typically
installed using existing holes in the mast (figure 5).

Figure 5: Using existing threaded hole

If there are no such holes available, then the pulley can be installed
on existing bolts – this may require longer bolts than originally
used see figure 6.

Figure 6: Installed on existing bolt

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Also, it is possible to install a steel strip on the truck and mount the
pulley to that – as shown in figure 7.

Figure 7: Install Pulley on steel strip

It should be noted that the pulley can also be installed on its center
bolt – the standard bolt is metric M8 but this can be changed to
metric M10 (a bushing can be taken out of the bearing)
figure 8 and figure 9 show some installations where the pulley’s
center bolt is screwed into existing threaded holes in the truck.

Figure 8: Install on existing bolt-hole

Figure 9: Install on existing bolt-hole

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As noted previously, sometimes an extra steel strip can be added to

mount the pulley on – as shown in figure 10.

a: prepare mounting strip b: install strip on existing bolt c: Install Orlaco pulley on strip
Figure 10: Install steel mounting strip

If it is not possible to use any of these installation methods, then

the pulley may be installed on a non-structural part of the truck, eg
on the cover of pulleys for the hydraulic hoses.
Figure 11 to 14 show some examples of such installations.

Figure 11: Install on coverplate

Figure 13: Install on coverplate Figure 14: Install on coverplate Figure 12: Install on coverplate

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As can be seen in figure 13, sometimes the size of the Freelift

cylinder can be far bigger than the 80mm Pulley diameter. For
bridging very big spans it may be necessary to use two pulleys as
shown in figure 15 and figure 16.

Figure 15: Two pulleys installed on existing bolts

Figure 16:
Two pulleys installed on mounting strip

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It should be noted that there is hardly any pulling force on the

Orlaco mastcable.
The cable is kept tight on the pulley’s by the Orlaco springset, the
force is no more than a few pounds. The Springsets are installed
in the mast in a similar way as the pulleys – see pictures figure 17
and figure 18.

Figure 17: Springsets attached to existing bolts

Figure 18:
Springsets attached to existing structure
4. Sideshift, Forkpositioner
Nowadays, most trucks are standard equipped with a sideshift, or
sometimes a fork positioner
The mastcable is to be put in a loop to allow for the movement of
the sideshift.
No additional materials are required, the mastcable only needs to
be laid out correctly.
The technician should carefully check that the total stroke of the
sideshift can be utilized.

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5. Disposal
Disassembly, removal and disposal. Local regulations for dealing
with waste must be followed when disposing of disassembled
components or entire units.

6. General terms and conditions

Orlaco Products BV is not liable for damage resulting from
inadequate servicing, incorrect usage or alterations made to the
equipment without informing the manufacturer in writing.

This installation manual has been made available by Orlaco

Products BV. All rights reserved. No part of this manual may be
reproduced and/or made public in printed form, in photocopy
form or on microfi lm, or in any other way, without the prior
written permission of Orlaco. This also applies to the associated
drawings and figures.

Orlaco reserves the right to make changes to components at any

time without informing customers beforehand or directly. All
dimensions given are for commercial purposes.

For information regarding repairs that is not covered in this ma-

nual, please contact the Orlaco Products BV service department.

This manual has been prepared with all due care and attention.
However, Orlaco Products BV cannot be held responsible for any
errors in this manual or any consequences thereof.

7. Revisions
1-0 First issue; May 2007
1-1 Update; October 2007
1-2 Update; February 2008
1-3 Update; February 2008
1-4 Update; June 2011
2-0 Overall update; August 2013

IM0993600 R2-0 11
ORLACO

Orlaco is a Manufacturing company that specializes in making

cameras and monitor systems for commercial vehicles, fork-lift
trucks, cranes, off shore and maritime.

Our objective is to design and produce camera systems for the

professional market that improve the drivers’ view and increase
operating efficiency.

At our facility in Barneveld we locate our design, manufacturing,

warehousing and service department.

Vision is our mission. Orlaco therefore deploys the development,

manufacture, supply and service of camera and display systems
that will improve safety and efficiency of all vehicles,
machinery and vessels. Our systems give the end user a view on
each blind spot and will create comfort and improved working
conditions. Our active approach will support market demands
and innovations and will lead to enthusiastic ambassadors in the
market; our customers.

For more information: www.orlaco.com

ORLACO PRODUCTS BV
Albert Plesmanstraat 42, 3772 MN Barneveld
PO Box 193, 3770 AD Barneveld
The Netherlands

Phone: +31 (0) 342 404555

Fax: +31 (0) 342 404556
E-mail: [email protected]
Internet: http://www.orlaco.com