Raymond Forklift 8210 Mobile Scale Forks Supplement Maintenance Manual SN 821-15-00100 & Up - PDF

Maintenance Manual Supplement Mobile Scale Forks

Model

Serial Numbers

Publication: 1284782A

Issued: 20 Mar 2018

8210

821-15-00100 & Up

This publication applies to Mobile Scale Forks for Model 8210 pallet trucks S/N 821-15-00100 and Up, and to all subsequent releases of these products until otherwise indicated in new editions or bulletins. Changes occur periodically to the information in this publication.

Technical changes or additions to the text and illustrations are indicated by a vertical line to the left of the change.

If you need assistance with your pallet truck, contact your local authorized Raymond Sales and Service Center.

To locate a Sales and Service Center, go to www.raymondcorp.com. ©2018 The Raymond Corporation.

The following terms are trademarks of The Raymond Corporation: Raymond, iWAREHOUSE, iPORT, iALERT, iCONTROL, iBATTERY, and Safety On The Move, All other brand and product names are trademarks or registered trademarks of their respective companies.

Mobile Scale Fork Truck Maintenance Manual Supplement Table of Contents

Table of Contents NOTICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Document Revision History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Special Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 100-Hour Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Cleaning Mobile Scale Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Tool Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Display Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Other Display Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Basic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Check Display Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Check Weight Readout At Each Load Cell . . . . . . . . . . . . . . . . . . . 15 Debug Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 To View Digital Corner Calibration Values: . . . . . . . . . . . . . . . 17 Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Fork Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Load Cell Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Load Cells. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Testing Individual Load Cells. . . . . . . . . . . . . . . . . . . . . . . . . . 20 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Accessing The Parameters Menu . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Changing A Parameter's Setting . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Parameter Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 View Current Calibration Settings . . . . . . . . . . . . . . . . . . . . . . . . . 35 Change Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Reset Current Parameter and Calibration Settings To Default (Factory) Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Non-NTEP Three Part Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Calibration Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Prior to Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Zero Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Corner Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Weight Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 NTEP Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Calibration Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Prior to Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Single Point Scan Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 NTEP Corner Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 NTEP Zero Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Full Span Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Change Parameter 40 Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

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Mobile Scale Fork Truck Maintenance Manual Supplement Table of Contents Load Cells and Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Load Cell and Level Sensor Removal . . . . . . . . . . . . . . . . . . . . . . .

Load Cell & Level Sensor Installation . . . . . . . . . . . . . . . . . . . . . .

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Load Cell and Level Sensor Cable Routing . . . . . . . . . . . . . . . . . .

Non-NTEP Truck Junction Box Wiring Connections . . . . . . . . . . .

NTEP Truck Junction Box and Display Wiring Connections . . . . .

ii

62 62 63 65 65 68 70

Publication: 1284782A, Issued: 20 Mar 2018

Mobile Scale Fork Truck Maintenance Manual Supplement

NOTICE

NOTICE Mobile Scale Fork truck are available in two variations: NTEP and Non-NTEP. NTEP scales are accurate within 0.1% of the maximum calibrated load weight. Non-NTEP scales are ideal for applications requiring less precise measurements.

NTEP stands for National Type Evaluation Program, which is a non-profit corporation.

Scales and other weighing equipment that are NTEP approved have been tested and evaluated to make sure that they meet all government standards and requirements. The National Conference on Weights and Measures issues an NTEP Certificate of Conformance following successful completion of an evaluation of a device. It indicates that the device(s) described in the Certificate is/are capable of meeting specific requirements.

Tampering or removing the Mobile Scale Fork system NTEP Security wire or label will void NTEP Certification. If NTEP Mobile Scale Forks require service, the forks must be re-certified.

The Mobile Scale Forks system components are paired and calibrated as a set. Do not separate.

Consult your local Raymond Sales and Service Center with any questions.

This is a precise weighing system, treat it 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 Mobile Scale Forks system.

Publication: 1284782A, Issued: 20 Mar 2018

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NOTICE

Mobile Scale Fork Truck Maintenance Manual Supplement

Document Revision History

Document Revision History This section contains a record of the revision history. Whenever this manual is revised, this section is updated with the revision, date of revision, and a description of the changes.

Revision

Date

Description of Change

1281782A

20 Mar 2018

Initial Release

2

Publication: 1284782A, Issued: 20 Mar 2018

Mobile Scale Fork Truck Maintenance Manual Supplement

NOTICE Special Tools

Special Tools To prevent damage to the Junction Box Wires during the wire installation process, the following tools should be used.

Part Number

Description

990-1238

NTEP Junction Box Wire Installation Tool

990-1239

Non-NTEP Junction Box Wire Installation Tool

Publication: 1284782A, Issued: 20 Mar 2018

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NOTICE

Mobile Scale Fork Truck Maintenance Manual Supplement

Introduction

Introduction This manual provides Periodic Maintenance, Troubleshooting and Service for the Mobile Scale Fork Truck.

FK0485.eps

NOTE: Specifications are shown in both US and (Metric) units. All fasteners have a torque value range of ±10% of stated value.

4

Publication: 1284782A, Issued: 20 Mar 2018

Mobile Scale Fork Truck Maintenance Manual Supplement

NOTICE Special Definitions

Special Definitions The statements shown appear throughout this manual where special emphasis is required.

Read all WARNINGS and CAUTIONS before proceeding with any work.

A statement preceded by WARNING is information that should be acted upon to prevent bodily injury.

A statement preceded by CAUTION is information that should be acted upon to prevent machine damage.

NOTE: A statement preceded by NOTE is additional information that possesses special significance or is handy to know and may make your job easier.

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Periodic Maintenance

Mobile Scale Fork Truck Maintenance Manual Supplement

Special Definitions

Periodic Maintenance NOTE: Only trained and authorized personnel are allowed to service Mobile Scale fork assemblies. Other maintenance procedures are the sole responsibility of the purchaser.

NOTE: 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.

Raymond recommends a minimum interval of every 12 months or 2000 hours, whichever comes first.

6

Publication: 1284782A, Issued: 20 Mar 2018

Mobile Scale Fork Truck Maintenance Manual Supplement

Periodic Maintenance 100-Hour Maintenance

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: •

Without removing the fork skin, visually check for debris between fork and fork shoe (for example: wood chips).

•

Remove any debris found.

•

Tighten the fork shoe cap screws after the initial 100 hours of service. Tighten to a torque of 80 ft. lbs. (112 Nm). Replace the cover spool, fork shoe cap screws, and nuts as necessary.

Cleaning Mobile Scale Forks 1. As required, use a mild cleanser and wipe down the forks with a towel. Rinse the fork with a non-pressurized stream of water.

Do not rinse the display or the junction box.

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Periodic Maintenance

Mobile Scale Fork Truck Maintenance Manual Supplement

100-Hour Maintenance

8

Publication: 1284782A, Issued: 20 Mar 2018

Mobile Scale Fork Truck Maintenance Manual Supplement

Troubleshooting 100-Hour Maintenance

Troubleshooting

Publication: 1284782A, Issued: 20 Mar 2018

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Troubleshooting

Mobile Scale Fork Truck Maintenance Manual Supplement

Preparation

Preparation Tool Required In addition to a normal selection of technician's hand tools, the following tools are needed to troubleshoot the Mobile Scale Forks system: •

Digital Multimeter, test leads and adapter (Service Kit 213867)

Figure 1-1.

Digital Multimeter Kit 213867 AC0311.eps

!

Before Starting 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.

Mobile Scale Forks system problems and solutions are listed on the following pages, under these categories: •

Display Messages • Error Messages • Other Display Messages

•

Basic Troubleshooting • Check Display Power • Display Debug Mode

•

Hardware • Fork Assembly • Wire Harness • Load Cells • Display • Printer

10

Publication: 1284782A, Issued: 20 Mar 2018

Mobile Scale Fork Truck Maintenance Manual Supplement

Troubleshooting Display Messages

Display Messages Error Messages Display Shows:

Meaning:

To Exit Error Mode:

Err01

Load cell signal is unstable.

Automatic

Err02

Mobile Scale Forks 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 set-point value 2 < set-point value 1. This is not allowed.

Automatic

Err97

NTEP (OIML) only: Calibration not allowed.

Press the “On/Off” button two times. Contact your local Raymond Sales and Service Center 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 the display to return to the original unit format (lb. or kg).

ErrF1

Problem with Mobile Scale Fork 1 (no communication).

Restart the display.

ErrF2

Problem with Mobile Scale Fork 2 (no communication).

Restart the 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 your local Raymond Sales and Service Center

Publication: 1284782A, Issued: 20 Mar 2018

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Troubleshooting

Mobile Scale Fork Truck Maintenance Manual Supplement

Display Messages

Other Display Messages Display Shows:

Meaning:

BltF1

Successful connection with Fork 1

BltF2

Successful connection with Fork 2

12

Publication: 1284782A, Issued: 20 Mar 2018

Mobile Scale Fork Truck Maintenance Manual Supplement

Troubleshooting Basic Troubleshooting

Basic Troubleshooting There are five potential problem areas that can affect the function of the Mobile Scale Forks: •

Power supply – Blown fuse, or power supply.

•

Pinched or worn out cabling.

•

Loose screws or bolts.

•

Mechanical problems – Weighing part interferes with non-weighing parts of the system due to deformation or accumulated dirt or debris in between components.

•

Moisture in the electronics or load cells.

Problem

Solution

Nothing works.

The display is dead, even when pressing the keys.

Check power supply. Refer to “Check Display Power” on page 14.

The display is unstable; values change.

Check the display for moisture or loose contact. Refer to “Display” on page 21 for further diagnosis.

Check the display for bad contact. Refer to “Display” on page 21 for further diagnosis.

Check load cell cables and load cell. Refer to “Check Weight Readout At Each Load Cell” on page 15, “Debug Mode” on page 16, and “Load Cells” on page 19.

Check the Mobile Scale Forks assembly. Verify the cap screws are correctly tightened. Refer to “Fork Assembly” on page 18 for further diagnosis.

With the same load, different weights show on the display.

Make sure the weight is centered on the Mobile Scale Forks and that the Mobile Scale Forks are level.

Check the Mobile Scale Forks assembly. Refer to “Fork Assembly” on page 18 for further diagnosis.

Check the load cells by verifying that the parts do not interfere with fixed, non-weighing parts.

Smaller weights are accurate but inaccurate with heavy weights.

Check the Mobile Scale Forks assembly. Refer to “Fork Assembly” on page 18 for further diagnosis.

System is inaccurate but linear.

Calibrate the system. Refer to “Non-NTEP Three Part Calibration” on page 39.

Display shows a positive or negative, weight and the display will not zero.

The scale reacts normal when a load is placed on the scale.

Calibrate the system. Refer to “Non-NTEP Three Part Calibration” on page 39.

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Troubleshooting

Mobile Scale Fork Truck Maintenance Manual Supplement

Basic Troubleshooting Problem

Solution

With or without a load, the display shows an over or underload error message (Err02).

Calibrate the system. Refer to “Non-NTEP Three Part Calibration” on page 39.

Check load cell cables and load cell. Refer to “Check Weight Readout At Each Load Cell” on page 15, “Debug Mode” on page 16, and “Load Cells” on page 19.

Check the display. Refer to “Display” on page 21 for further diagnosis.

The display does not react to loads being weighed.

Check load cell cables and load cell. Refer to “Check Weight Readout At Each Load Cell” on page 15, “Debug Mode” on page 16, and “Load Cells” on page 19.

The buttons on the display do not work.

Check the display. Refer to “Display” on page 21 for further diagnosis.

Segments fail on the display.

Check the display. Refer to “Display” on page 21 for further diagnosis.

Check Display Power Step

Troubleshooting Check

Result

1

Check voltage going into the display. Is there voltage?

YES

2

Is there 6 or 12 VDC?

Next Action • Check fuses • Check power to power supply

NO

Go to Step 2

YES

Go to Step 3

NO

• Check fuses • Check power to power supply

3

14

Problem with power

YES

Troubleshoot display, refer to “Display” on page 21.

NO

Display power check complete, return the lift truck to service.

Publication: 1284782A, Issued: 20 Mar 2018

Mobile Scale Fork Truck Maintenance Manual Supplement

Troubleshooting Basic Troubleshooting

Check Weight Readout At Each Load Cell

7. Move the weight to position C, as shown.

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. Park the lift truck in an area with a level surface.

8. Note the weight shown on the display.

2. If required, turn on the display. Verify that the display is zeroed.

9. Move the weight to position D, as shown.

3. Place a known weight on position A, as shown.

10. Note the weight shown on the display.

4. Note the weight shown on the display.

5. Move the weight to position B, as shown.

11. 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 your local Raymond Sales and Service Center.

Scale Fork Capacity 4500 lb.

(2045 kg)

Non-NTEP Truck Weight 'A'

NTEP Truck Weight 'A'

2 lb. (1 kg)

2 lb. (1 kg)

6. Note the weight shown on the display.

Publication: 1284782A, Issued: 20 Mar 2018

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Troubleshooting

Mobile Scale Fork Truck Maintenance Manual Supplement

Basic Troubleshooting

Debug Mode

1. If required, turn ON the display.

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 Mobile Scale Fork assembly transmitter module has two AD (analog-to-digital converter) chips and each load cell has one AD chip.

2. Press and hold the “Tare” button for 25 seconds.

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.

Figure 1-2.

3. Press the “Total” button until “DEBUG” shows.

Load Cell Layout and Corresponding Display Arrow

C

D

4. Press the “Zero” button to enter debug mode.

B

A FK0489.eps

16

Corner (load cell location)

Display Arrow

A

e1

B

e2

C

e3

D

F1

5. The display will show the AD count for Corner A. An arrow over “e1” will show.

5 6

6. Press the “Total” button to view the next AD count.

Publication: 1284782A, Issued: 20 Mar 2018

Mobile Scale Fork Truck Maintenance Manual Supplement

Troubleshooting Basic Troubleshooting

7. The display will show the AD count for Corner B. An arrow over “e2” will show.

7 8

8. Press the “Total” button to view the next AD count.

9. The display will show the AD count for Corner C. An arrow over “e3” will show.

9

10

10. Press the “Total” button to view the next AD count.

To View Digital Corner Calibration Values: Typically, parameter 80 (digital corner calibration) is enabled and parameters 81 through 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 through 84) after a corner calibration is performed.

Example calibration of a load cell: 2319 x 1.0026 = 2325 •

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.

11. The display will show the AD count for Corner D. An arrow over “F1” will show.

11

12

12. To exit Debug mode, press the “On/Off” button to leave debug mode. The display will go back to weighing mode.

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 “Parameters” on page 24 for accessing parameters.

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Troubleshooting

Mobile Scale Fork Truck Maintenance Manual Supplement

Hardware

Hardware Fork Assembly Step

Troubleshooting Check

Result

Next Action

1

Place a single weight on the bolt of each Mobile Scale Forks assembly.

Does the Display show weight identical on all corners?

YES

Go to Step 2.

NO

Go to Step 3.

Weigh a normal to heavy load. Press the “Tare” button to reset the display to zero. Move the weight to load each extreme corner of the Mobile Scale Forks.

Does the Display show weight identical on all corners?

YES

Troubleshooting check is complete, return the lift truck to service.

NO

Go to Step 3.

Dismantle the system and look for interference between weighing and non-weighing components.

Is there any sign of interference?

YES

Calibrate the load cells. Refer to “Service” on page 23.

Then go to Step 4.

NO

Go to Step 5.

Assemble the weighing system with paper between the weighing and non-weighing parts. Load the Mobile Scale Forks to full capacity and move the load sideways.

Does the paper shows friction?

YES

Fix areas of friction. Example: Align the platform, clean the inside, align the forks.

NO

Go to Step 5.

Are the load cell cap screws tightened correctly?

YES

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.

NO

Check that the load cell cap screws are firmly tightened. For further troubleshooting, refer to “Check Weight Readout At Each Load Cell” on page 15, “Debug Mode” on page 16, and “Load Cells” on page 19.

2

3

4

5

18

Publication: 1284782A, Issued: 20 Mar 2018

Mobile Scale Fork Truck Maintenance Manual Supplement

Troubleshooting Hardware

Load Cell Cables Step

Troubleshooting Check

Result

Next Action

1

Check cables, especially where the cable enters the load cell connector.

Move the cable and observe the display.

Does the Display react?

YES

Cable or connector is damaged or has oxidized.

NO

Go to Step 2.

Check the load cell calibration board.

Without touching the contact points, move the board or cables.

Does the Display react?

YES

Contact is bad.

NO

Load cell cable troubleshooting is complete, return the lift truck to service.

2

Load Cells

If further troubleshooting is required, perform the troubleshooting checks in the following table.

NOTE: Raymond recommends using Debug Mode first.

Step

Troubleshooting Check

Result

Next Action

1

Place a weight on each of the bolts of the Mobile Scale Fork assembly.

Is the difference between each cell large?

YES

Go to Step 2.

NO

The load cell is not the problem.

Dismantle the Mobile Scale Fork assembly. Place cap screws in the assembly holes of the load cells.

Balance a test weight that is 1% of the capacity of each load cell on the cap screws.

Does each load cell give the same weight?

YES

Check the Mobile Scale Fork assembly, refer to “Fork Assembly” on page 18.

NO

Go to Step 3.

Is the difference larger than 1/2 graduation?

YES

Calibrate the load cells. Refer to “Service” on page 23.

Go to Step 4.

NO

Check the Mobile Scale Fork assembly, refer to “Fork Assembly” on page 18.

With or without a load, does the display show an over-load or under-load error message and the system will not reset to zero?

YES

Calibrate the load cells. Refer to “Service” on page 23.

Go to Step 5.

NO

Troubleshooting check is complete, return the lift truck to service.

Does the Display still show an error?

YES

Verify the display is not creating the problem.

Replace the display and then calibrate.

Go to Step 6.

NO

Troubleshooting check is complete, return the lift truck to service.

2

3

4

5

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Troubleshooting

Mobile Scale Fork Truck Maintenance Manual Supplement

Hardware Step

Troubleshooting Check

Result

Next Action

6

Does the Display still show an error?

YES

Check the load cells separately. Refer to “Testing Individual Load Cells” on page 20.

Go to Step 7.

NO

Troubleshooting check is complete, return the lift truck to service.

YES

Check the display, refer to “Display” on page 21.

NO

Troubleshooting check is complete, return the lift truck to service.

7

Is the Display unstable?

Testing Individual Load Cells With a load cell disconnected from the Mobile Scale Fork 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

•

20

To determine if one load cell is the problem, connect each load cell to the display (using it as a volt meter) and compare the values shown for each load cell. The separate values should be close in value. If one value differs from the others by a considerable amount, replace the load cell. Verify that the cables are not damaged.

Publication: 1284782A, Issued: 20 Mar 2018

Mobile Scale Fork Truck Maintenance Manual Supplement

Troubleshooting Hardware

Display Problem

Solution

The display is unstable and does not react to weights.

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 your local Raymond Sales and Service Center.

Check for moisture. Look for condensation or water drops. Contact your local Raymond Sales and Service Center.

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 no load cell is connected.

The display reacts when going over bumps or other kinds of shock.

Display does not turn ON.

Power Supply Equipped: Check the fuse and verify that an extra fuse is not installed.

Display automatically shuts off after 2 minutes.

Power Supply Equipped: Check the voltage. If the voltage is below 11.8 VDC, the converter or fuse may be damaged. Replace the fuse.

If the fuse is not damaged, contact your local Raymond Sales and Service Center.

Display shows low battery indication and remains ON.

Verify that parameter 60 setting is set correctly.

If equipped with a power supply, parameter 60 should be set to 12V.

Buttons on display have no reaction.

Disconnect additional features (printer). Then check if the display buttons work. If the buttons still do not work, contact your local Raymond Sales and Service Center. The touch panel may need to be replaced.

If equipped with a printer, verify the LED on printer is ON.

Totaling button (also printer function) does not function.

Verify the scale is unloaded before accepting a new print.

Check the power supply. Refer to “Check Display Power” on page 14.

Check the wiring to the printer.

Restart the display.

Check the motion detection parameter. Contact your local Raymond Sales and Service Center.

Display does not react when buttons are pressed and weights change.

Disconnect additional features (printer). Then check if the display buttons work. If the buttons still do not work, contact your local Raymond Sales and Service Center. The touch panel may need to be replaced.

Touch panel connector may need to be replaced, contact your local Raymond Sales and Service Center.

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Hardware

Printer Problem

Solution

Unstable while printing.

External Power Supply: Check the voltage output. If the voltage is below 11.8 VDC, check the converter or fuse for damage.

With a printer installed, check the amperage to and from the converter. Amperage should be 3 Amps.

No printout while printer is ON – Display shows subtotal and sequence number on the display but the display does not show “added”.

Contact your local Raymond Sales and Service Center to check parameter P35.

No printout while printer is ON – Display shows subtotal and sequence number on the display and the display does show “added”.

Wrong COM port selected (see user settings submenu on the display).

Wrong parameter setting. Contact your local Raymond Sales and Service Center.

CTS wire may be damaged. Contact your local Raymond Sales and Service Center.

Wiring to display may be wrong. Contact your local Raymond Sales and Service Center.

No printout while printer is OFF – Display shows subtotal and sequence number on the display and the display does show “added”.

Check that the printer cable is installed.

No printout – Display shows “NTEP”.

Action not allowed because system is NTEP approved. Unload the scale then perform the next weighing and printing action.

NTEP regulations allow for weight to be recorded once.

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Parameters

Parameters NOTE: Parameters should only be changed when calibrating (refer to “Non-NTEP Three Part Calibration” on page 39 or “NTEP Calibration” on page 49), advised by your local Raymond Sales and Service Center, or as a last option.

Contact your local Raymond Sales and Service Center before making changes to the parameters.

Accessing The Parameters Menu 1. If required, turn ON the display.

2. Press and hold the “On/Off” button for 30 seconds.

3. The display will show “P_ _00”.

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Changing A Parameter's Setting NOTE: Refer to the “Parameter Table” beginning on page 28 to determine the parameter number.

1. Access the Parameters Menu as described in “Accessing The Parameters Menu”.

2. Enter the parameter number of the parameter setting to change. Use the Entry Mode Guide (below) as an aid to change the parameter number (A and B).

Always accept the value by pressing the “Zero” button, C.

The following buttons are available while in Entry Mode:

Entry Mode Guide

A

Decrease the Value

Selected value will flash

Increase the Value

B

C

B

Shift to the next digit on the left

C

Accept the value (press last)

A

3. Press the “Zero” button to enter the selected parameter.

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Parameters 4. Refer to the “Available Setting Options” column, found on the “Parameter Table” (beginning on page 28) to determine if the current setting should be changed and setting options available.

Example: Setting Options Column

Selected Parameter Row

Current Settings

Setting Options Available

5. 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

The following buttons are available while in Entry Mode: A

Decrease the Value

Selected value will flash

Increase the Value

C C

26

A

A

Example Available Setting Options:

B

Shift to the next digit on the left

C

Accept the value (press last)

B

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Service Parameters

6. After pressing the “Zero” button to accept the value (the value is accepted in Step 5), the display screen will go to the main parameter screen, showing the next parameter number. Repeat Steps 2-5 for each parameter to verify or change.

Next Parameter (example shown)

7. To exit and save settings, press the “On/Off” button two times.

8. The display will return to normal weighing mode.

9. Restart the display to enable the recent changes:

• Press and hold the “On/Off” button for three seconds to turn OFF the display.

• Then, press the “On/Off” button to turn ON the display.

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Parameters

Parameter Table Default Settings Parameter Number

Function

Software Version

NTEP

EU

NonNTEP

Available Setting Options

US 01

Weight units

1

2

2

1 = kg 2 = lb.

02

Smallest graduation step for multi-range

1

2

2

0.1, 0.2, 0.5, 1, 2, 5, 10, 20, 50

03

Biggest graduation step for multi-range

2

5

2

0.1, 0.2, 0.5, 1, 2, 5, 10, 20, 50

NOTE: Parameter 3 limits the maximum value setting of Parameter 2. Parameter 3 must be set before Parameter 2. If not, Parameter 2 will not be changeable.

04

Number of divisions for every range

1000

1000

1000

0000 – 9999 divisions

05

Weighing capacity system (full scale)

2500

4500

4500

0 – 99999 units

06

Motion Tolerance for stable

2

2

2

off, 0.5, 1, 2, 4, 8, 16, 32 grad./sec

07

Filter Size

8

8

8

off, 1-12 (Scale: 1 light filtering, 12 high filtering)

08

Auto zero range (zero track)

0.5

0.5

0.5

off, 0.5, 1, 3 grad./sec.

09

Zero range positive (+)

10

10

10

0 – 100 percentage of span

10

Zero range negative (-)

10

0

0

0 – 100 percentage of span

11

Test function (display service mode)

basic

basic

basic

basic, count, res10

12

Power on – automatic zero

no

no

no

yes, no

13

Approved/Non-approved version

none

ntep

none

none, ntep, oiml, ntepC

14

Sampling quantity

10

10

10

1, 2, 5, 10, 20, 50, 95

15

Units switch mode active

yes

yes

yes

no, yes

A

A Some software versions may not offer “ntepC” as an option.

B Some software versions may only have options 1 through 10 available.

C Com2.1 is used with a printer and Com2.2 is used for Bluetooth® communication to a PDA. D Some software versions may only have options 1 through 5 available.

E Some software versions may not offer this parameter.

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Service Parameters

Default Settings Parameter Number

Function

Software Version

EU

NTEP

NonNTEP

Available Setting Options

US 16

Set-point function

18

B

0

0

0

0 = not used 1 = gross overload 2 = net overload 3 = fill manual tare 4 = fill auto tare 5 = gross overload not authorized to change gross setting 6 = net overload not authorized to change net setting 7 = gross overload delayed 8 = net overload delayed 9 = gross overload delay not authorized to change gross setting 10 = net overload delay not authorized to change net setting 11 = gross over-load + errors 12 = gross over-load + errors, no changes allowed 13 = gross over-load + errors, delayed 14 = gross over-load + errors delayed, no changes allowed

Gravity value working area

9.812

9.803

9.803

9.750 – 9.850

19

Print format date/time

EU

US

US

EU = dd/mm/yy US = mm/dd/yy

28

Printout format for com1 and com2

2.15 & before

stnd

stnd

stnd

stnd, total, confi

Printout format for com2.1 C

2.18 0

0

0

0–3

29

Header lines added

A Some software versions may not offer “ntepC” as an option.

B Some software versions may only have options 1 through 10 available.

C Com2.1 is used with a printer and Com2.2 is used for Bluetooth® communication to a PDA. D Some software versions may only have options 1 through 5 available.

E Some software versions may not offer this parameter.

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Parameters Default Settings Parameter Number

Function

Software Version

NTEP

EU

NonNTEP

Available Setting Options

US 30

Baud rate com2

2.15 & before

9600

9600

9600

600, 1200, 2400, 4800, 9600, 19200

Baud rate com2.1 C

2.18

Setting com2

2.15 & before

8_n_1

8_n_1

8_n_1

8_n_1, 8_n_2, 7_n_1, 7_n_2

Setting com2.1 & 2.2 C

2.18

32

End Character com2.2 only C

2.18

cr

cr

cr

cr, lf, crlf

34

End character com2

cr

cr

cr

cr, lf, crlf

35

Protocol com2

0

0

0

0 = PC bi-directional NU 1 = PC Excel format on print command 2 = remote display 3 = printer protocol with power control 4 = printer protocol without power control 5 = Not used 6 = PC Excel format with ack/nack 7 = Mobile barcode printer 8 = Scanner serial prot.

36

Number of line feeds com2

4

4

4

0–9

37

Handshake com2

soft

soft

soft

soft (Xon/Xoff), hard (CTS)

38

Print Twice

E

0

0

0

0 = Print only once 1 = Print twice

39

Protocol com2.2 only C

2.18

None

None

None

None, 0 (PC bidirectional)

31

D

NOTE: This is automatically set based on parameter 35 setting.

A Some software versions may not offer “ntepC” as an option.

B Some software versions may only have options 1 through 10 available.

C Com2.1 is used with a printer and Com2.2 is used for Bluetooth® communication to a PDA. D Some software versions may only have options 1 through 5 available.

E Some software versions may not offer this parameter.

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Service Parameters

Default Settings Parameter Number

Function

Software Version

EU

NTEP

NonNTEP

Available Setting Options

US 40

Level sensor

no/ls

no

no

no/ls, nc/ls, no/cs, ra/cs, ls

41

Delay trigger time level sensor

3

3

3

0 – 10 sec

43

Compensation factor correction factor

1

1

1

0.1 – 10.0

44

Compensation factor X-direction

1

1

1

0.1 – 10.0

45

Compensation factor Y-direction

1

1

1

0.1 – 10.0

49

Under-load percentage of FS

002

002

002

0%-100%

60

Battery used

6

12V

FLT

6V, 12V

61

Low Bat switch-off time

2

2

2

0 = never off, 1 – 99 minutes

62

Auto shut-off time indicator

2

99

99

0 = never off, 1 – 99 minutes

63

Auto shut-off time forks

3

3

3

0 = never off 1 = 30 min 2 = 1 hour 3 = 2 hour

64

Sleep time indicator if used

0

0

0

0 (not used), 1 – 99 min

65

Auto shut-off time backlight

20

20

20

off, 20, 40, 80, 160, 320 sec

66

Backlight brightness

100

100

100

100%, 75%, 50%, 25%, 0% (NOTE: 0% means the backlight is off)

67

Low bat switch off time forks

10

10

10

0 = never off, 1 – 99 min

A Some software versions may not offer “ntepC” as an option.

B Some software versions may only have options 1 through 10 available.

C Com2.1 is used with a printer and Com2.2 is used for Bluetooth® communication to a PDA. D Some software versions may only have options 1 through 5 available.

E Some software versions may not offer this parameter.

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Parameters Default Settings Parameter Number

Function

Software Version

NTEP

EU

NonNTEP

Available Setting Options

US 68

Buzzer function active

Before 2.15

off

off

off

off, on = direct OR on = 2 sec delay

2.15 & 2.18

no

no

no

Yes, No

69

Disable buttons NOTE: Use this option only if P16 is set to one of following numbers: 1 14.

E

0

0

0

0 = All buttons and additional options are enabled 1 = Disable Tare function 2 = Disable Tare and Sum functions 3 = Disable Tare, Sum and Entry Mode functions

70

Tare clear

2.18

no

no

no

No = Tare remains in memory after new weight has been picked Yes = Tare is cleared after new weight is picked

NOTE: This is default when P13 is selected as “OIML”.

80

Digital corner calibration active

0

0

0

0 = enabled 1 = disabled

81

Compensation factor digital corner A

1.000

1.000

1.000

Do not change value after the forks are calibrated (corner calibration).

82

Compensation factor digital corner B

1.000

1.000

1.000

Do not change value after the forks are calibrated (corner calibration).

83

Compensation factor digital corner C

1.000

1.000

1.000

Do not change value after the forks are calibrated (corner calibration).

84

Compensation factor digital corner D

1.000

1.000

1.000

Do not change value after the forks are calibrated (corner calibration).

A Some software versions may not offer “ntepC” as an option.

B Some software versions may only have options 1 through 10 available.

C Com2.1 is used with a printer and Com2.2 is used for Bluetooth® communication to a PDA. D Some software versions may only have options 1 through 5 available.

E Some software versions may not offer this parameter.

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Service Parameters

Default Settings Parameter Number

Function

Software Version

EU

NTEP

NonNTEP

Available Setting Options

US 90

91

92 E

93 E

Default settings without changing calibration

2.15 & before

Reset current parameter settings to default (factory) settings.

NOTE: Calibration settings will not change.

2.18

Default settings with changing calibration

2.15 & before

Reset current parameter and calibration settings to default (factory) settings.

Refer to “Reset Current Parameter and Calibration Settings To Default (Factory) Settings” on page 38.

2.18

Recall stored settings calibration

2.15 & before

View (recall) current calibration settings.

Refer to “View Current Calibration Settings” on page 35.

Convert calibration settings when Parameter 1 has changed. Refer to “Change Units” on page 37.

2.18

Read out last 10 error messages

2.15 & before

Read out last 50 error messages with time stamp

2.18

NOTE: Actual registration of the 50 error messages with time stamp (the date and time must be set first).

A Some software versions may not offer “ntepC” as an option.

B Some software versions may only have options 1 through 10 available.

C Com2.1 is used with a printer and Com2.2 is used for Bluetooth® communication to a PDA. D Some software versions may only have options 1 through 5 available.

E Some software versions may not offer this parameter.

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Parameters Default Settings Parameter Number

Function

Software Version

NTEP

EU

NonNTEP

Available Setting Options

US 94 E

Back up initial parameter settings and calibration (factory use only)

2.18

00000

00000

00000

NOTE: This is password protected.

95 E

Factory use only

00000

00000

00000

96

Printout parameter setup

Pr-C1

Pr-C1

Pr-C1

Pr-C1, Pr-C2

97

Key Test Function (buzzer and nr)

98

Scale ID number

1

1

1

0 – 9999

99

Software version

2.XX

2.XX

2.XX

A Some software versions may not offer “ntepC” as an option.

B Some software versions may only have options 1 through 10 available.

C Com2.1 is used with a printer and Com2.2 is used for Bluetooth® communication to a PDA. D Some software versions may only have options 1 through 5 available.

E Some software versions may not offer this parameter.

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View Current Calibration Settings NOTE: Some software versions may not offer this parameter.

6. Each corner calibration value will show for two seconds.

Corner A value:

Corner B value:

Corner C value:

Corner D value:

1. Access the Parameters Menu as described in “Accessing The Parameters Menu” on page 24.

2. Verify that Parameters 1 through 5 are correct according to US (EU) values found on the sticker on the display. Refer to “Accessing The Parameters Menu” on page 24, Steps 2, 3 and 4. Press the “Zero” button after viewing each value.

3. Change the current parameter menu number to “92”. Refer to “Accessing The Parameters Menu” on page 24, Steps 2 and 3.

7. Press the “Total” button (up) to view the zero calibration and weight calibration values.

4. The display will show “FC_bE”.

5. Press the “Tare” button (down) to view the four corner calibration values.

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Parameters 8. The following values will show on the display in sequence: • A = Unit type used for calibration • B = Gravity value • C = Zero calibration value and AD value.

• D = Weight calibration value(s) and AD values.

NOTE: If one weight was used for weight calibration, “Weight 2” and “Weight 3” will show zero for weight on the display.

A Unit type – lb. or kg

B Gravity Value

C Zero Calibration Value

Zero Calibration AD Value

D

Weight Calibration 1, Weight value

Weight Calibration 1, AD value

Weight Calibration 2, Weigh value

Weight Calibration 2, AD value

Weight Calibration 3, Weigh value

Weight Calibration 3, AD value

Number of Calibration Points

9. After the sequence is performed, the display will show “FC_bE”.

10. To exit, press the “On/Off” button two times.

9 10

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Change Units

4. Change the parameter from kg to lb. or lb. to kg using the “Total” button. Refer to “Changing A Parameter's Setting” on page 25, Step 5.

NOTE: Some software versions may not offer this parameter.

NOTE: This procedure requires calibration settings to be converted to the changed unit (lb. or kg).

Change units

Verify that the display is version 2.13 or greater. Earlier versions before 2.13 will require recalibrating the Mobile Scale Forks. Contact your local Raymond Sales and Service Center.

Use the “Tare” and “Total” Buttons 5. To accept the changed unit, press the “Zero” button.

1. Access the Parameters Menu as described in “Accessing The Parameters Menu” on page 24.

6. Update Parameters 2 through 5 referencing the chart below. Refer to “Changing A Parameter's Setting” on page 25 to update the parameters.

2. Change the current parameter menu number to “01”. Refer to “Changing A Parameter's Setting” on page 25, Steps 2 and 3.

NOTE: The following changes are for standard Mobile Scale Forks. If the Mobile Scale Forks system is customized, contact your local Raymond Sales and Service Center on updating Parameters 2 through 5.

3. Press the “Zero” button to enter the selected parameter.

Mobile Scale Forks Capacity (Non-NTEP only)

Parameter 2

Parameter 3

Parameter 4

Parameter 5

US

EU

US

EU

US

EU

US

EU

4500 lb. (2045 kg)

2

1

2

1

1000

550

4500

2045

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Parameters 7. Change the current parameter menu number to “92”. Refer to “Changing A Parameter's Setting” on page 25, Steps 2 and 3.

Reset Current Parameter and Calibration Settings To Default (Factory) Settings NOTE: Initial parameter settings are backed up at the factory. The following procedure recovers factory parameter settings.

8. Press the “Zero” button to enter Parameter 92.

1. Access the Parameters Menu as described in “Accessing The Parameters Menu” on page 24.

9. The display will show “FC_bE”.

9 10

10. Press and hold the “On/Off” button for three seconds.

2. Change the current parameter menu number to “91”. Refer to “Changing A Parameter's Setting” on page 25, Steps 2 and 3.

11. The display will show “donE” for two seconds.

3. The display will show “SEt” for ten seconds.

12. The display will revert to the parameter menu, showing parameter 93.

12 13

13. Press the “On/Off” button two times.

14. The display will show “SEt” and then return to normal weighing mode.

4. The display will revert to the parameter menu, showing parameter 92.

4

5

5. To exit, press the “On/Off” button two times.

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Service Non-NTEP Three Part Calibration

Non-NTEP Three Part Calibration Calibration Introduction

Read all the instructions prior to performing each calibration procedure.

Always contact your local Raymond Sales and Service Center prior to performing any calibration procedure.

Failure to follow instructions exactly will change the accuracy of the Mobile Scale Forks and could compromise the system's ability to weigh.

There are three parts to calibrating non-NTEP Mobile Scale Fork trucks. Some cases only require a portion of the Three Part Calibration to be performed. Refer to the chart below. A summary of each part is as follows: •

Zero Calibration – Determines and sets the zero point for the Mobile Scale Forks system.

•

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 Mobile Scale Forks system by using a sample of known weight(s).

When to Calibrate 1

Calibration Procedures 3

When the Mobile Scale Forks are not within system tolerance.

Perform “Zero Calibration” (page 41) and “Weight Calibration” (page 44) with at least one known weight

When the weighing range does not meet end user preferences.

Perform “Zero Calibration” (page 41) and “Weight Calibration” (page 44) with at least one known weight

When the display or wire harness has been replaced. 2

Perform “Zero Calibration” (page 41), “Corner Calibration” (page 42) and “Weight Calibration” (page 44)

1 Always use correct handling and

troubleshoot the Walkie Scale Fork assemblies first before calibrating.

Inaccuracies can occur when debris becomes wedged into and between the fork shoe and arm. Always use calibration as a last option.

NOTE: 2 Prior to calibration, the Mobile Scale Forks system must have an established connection between the Mobile Scale Forks Bluetooth® receivers and the display. Refer to “Load Cell and Level Sensor Removal” on page 62.

3 Always perform the tasks and

calibration in the order listed.

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Non-NTEP Three Part Calibration

Prior to Calibration 1. Determine which fork is Fork 1 and which fork is Fork 2. Each fork is assigned specific load cell (corner) positions.

NOTE: Load cell positions can be found where fork shoe cap screws are located, as shown in Figure 1-3.

Figure 1-3.

Load Cell Position Identification

Fork 1

Position A (near fork base) Position B (toward fork tip)

Fork 2

Position D (near fork base) Position C (toward fork tip)

Position D Position C FK0491.eps

Position A Fork 2

Position B Fork 1

2. Verify down-stops are set correctly. Refer to the lift truck service manual for instructions.

3. Make sure the forks shoes are seated before starting the calibration procedure.

To seat the forks, place the weight in the center of a pallet and lift three to five times. Fork shoes that are not seated correctly can cause inaccuracies in the calibration process.

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Zero Calibration Zero Calibration is the first procedure of the Three Part Calibration. This procedure is also used when the Mobile Scale Forks are not within system tolerance or end user preferences. This calibration procedure defines the zero point of the system.

1. If required, turn on the display.

4. Once the display shows “Adj08”, the display will count down from 8 while the system zeros.

5. After the system has zeroed, the display will show “AP” or “AP 0”.

2. Place an empty pallet on the Mobile Scale Forks (and/or if desired, use a protective cover). Raise the Mobile Scale Forks so that the pallet/cover is not touching the ground.

6. The display will show “donE”.

NOTE: If performing this procedure alone or after finishing the “Weight Calibration” procedure (page 44) the forks must be empty of pallets, covers, bins and/or loads.

3. Hold the “Zero” button for approximately 10 seconds. During the 10 second interval, the display will show “00000” and then “Adj08”. Release the “Zero” button when “Adj08” shows on the display.

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While “donE” shows, press and hold the “Zero” button for three seconds. This will store the calibration value. The display will show “SEt” while storing the calibration value.

To Store Zero Calibration Value: Press and hold the “Zero” button for three seconds.

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Non-NTEP Three Part Calibration 7. The display is zeroed and will return to normal weighing mode.

Corner Calibration 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.

NOTE: This procedure is set up where Fork 1 is the left fork and corner positions are as shown on page 40. Verify fork layout prior to performing this procedure.

NOTE: Use a minimum 100 lbs. (45 kg). For optimal corner calibration, use 1000 lbs. (454 kg).

3. Press the “Zero” button. The display will show an average output value of all the load cells (example 45520),

4. Press the “Zero” button.

5. “Corn A” will show on the display.

6. Place a weight on pallet, position A.

NOTE: Use the same weight for each corner 1. From normal weighing mode, press and hold the “Tare” button until “CAL” appears on the display.

NOTE: Various screens may show on the display. Depending on the display’s software version, the amount of time for “CAL” to appear, will vary from 20 to 30 seconds.

2. Press the “Total” button. “Corn” will appear.

42

7. Press the “Zero” button, to accept the weight (load cell output) value.

8. A new value will show on the display (example 45144). Then “Cornb” will show on the display.

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9. Move the same weight to position B.

10. Press the “Zero” button, to accept the weight (load cell output) value.

14. A new value will show on the display (example 45340). Then “Cornd” will show on the display.

15. Move the same weight to position D.

11. A new value will show on the display (example 46014). Then “CornC” will show on the display.

16. Press the “Zero” button, to accept the weight (load cell output) value.

12. Move the same weight to position C.

17. A new value will show on the display (example 45582). Then “donE” will show on the display.

13. Press the “Zero” button, to accept the weight (load cell output) value.

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Non-NTEP Three Part Calibration 18. Press and hold the “Zero” button until the display shows “SEt”.

1. If necessary, turn on the display.

2. Press and hold the “Tare” button until “CAL” appears on the display.

19. The display will return to normal weighing mode.

NOTE: If the display has a negative weight, perform the “Zero Calibration” procedure (page 41) with the pallet/cover remaining on the Mobile Scale Forks. Then continue to the next procedure, “Weight Calibration”.

NOTE: Various screens will show on the display. Depending on the display’s software version, the amount of time for “CAL” to appear, will vary from 20 to 30 seconds.

3. Press the “Zero” button.

Weight Calibration Weight Calibration is the third procedure of the Three Part Calibration. This procedure uses the sample of weights to determine the curve of how the system measures weight based on three known weights. If no known weights are available, contact your local dealer or scale company to obtain the weights. Weight range should be as follows:

4. “Unit” will show. If necessary, change the units from kg to lb. by pressing the “Total” button.

Choose lb. or kg

Weight 1 – 1/3 Capacity, for example: 1,500 lb. (680 kg) Weight 2 – 2/3 Capacity, for example: 3,000 lb. (1,360 kg) Weight 3 – Full Capacity, for example: 4,500 lb. (2,045 kg)

NOTE: Always calibrate with the same unit (lb. or kg) of the known weight's rated unit. Example: If the weight is rated at 1,000 lb., the unit selected on the display will use “lb”.

5. Press the “Zero” button to accept the unit.

The Mobile Scale Forks system tolerance can be achieved using three known weights (0.1%). If the handled product weight range is very consistent, 1 or 2 weight(s) is sufficient.

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6. An arrow above “e1” will show on the screen. Press the “Zero” button to begin calibration for the first (known) weight, Weight 1.

NOTE: If a pallet/cover was not a part of the “Zero Calibration” (page 41), the weight entered must include pallet weight (Weight 1 + Pallet Weight).

7. If required, change the weight value shown on the display to match the value of the known weight (Weight 1). Use the Entry Mode Guide (below) as an aid to change the total weight (A and B). Always accept the value by pressing the “Zero” button, C.

e1 arrow will flash

The following buttons are available while in Entry Mode:

Entry Mode Guide

A

Decrease the Value

Selected value will flash

Increase the Value

C

A

B

B

Shift to the next digit on the left

C

Accept the value (press last)

8. Place a Weight 1 on the pallet/cover so that the weight is centered evenly between the four corner positions.

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9. Allow the load to rest for 5 seconds on the Mobile Scale Forks. Press and hold the “Zero” button for three seconds.

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Non-NTEP Three Part Calibration 10. 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”.

14. Place Weight 2 on the pallet/cover so that the weight is centered evenly between the four corner positions.

Weight 2

15. Allow the load to rest for 5 seconds on the Mobile Scale Forks. Press and hold the “Zero” button for three seconds.

11. Press the “Total” button.

12. The arrow above “e1” will move to “e2”. If required, remove the weight from the Mobile Scale Forks. Press the “Zero” button to begin calibration for the second (known) weight, Weight 2.

16. 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 “e2”.

e2 arrow will flash

NOTE: If a pallet/cover was not a part of the “Zero Calibration” (page 41), the weight entered must include pallet weight (Weight 2 + Pallet Weight).

13. If required, change the weight shown on the display to match the value of the known weight (Weight 2). Use the Entry Mode Guide (shown in step 7) as an aid to change the total weight (A and B). Always accept the value by pressing the “Zero” button, C.

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17. Press the "Total" button.

18. The arrow above “e2” will move to “e3”. If required, remove the weight from the Mobile Scale Forks. Press the “Zero”

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button to calibrate for the third (known) weight, Weight 3.

to showing the weight and an arrow flashing over “e3”.

e3 arrow will flash

NOTE: If a pallet/cover was not a part of the “Zero Calibration” (page 41), the weight entered must include pallet weight (Weight 3 + Pallet Weight).

19. If required, change the weight shown on the display to match the value of the known weight (Weight 3). Use the Entry Mode Guide (shown in step 7) as an aid to change the total weight (A and B). Always accept the value with the “Zero” button, C. 20. Place a Weight 3 on the pallet/cover so that the weight is centered evenly between four corner positions.

23. Press the “Total” button.

24. The screen will show an AP value, for example “AP 27”. Press the “Zero” button.

The value on the screen is the percentage of weight used.

Weight 3

21. Allow the load to rest for 5 seconds on the Mobile Scale Forks. Press and hold the “Zero” button for three seconds.

25. The screen will show “Zone” and then show a gravitation value. If needed, change the gravitation value. Use the Entry Mode Guide (shown in Step 7) as an aid to change the gravitation value (A and B). Always accept the value by pressing the “Zero” button, C. USA – 9.803 European – 9.812 NOTE: High altitude and other circumstances may require a different value. Contact

22. The screen will show “Adj08” and then will count down from 8 while the display records the weight. The screen will return

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Non-NTEP Three Part Calibration your local Raymond Sales and Service Center for gravitational value.

29. In the following order, confirm that each weight shown on the display matches the rated weight value: A No weight B Weight 1 C Weight 2 D Weight 3 Cycle through the order listed above one to five times.

30. If the rated weight and the display are within the expected tolerance, remove the pallet/cover from the Mobile Scale Forks.

Perform “Zero Calibration” (page 41).

26. The display will shown “done”.

• To store the calibration value into the display’s memory, while “done” shows, press and hold the “Zero” button for three seconds. The display will show “Set” while storing information in the memory.

27. The display will return to normal weighing mode, showing the current weight on the Mobile Scale Forks.

28. Remove the weight from the Mobile Scale Forks.

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NTEP Calibration Calibration Introduction

Read all the instructions prior to performing each calibration procedure.

Always contact your local Raymond Sales and Service Center prior to performing any calibration procedure.

Failure to follow instructions exactly will change the accuracy of the Mobile Scale Forks and could compromise the system's ability to weigh.

There are four parts to calibrating NTEP Mobile Scale Fork trucks. NTEP trucks require all portions of the Calibration to be performed.

Refer to chart below. A summary of each part is as follows: •

Single Point Scan Calibration – Uses a single known weight to set the scale.

Single Point Calibration is less accurate over the truck’s full capacity ability than the Full Point Calibration.

•

NTEP Corner Calibration – Takes any inconsistency between the load cells (corners) and equalizes them with each other by adjusting the potentiometers in the junction box.

•

NTEP Zero Calibration – Determines and sets the zero point for the Mobile Scale Forks system.

•

Full Point Scan Calibration – Uses three known weights to build a more accurate trend line for the scale.

When to Calibrate 1

Calibration Procedures 3

When the Mobile Scale Forks are not within system tolerance.

Perform all portions of the calibration procedure in the order listed.

When the weighing range does not meet end user preferences.

Perform all portions of the calibration procedure in the order listed.

When the display or wire harness has been replaced. 2

Perform all portions of the calibration procedure in the order listed.

NOTE: An NTEP truck must be re-certified whenever the display, harness, level sensor, or any load cell is replaced.

1 Always use correct handling and

troubleshoot the Walkie Scale Fork assemblies first before calibrating.

Inaccuracies can occur when debris becomes wedged into and between the fork shoe and arm. Always use calibration as a last option.

3 Always perform the tasks and

calibration in the order listed.

NOTE: 2 Prior to calibration, the Mobile Scale Forks system must have an established connection between the Mobile Scale Forks Bluetooth® receivers and the display. Refer to “Load Cell and Level Sensor Removal” on page 62.

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NTEP Calibration

Prior to Calibration 1. Determine which fork is Fork 1 and which fork is Fork 2. Each fork is assigned specific load cell (corner) positions.

NOTE: Load cell positions can be found where fork shoe cap screws are located, as shown in Figure 1-3.

Figure 1-4.

Load Cell Position Identification

Fork 1

Position A (near fork base) Position B (toward fork tip)

Fork 2

Position D (near fork base) Position C (toward fork tip)

Position D Position C FK0491.eps

Position A Fork 2

Position B Fork 1

2. Verify down-stops are set correctly. Refer to the lift truck service manual for instructions.

3. Make sure the forks shoes are seated before starting the calibration procedure.

To seat the forks, place the weight in the center of a pallet and lift three to five times. Fork shoes that are not seated correctly can cause inaccuracies in the calibration process.

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Single Point Scan Calibration

5. Press the “Zero” button to accept the unit.

Single Point Scale Calibration is the first procedure in the calibration of an NTEP truck.

1. If necessary, turn on the display.

6. An arrow above “e1” will show on the screen. Press the “Zero” button to begin calibration for the first weight, Weight 1.

2. Press and hold the “Tare” button until “CAL” appears on the display.

NOTE: The weight entered must include pallet weight (Weight 1 + Pallet Weight). e1 arrow will flash

NOTE: Various screens will show on the display. Depending on the display’s software version, the amount of time for “CAL” to appear, will vary from 20 to 30 seconds.

3. Press the “Zero” button.

7. If required, change the weight value shown on the display to match the value of the known weight (Weight 1). Use the Entry Mode Guide (below) as an aid to change the total weight (A and B). Always accept the value by pressing the “Zero” button, C.

4. “Unit” will show. If necessary, change the units from kg to lb. by pressing the “Total” button.

Choose lb. or kg

NOTE: Always calibrate with the same unit (lb. or kg) of the known weight's rated unit. Example: If the weight is rated at 1,000 lb., the unit selected on the display will use “lb”.

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The following buttons are available while in Entry Mode:

Entry Mode Guide

A

Decrease the Value

Selected value will flash Increase the Value

C

A

B

Shift to the next digit on the left

C

Accept the value (press last)

B

8. Place a Weight 1 on the pallet/cover so that the weight is centered evenly between the four corner positions.

10. 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”.

9. Allow the load to rest for 5 seconds on the Mobile Scale Forks. Press and hold the “Zero” button for three seconds.

11. Press the “Total” button.

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12. The arrow above “e1” will move to “e2”. e2 arrow will flash

19. Remove the weight from the Mobile Scale Forks.

20. If the rated weight and the display are within the expected tolerance, remove the pallet/cover from the Mobile Scale Forks.

Perform “NTEP Corner Calibration” (page 53).

13. Press the “Total” button again.

14. The arrow above “e2” will move to “e3”. e3 arrow will flash

15. Press the “Total” button again.

16. The screen will show AP. Press the “Zero” button. The value on the screen should read 9.803.

17. The display will shown “done”.

NTEP Corner Calibration Corner Calibration is the second procedure in the calibration of an NTEP truck.

NOTE: This procedure is set up where Fork 1 is the left fork and corner positions are as shown on page 50. Verify fork layout prior to performing this procedure.

NOTE: Use a minimum 100 lbs. (45 kg). For optimal corner calibration, use 1000 lbs. (454 kg).

NOTE: Use the same weight for each corner.

1. Raise the forks approximately 1/2 to 1 in.

(13 to 24.5 mm). Place aluminum wedges under the frame near the flag pin.

• Press and hold the “Zero” button until “SEt” displays, then release the “Zero” button.

2. Check the weight on the display for each of the four corners. Normally at least two of the corner’s weight is the same on the display.

18. The display will return to normal weighing mode, showing the current weight on the Mobile Scale Forks.

3. Remove the junction box from the accessory bar. Remove the screws and cover from the junction box.

4. Place the weight on one of the corners that does not match.

5. Adjust the corresponding potentiometer inside the junction box. Turn the potentiometer screw 1 to 1.5 turns then

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NTEP Calibration check the display reading. Repeat as needed until this corner matches the other two.

NTEP Zero Calibration Zero Calibration is the third procedure in the calibration of an NTEP truck. This calibration procedure defines the zero point of the system.

NOTE: It is important that you do not lean on or touch the truck while performing this calibration procedure. Movement during calibration can corrupt the calibration.

1. If required, turn on the display.

6. Repeat step 2 for the remaining corner.

7. Recheck the weight on the display for each of the four corners. Repeat step 2 until the display shows the same weight for all corners.

NOTE: The displayed weight must be the same for all corners, it does not need to match the actual weight.

2. Place an empty pallet on the Mobile Scale Forks (and/or if desired, use a protective cover). Raise the Mobile Scale Forks approximately 1 in. (25.4 mm) so that the pallet/cover is not touching the ground.

8. Place the cover on the junction box and secure with screws.

Use care when installing the cover to prevent damage to wires. Damaged wires can affect load cell operation and weight accuracy.

9. Mount the junction box in the original location under the accessory bar.

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NOTE: If performing this procedure alone or after finishing the “Weight Calibration” procedure (page 44) the forks must be empty of pallets, covers, bins and/or loads.

3. Hold the “Zero” button for approximately 10 seconds. During the 10 second interval, the display will show “00000” and then “Adj08”. Release the “Zero” button when “Adj08” shows on the display.

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4. Once the display shows “Adj08”, the display will count down from 8 while the system zeros.

Full Span Calibration Full Span Calibration is the forth procedure in the calibration of an NTEP truck.

1. If necessary, turn on the display.

5. After the system has zeroed, the display will show “AP” or “AP 0”.

2. Press and hold the “Tare” button until “CAL” appears on the display.

6. The display will show “donE”.

NOTE: Various screens will show on the display. Depending on the display’s software version, the amount of time for “CAL” to appear, will vary from 20 to 30 seconds.

3. Press the “Zero” button.

To Store the Zero Calibration Value: While “donE” shows, press and hold the “Zero” button for three seconds. This will store the calibration value.

4. “Unit” will show. If necessary, change the units from kg to lb. by pressing the “Total” button.

Choose lb. or kg

The display will show “SEt” while storing the calibration value.

7. The display is zeroed and will return to normal weighing mode.

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NOTE: Always calibrate with the same unit (lb. or kg) of the known weight's rated unit. Example: If the weight is rated at 1,000 lb., the unit selected on the display will use “lb”.

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NTEP Calibration 5. Press the “Zero” button to accept the unit.

entered must include pallet weight (Weight 1 + Pallet Weight). e1 arrow will flash

6. An arrow above “e1” will show on the screen. Press the “Zero” button to begin calibration for the first (known) weight, Weight 1.

NOTE: If a pallet/cover was not a part of the “Zero Calibration” (page 41), the weight

7. If required, change the weight value shown on the display to match the value of the known weight (Weight 1). Use the Entry Mode Guide (below) as an aid to change the total weight (A and B). Always accept the value by pressing the “Zero” button, C.

The following buttons are available while in Entry Mode:

Entry Mode Guide

A

Decrease the Value

Selected value will flash Increase the Value

C

A

B

Shift to the next digit on the left

C

Accept the value (press last)

B

8. Place a Weight 1 on the pallet/cover so that the weight is centered evenly between the four corner positions.

9. Allow the load to rest for 5 seconds on the Mobile Scale Forks. Press and hold the “Zero” button for three seconds.

10. The screen will show “Adj08” and then will count down from 8 while the display records the weight. The screen will return

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to showing the weight and an arrow flashing over “e1”.

14. Place Weight 2 on the pallet/cover so that the weight is centered evenly between the four corner positions.

Weight 2

11. Press the “Total” button.

15. Allow the load to rest for 5 seconds on the Mobile Scale Forks. Press and hold the “Zero” button for three seconds.

12. The arrow above “e1” will move to “e2”. If required, remove the weight from the Mobile Scale Forks. Press the “Zero” button to begin calibration for the second (known) weight, Weight 2.

16. 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 “e2”.

e2 arrow will flash

NOTE: If a pallet/cover was not a part of the “Zero Calibration” (page 41), the weight entered must include pallet weight (Weight 2 + Pallet Weight).

13. If required, change the weight shown on the display to match the value of the known weight (Weight 2). Use the Entry Mode Guide (shown in step 7) as an aid to change the total weight (A and B). Always accept the value by pressing the “Zero” button, C.

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17. Press the "Total" button.

18. The arrow above “e2” will move to “e3”. If required, remove the weight from the Mobile Scale Forks. Press the “Zero”

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NTEP Calibration button to calibrate for the third (known) weight, Weight 3.

to showing the weight and an arrow flashing over “e3”.

e3 arrow will flash

NOTE: If a pallet/cover was not a part of the “Zero Calibration” (page 41), the weight entered must include pallet weight (Weight 3 + Pallet Weight).

19. If required, change the weight shown on the display to match the value of the known weight (Weight 3). Use the Entry Mode Guide (shown in step 7) as an aid to change the total weight (A and B). Always accept the value with the “Zero” button, C. 20. Place a Weight 3 on the pallet/cover so that the weight is centered evenly between four corner positions.

23. Press the “Total” button.

24. The screen will show an AP value, for example “AP 27”. Press the “Zero” button.

The value on the screen is the percentage of weight used.

Weight 3

21. Allow the load to rest for 5 seconds on the Mobile Scale Forks. Press and hold the “Zero” button for three seconds.

25. The screen will show “Zone” and then show a gravitation value. If needed, change the gravitation value. Use the Entry Mode Guide (shown in Step 7) as an aid to change the gravitation value (A and B). Always accept the value by pressing the “Zero” button, C. USA – 9.803 European – 9.812 NOTE: High altitude and other circumstances may require a different value. Contact

22. The screen will show “Adj08” and then will count down from 8 while the display records the weight. The screen will return

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your local Raymond Sales and Service Center for gravitational value.

30. In the following order, confirm that each weight shown on the display matches the rated weight value: A No weight B Weight 1 C Weight 2 D Weight 3 Cycle through the order listed above one to five times.

26. The display will shown “done”.

31. If the rated weight and the display are within the expected tolerance, remove the pallet/cover from the Mobile Scale Forks.

If the rated weight and display are not within the expected tolerance. Repeat all portions of the “NTEP Calibration” beginning on page 49.

• To store the calibration value into the display’s memory, while “done” shows, press and hold the “Zero” button for three seconds. The display will show “Set” while storing information in the memory.

27. The display will return to normal weighing mode, showing the current weight on the Mobile Scale Forks.

28. Remove the weight from the Mobile Scale Forks.

29. Change Parameter 40 setting. See “Change Parameter 40 Setting” on page 60.

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Change Parameter 40 Setting

3. The display will show “P_ _00”.

The NTEP Calibration process requires Parameter 40 to be changed. Use the following procedure to change Parameter 40.

1. After calibration, turn the display OFF. 4. Change the parameter value to 40. Use the Entry Mode Guide (below) as an aid to change the parameter number (A and B).

Always accept the value by pressing the “Zero” button, C. 2. Press and hold the “On/Off” button for 30 seconds to turn the display ON.

The following buttons are available while in Entry Mode:

Entry Mode Guide

A

Decrease the Value

Selected value will flash

Increase the Value

B

C

5. Press the “Zero” button to enter the selected parameter.

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B

Shift to the next digit on the left

C

Accept the value (press last)

A

6. Change parameter 40 setting to “CSFA”.

Press the “Zero” button. The display screen will go to the main parameter screen, showing the next parameter number.

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7. To exit and save settings, press the “On/Off” button two times.

8. The display will return to normal weighing mode.

9. Restart the display to enable the recent changes:

• Press and hold the “On/Off” button for three seconds to turn OFF the display.

• Then, press the “On/Off” button to turn ON the display.

NOTE: The display must be cycled OFF/ON to finalize the parameter settings.

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Load Cells and Level Sensor

Load Cells and Level Sensor

Cap Screws and Tolerance Rings

Cap Screws

Level Sensor (NTEP) Junction Box

Fork Shoe

Cover Spool FK0501.eps

Fork Carriage Nuts

Load Cells

Load Cell and Level Sensor Removal The following procedure can be performed with the Mobile Scale Forks mounted on the lift truck.

1. Remove the fork shoe from the fork carriage. Remove the cap screws and nuts from the fork shoe. Slide the fork shoe from the fork carriage. Keep track of the cover spools, cap screws, and nuts.

2. Remove the cap screws and tolerance rings from the load cells. If equipped with a level sensor, remove the cap screws.

3. Remove the load cell or level sensor. Note the wire harness routing to aid with installation. Taking a photo of the routing is recommended.

4. Disconnect the load cell wire ends from the junction box terminals.

5. Clean any debris and dirt from the fork carriages, fork shoes, and other components.

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Load Cell & Level Sensor Installation

1. Remove the old load cells as described in “Load Cell and Level Sensor Removal” on page 62.

Handle the load cells with care. Picking up the load cell by its wires or letting the load cells hit each other, will damage the connection between the load cells and wires.

2. Install the two tolerance rings to each load cell.

Use extreme caution and care when installing the load cells and wiring. Touching wires, pinched wires, kinked wires, or sharp bends in wiring will affect the signal of the load cells.

3. Install the load cells and level sensor (if equipped) into the fork carriage. Tighten the cap screws to the torque of: Load Cells – 80 ft. lbs. (110 Nm) Level Sensor – 2.1 ft. lbs. (2.8 Nm)

Junction Box Level Sensor (NTEP) Tolerance Rings Load Cells Fork Carriage

FK0502.eps

4. Perform the correct Wiring procedures for this type of truck. Refer to “Load Cell and Level Sensor Cable Routing” on page 65, and “Non-NTEP Truck Junction Box Wiring Connections” on page 68 or “NTEP Truck Junction Box and Display Wiring Connections” on page 70.

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Load Cells and Level Sensor 5. Install the cover spools to the load cells.

Cap Screws Fork Shoe

Cover Spool FK0503.eps

Fork Carriage Nuts

Load Cells

6. Slide the fork shoe onto the fork carriage until the mounting holes line up. Install the cap screws and nuts. Tighten to 80 ft. lbs. (110 Nm).

NOTE: Make sure the forks shoes are seated before moving on to the calibration procedure. To seat the forks, place the weight in the center of a pallet and lift three to five times. Fork shoes that are not seated correctly can cause inaccuracies in the calibration process.

7. Perform the correct Calibration procedure for this type of truck. Refer to “Non-NTEP Three Part Calibration” on page 39 or “NTEP Calibration” on page 49.

NOTE: If the display errors, the wires may be touching the shoe or may be pinched.

Check for marks indicating a pinch point. Reposition the wires and reinstall the fork shoe. Repeat until the display no longer shows an error.

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Wiring

Figure 1-6.

A

Load Cell and Level Sensor Cable Routing Figure 1-5.

Load Cell and Level Sensor Locations/Wire Routing – Forks Section

A C

6

Load Cell and Level Sensor Wire Routing – Under Battery Box

A 3

4

2

5

A = Secure cables with cable ties in these locations.

1

Load Cell and Level Sensor Locations/Wire Routing Legend

1. Route Load Cell A [1] cable through the channel along the fork carriage to the underside of the battery box (Figure 1-5).

Route the cable through the hole under the battery box (Figure 1-6) and out the left side of the truck. Secure the cable under the tab on the fork carriage with a cable tie.

2. Route Load Cell E [5] cable through the channel along the fork carriage, between Load Cell B and the fork carriage, to the underside of the battery box (Figure 1-5).

Route the cable through the hole on the inside carriage rail. Continue routing the cable through the center hole under the battery box (Figure 1-6) and toward the right side of the truck. Make sure to stay above the lower link.

1

Load Cell 1/A

2

Load Cell 2/B

3

Load Cell 3/C

4

Load Cell 4/D

5

Load Cell 5/E

6

Load Cell 6/F

C

Level Sensor (NTEP trucks only)

A

Secure cables under tab in these locations

3. Create a 1 to 1.5 in. loop in the Load Cell B cable [2]. Push the loop into the guide channel. Continue routing the cable between Load Cell B and the fork carriage, to the underside of the battery box (Figure 1-5). Route the cable through the hole on the inside carriage rail. Continue routing the cable through the center hole under the battery box (Figure 1-6) and toward the right side of the truck. Make sure to stay above the lower link. Secure

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Wiring the cables B and E under the tab on the inner fork carriage with a cable tie.

9. Continue to route the four cables to the right side of the truck.

4. Route Load Cell F cable [6] through the channel along the fork carriage to the underside of the battery box (Figure 1-5).

Route the cable through the hole under the battery box (Figure 1-6) and out the right side of the truck. Secure the cable under the tab on the fork carriage with a cable tie.

NOTE: Make sure the wires are not in the pinch point for the pull rods and linkage as they exit the right side of the truck.

5. Route Load Cell D cable [4] through the channel along the fork carriage, between Load Cell C and the fork carriage, to the underside of the battery box (Figure 1-5).

Route the cable through the hole on the inside carriage rail. Continue routing the cable through the center hole under the battery box (Figure 1-6) and toward the right side of the truck. Make sure to stay above the lower link.

6. Create a 1 to 1.5 in. loop in the Load Cell C cable [3]. Push the loop into the guide channel. Continue routing the cable between Load Cell C and the fork carriage, to the underside of the battery box (Figure 1-5). Route the cable through the hole on the inside carriage rail. Continue routing the cable through the center hole under the battery box (Figure 1-6) and toward the right side of the truck. Make sure to stay above the lower link. Secure the cables C and D under the tab on the inner fork carriage with a cable tie.

7. Route Level Sensor cable [C] along the same path as Load Cell F along the fork carriage to the underside of the battery box (Figure 1-5). Route the cable through the hole under the battery box (Figure 1-6) and out the right side of the truck. Secure the cable under the tab on the fork carriage with a cable tie.

8. Route the four centrally located cables (2/B, 3/C, 4/D, and 5/E) over the bracket on the bottom of the battery box (Figure 1-6). Secure the cables to the top side of the bracket with cable ties.

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10. Route the four cables along with cable 6/F and level sensor cable (if equipped) up the bulkhead on the right side of the truck and through the hole with the load backrest in the top right of the tractor compartment (Figure 1-7).

Figure 1-7.

Load Cell and Level Sensor Wire Routing – Tractor Compartment to Junction Box

A A

A

A A

A

A

A = Secure cables with cable ties in these locations.

Publication: 1284782A, Issued: 20 Mar 2018

Mobile Scale Fork Truck Maintenance Manual Supplement

Service Wiring

Figure 1-8.

Wire Routing, Tractor Right Side

13. Apply protective sleeve over the cables.

14. Route the cables up the inside of the accessory bar to the junction box. Secure with cable ties. Refer to Figure 1-7.

11. Secure the cables with a cable tie only at the bottom tab.

12. Route Cable 1/A up the left side of the truck, across the top of the tractor compartment, and through the hole with the load backrest in the top right of the tractor compartment (Figure 1-7).

Publication: 1284782A, Issued: 20 Mar 2018

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Non-NTEP Truck Junction Box Wiring Connections

Load Cell Wire Color

Terminal Marking

Terminal Position

None

SH

5

To prevent damage to the Junction Box Wires during the wire installation process, it is recommended that the Junction Box Wire Installation tool (P/N 990-1239) be used. Pinched wires can cause the weight readings to be off or the calibration process to fail.

Green

S+

4

White

S–

3

Black

E–

2

Red

E+

1

Orient the junction box so that the two larger terminal blocks are on the left and the wire entrances are toward you.

Figure 1-10.

Figure 1-9.

Non-NTEP Junction Box Terminals – Load Cell Wiring (Load Cells 4/D through 6/F Shown)

Junction Box Terminal and Wire Location Identification

7

65

43

21

12

le Sca

34

4/D

5

12

34

5/E 12

34

1/A

5

12

34

6/F 5

12

34

2/B

5

12

34

3/C

5

5

Load Cell

Junction Box Terminal Block

1/A

1

2/B

2

3/C

3

4/D

4

5/E

5

6/F

6

Scale (Display) Wire Color

Terminal Marking

Terminal Position

Pink

VCC

7

Gray

GND

6

Blue

CTS

5

Brown

RTS

4

White

TXD

3

Green

RXD

2

Red

VIN

1

1. Route the load cell wire to the junction box. Connect the wires to the terminals as indicated in Figure 1-10, Figure 1-11 and the following tables.

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Publication: 1284782A, Issued: 20 Mar 2018

Mobile Scale Fork Truck Maintenance Manual Supplement

Service Wiring

Figure 1-11.

Non-NTEP Junction Box Terminals – Scale Wiring

8. Secure the junction box to the bottom of the accessory bar with three screws.

2. Align the cables on the foam section of the junction box.

3. Route the wires from terminal blocks 4, 5, and 6 to the right side of the junction box.

4. Route the wires from terminal blocks 1, 2, and 3 around the center of the junction box.

5. Route the wires from the left side terminal block down the left side of the junction box.

6. Place the junction box cover over the wired junction box. Use care so that the cables and wires are not pinched. Make any necessary adjustments to the cables before securing the cover.

7. Install the junction box cover screws.

Publication: 1284782A, Issued: 20 Mar 2018

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NTEP Truck Junction Box and Display Wiring Connections

To prevent damage to the Junction Box Wires during the wire installation process, it is recommended that the Junction Box Wire Installation tool (P/N 990-1238) be used. Pinched wires can cause the weight readings to be off or the calibration process to fail.

3. Place a flat screw driver into the top of the green wire slot. Pry up to open the wire slot, Slide the green wire ferrule all the way into the slot labeled “green”. Repeat for the white wire in the slot marked “white” and the black wire in the slot marked “black”.

Figure 1-13.

NOTE: The NTEP truck display must be opened to complete the wire connections for the level sensor and junction box.

1. Separate the wires from the load cells so that they are the least amount tangled where they exit the protective sleeve. Align the cables on the foam section of the junction box with the end of the wires aligned with the end of the plastic holder.

Place the cable from the junction box in the center (larger) slot in the junction box cover. Place the six cables from the load cells in the remaining six slots.

4. Place a flat screw driver into the top of each red wire slot. Pry up to open the wire slot, Match the wire marking with the slot label. Insert the red wire all the way into the slot. Repeat for the remaining red wires.

Figure 1-14.

Figure 1-12.

2. Gather the six (6) green wires from the load cells together and crimp with a ferrule. Gather the six (6) white wires from the load cells together and crimp with a ferrule. Gather the six (6) black wires from the load cells together and crimp with a ferrule.

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Publication: 1284782A, Issued: 20 Mar 2018

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Service Wiring

5. Verify the wires are connected to the terminals as indicated in Figure 1-13, Figure 1-14, Figure 1-15, and the following table.

Figure 1-15.

6. Place the junction box cover over the wired junction box. Use care so that the cables and wires are not pinched.

NTEP Junction Box – Load Cell Wiring

7. Install the junction box cover screws. Then install the junction box in the mounting bracket under the accessory bar.

8. Remove the two bolts holding the display together.

Load Cell / Wire Color

Terminal Marking

Terminal Position

6/F / Red

redF

1

5/E / Red

redE

2

4/D / Red

redD

3

3/C / Red

redC

4

2/B / Red

redB

5

1/A / Red

redA

6

All / Black

black

7

All / White

white

8

All / Green

green

9

black

N/A

red

N/A

Publication: 1284782A, Issued: 20 Mar 2018

9. Carefully separate the display.

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Wiring 10. Route the level sensor and junction box wires to the display. Connect the wires to the terminals as indicated in Figure 1-16 and the following table.

11. Complete the following steps to calibrate the level sensor. a. Strip the wire cover on the blue wire back approximately 0.25 in. (6 mm).

NOTE: The blue wire from the level sensor is used for level sensor calibration. It is not installed in the display terminal block.

Figure 1-16.

NTEP Display – Level Sensor and Junction Box Wiring

b. Touch the blue wire in the open window in the back side of the socket that the black wire is installed in for four (4) seconds. The socket is labeled “GND”.

Terminal Marking

Terminal Position

–EX

1

Junction Box / Brown

S–

2

Junction Box / White

IN–

3

Junction Box / Green

IN+

4

Junction Box / Yellow

+EX

5

SH

6

TEMP

7

Level Sensor / White

SCL

8

Level Sensor / Green

SDO

9

Level Sensor / Yellow

SD1

10

Level Sensor / Black

GND

11

Level Sensor / Red

VCC

12

V–

13

V+

14

Wire Source/Color

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c. Apply heat shrink to the end of the blue wire.

Publication: 1284782A, Issued: 20 Mar 2018

Mobile Scale Fork Truck Maintenance Manual Supplement

Service Wiring

d. Press and hold the On/Off button on the display until the display turns OFF. 12. Carefully put the display back together.

Install the two bolts removed in step 2.

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Publication: 1284782A, Issued: 20 Mar 2018

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