Raymond Forklift 8210 Mobile Scale Forks Supplement Maintenance Manual SN 821-19-36193 & Up - PDF

Maintenance Manual Supplement Mobile Scale Forks

Model

Serial Numbers

Publication: 1329468/001A

Issued: 15 May 2019

8210

821-19-36193 & Up

This publication applies to Mobile Scale Forks for Model 8210 pallet trucks S/N 821-19-36193 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. ©2019 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 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 100-Hour Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Cleaning Mobile Scale Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Tool Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Display Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Weigh Mode Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Other Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Basic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Check Display Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Check Weight Readout At Each Load Cell . . . . . . . . . . . . . . . . . . . 12 Diagnostic Test Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Debug Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Fork Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Load Cells. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Testing Individual Load Cells. . . . . . . . . . . . . . . . . . . . . . . . . . 20 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Configuration Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Configuration Mode Button Functions . . . . . . . . . . . . . . . . . . . . . 25 Accessing The Configuration Menus . . . . . . . . . . . . . . . . . . . . . . . 26 Configuration Menu Parameters . . . . . . . . . . . . . . . . . . . . . . . 26 Setup Menu “-F-” Parameters . . . . . . . . . . . . . . . . . . . . . . . . . 28 User Menu “-A-” Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Bluetooth Menu “-b-” Parameters . . . . . . . . . . . . . . . . . . . . . . 35 COM1 Menu “-C-” Parameters . . . . . . . . . . . . . . . . . . . . . . . . . 36 Set (or Change) Display Time and Date . . . . . . . . . . . . . . . . . . . . . 37 Reset Only Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Reset All Parameter Settings (To Default) and Calibration Data (Full Reset). . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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Mobile Scale Fork Truck Maintenance Manual Supplement Table of Contents Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Calibration Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Prior to Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Corner Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

View and/or Restore Corner Calibration . . . . . . . . . . . . . . . . . . . .

Zero Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weight (Span) Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

View Calibration Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Input Calibration Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Load Cells and Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

Junction Box, Display, and Voltage Filter . . . . . . . . . . . . . . . . . . . . . .

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39 39 40 41 42 43 44 46 48 50 50 51 53 53 56

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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 with 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: 1329468/001A, Issued: 15 May 2019

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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

1329468/001A

15 May 2019

Initial Release

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Publication: 1329468/001A, Issued: 15 May 2019

Mobile Scale Fork Truck Maintenance Manual Supplement

NOTICE 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.

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NOTICE

Mobile Scale Fork Truck Maintenance Manual Supplement

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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Mobile Scale Fork Truck Maintenance Manual Supplement

Periodic Maintenance Daily Inspection

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. A minimum interval of every 12 months or 2000 hours, whichever comes first, is recommended.

Daily Inspection Each day inspect the bottom of the forks for debris that might be wedged between the fork and the fork shoe. Remove any debris found.

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Periodic Maintenance

Mobile Scale Fork Truck Maintenance Manual Supplement

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 the fork and fork shoe (for example: wood chips).

•

Remove any debris found.

•

Inspect the bottom of the forks for debris that might be wedged between the fork and the fork shoe. 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. (108 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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Mobile Scale Fork Truck Maintenance Manual Supplement

Troubleshooting 100-Hour Maintenance

Troubleshooting

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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 • Weigh Mode Error Messages • Other Error Messages

•

Basic Troubleshooting • Check Display Power • Check Weight Readout at Each Load Cell • Diagnostic Test Modes • Debug Mode

•

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

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Mobile Scale Fork Truck Maintenance Manual Supplement

Troubleshooting Display Messages

Display Messages Weigh Mode Error Messages Display Shows:

Meaning:

To Exit Error Mode:

Mobile Scale Forks are overloaded.

Automatic after removing weight.

Weight on scale is negative or load cell signal is negative.

Press the “ZERO/OFF” key. Lift the forks from the ground.

Problem with Fork 1, no communication.

Verify weigh system is powered ON. Restart display.

Problem with Fork 2, no communication.

Verify weigh system is powered ON. Restart display.

Forks not detected.

Verify weigh system is powered ON. Restart display.

Meaning:

To Exit Error Mode:

Calibration Error – Test weight (or keyed in weight) is larger than the capacity of scale.

Use a different test weight.

Check input data.

Calibration Error – Test weight (or keyed in weight) is smaller than 1% of full capacity of the scale.

Use a different test weight.

Check input data.

Calibration Error – The load cell signal is too low.

Check load cell wiring, a mechanical obstruction or faulty/damaged load cell

Parameters are blocked.

Press the “UNITS” button

Other Error Messages Display Shows:

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Troubleshooting

Mobile Scale Fork Truck Maintenance Manual Supplement

Basic Troubleshooting

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

Power supply – Blown fuse, or damaged 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 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 11.

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 12, “Debug Mode” on page 15, 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 17 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 17 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 17 for further diagnosis.

System is inaccurate but linear.

Calibrate the system. Refer to “Calibration” on page 39.

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

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

Calibrate the system. Refer to “Calibration” on page 39.

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Mobile Scale Fork Truck Maintenance Manual Supplement

Troubleshooting Basic Troubleshooting

Problem

Solution

With or without a load, the display shows an overload (“000000”) or underload (“------”) error message.

Check the display. 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 12, “Debug Mode” on page 15, and “Load Cells” on page 19.

Calibrate the system. Refer to “Calibration” on page 39.

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 12, “Debug Mode” on page 15, 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.

NOTE: Each digit has seven segments (bars). When all segments are in use, the digit displays an “8”.

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

Problem with power

YES

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

NO

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

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Troubleshooting

Mobile Scale Fork Truck Maintenance Manual Supplement

Basic Troubleshooting

Check Weight Readout At Each Load Cell

7. Move the weight to Corner 3, 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 Corner 4, as shown.

3. Place a known weight on Corner 1, as shown.

10. Note the weight shown on the display.

4. Note the weight shown on the display.

5. Move the weight to Corner 2, 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

6. Note the weight shown on the display.

12

4500 lb.

(2041 kg)

Non-NTEP Truck Weight 'A'

NTEP Truck Weight 'A'

2 lb. (1 kg)

2 lb. (1 kg)

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Mobile Scale Fork Truck Maintenance Manual Supplement

Troubleshooting Basic Troubleshooting

Diagnostic Test Modes 1. With the display powered off, press and hold the “ON/PRINT” button for approximately 20 seconds.

2. The display will show "-F-".

Configuration Mode Button Functions

Enter Parameter Settings or Test Mode

Show the Previous Parameter or Test Mode

Show the Next Parameter or Test Mode

3. Press the "ON/PRINT" button.

4. Press the "ZERO/OFF" button.

Refer to Configuration Mode Button Functions

5. Refer to "Configuration Mode Button Functions" to go to and enter parameter "A 24".

Refer to Configuration Mode Button Functions

6. Refer to "Configuration Mode Button Functions" to go to and enter the desired Test Mode.

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Troubleshooting

Mobile Scale Fork Truck Maintenance Manual Supplement

Basic Troubleshooting The chart below describes each test mode code.

Test Mode Code and Name

Description

Manually End Test

A24-U1 – Display Test

Lights up all display segments with "666666" and counts down to "111111".

This test ends automatically when complete

A24-U2 – ADC Test

Shows internal A/D converter counts. This is useful for troubleshooting weighing issues.

Press the "NET/GROSS" button

A24-U3 – Load Cell Input Test

Display input logic (0 or 1) of input terminal.

0 = Grounded input pin 1 = Open input pin

Press the "NET/GROSS" button

A24-U4 – Load Cell Output Test

All output pins are set to 'ON'

Press the "NET/GROSS" button

A24-U5 – Serial Test

Transmit data string continuously out COM1 and COM2 serial ports.

COM1 sends 'Test1' COM2 sends 'Test2'

Press the "NET/GROSS" button

A24-U6 – Keyboard Test

Displays a code for each of the display's buttons.

1 = "UNITS" button 2 = "ZERO/OFF" button 3 = "NET/GROSS" button 4 = "TARE" button 5 = "ON/PRINT" button

Press the "NET/GROSS" button

A24-U7 – NTEP (or OIML) Test

Disables zero tracking and automatic shut-off.

The "ZERO" button only functions in this mode.

Press the "NET/GROSS" button

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Mobile Scale Fork Truck Maintenance Manual Supplement

Troubleshooting 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.

When the display is in Debug Mode, the number of counts received from each AD chip is shown, individually. This helps isolate the load cell thar could be the problem.

NOTE: The AD values shown on the display should be close to each other for calibration.

Figure 1-2.

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

3. The display shows the AD count for Corner 1 and a downward arrow appears.

3

Load Cell Layout 4 3

4

2

1

4. Press the “ZERO/OFF” button to view the next AD count.

FK0489.eps

Figure 1-3.

Load Cell Corresponding Display Arrow 3

4

2

1

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Troubleshooting

Mobile Scale Fork Truck Maintenance Manual Supplement

Basic Troubleshooting 5. The display shows the AD count for Corner 2 and a downward arrow appears.

6

5

6. Press the “ZERO/OFF” button to view the next AD count.

7. The display shows the AD count for Corner 3 and a downward arrow appears.

7

8

8. Press the “ZERO/OFF” button to view the next AD count.

9. The display shows the AD count for Corner 4 and a downward arrow appears.

9

11

10. Compare the AD counts from each load cell. If there is significant count range between one cell to the rest, OR the AD count for each load was recorded and there is a significant count change compared to the recorded values, the load cell requires further troubleshooting or replacement. Refer to “Load Cells” on page 19.

11. Press the “UNITS” button to exit Debug mode, The display returns to weighing mode.

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Mobile Scale Fork Truck Maintenance Manual Supplement

Troubleshooting 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 +2 lb.

(1 kg) 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 +2 lb.

(1 kg) 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

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 fork arm 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 12, “Debug Mode” on page 15, and “Load Cells” on page 19.

2

3

4

5

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Troubleshooting

Mobile Scale Fork Truck Maintenance Manual Supplement

Hardware

Wire Harness 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

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Mobile Scale Fork Truck Maintenance Manual Supplement

Troubleshooting Hardware

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 17.

NO

Go to Step 3.

Is the difference larger than 1/2 graduation?

YES

Calibrate the load cells. Refer to “Calibration” on page 39.

Go to Step 4.

NO

Check the Mobile Scale Fork assembly, refer to “Fork Assembly” on page 17.

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

YES

Calibrate the load cells. Refer to “Calibration” on page 39.

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 touch panel and then calibrate.

Go to Step 6.

NO

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

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.

2

3

4

5

6

7

Does the Display still show an error?

Is the Display unstable?

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Troubleshooting

Mobile Scale Fork Truck Maintenance Manual Supplement

Hardware

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 measurement 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.

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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 5 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.

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. If the display can be turned OFF, perform diagnostic test, Keyboard Test Cycle mode, A24-U6. Refer to “Diagnostic Test Modes” on page 13.

“ON/PRINT” button does not function.

Verify the scale is unloaded before accepting a new print.

Check the power supply. Refer to “Check Display Power” on page 11.

Check the wiring to the printer.

Restart the display.

Check the motion detection parameter setting (“F5”). 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.

If the display can be turned OFF, perform diagnostic test, Keyboard Test Cycle mode, A24-U6. Refer to “Diagnostic Test Modes” on page 13.

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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”.

Check User Menu "-A-" parameter setting "A 6". Contact your local Raymond Sales and Service Center.

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

Wrong parameter setting. Check User Menu "-A-" parameter setting "A 6". 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 and printer is OFF while printing – 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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Service Hardware

Service

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Parameters

Parameters NOTE: Parameters should only be changed when calibrating (refer to “Calibration” on page 39), 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.

Parameters are grouped into three configuration menus. Each configuration menu contains a list of numbered parameters. Each parameter contains selectable settings.

Configuration Menus

Parameters for “-F-” Configuration Menu

Example:

Settings “F1” Setting (selectable digits) “F2 Settings (selectable list)

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Service Parameters

Configuration Menus

•

There are four possible Configuration Menus.

The system has either Bluetooth or COM1. It cannot have both.

•

Setup Menu “-F-” All scale related parameters including calibration parameters.

•

User Menu “-A-” COM2 communication parameters and other miscellaneous parameters

Bluetooth Menu “-b-” All parameters relating to radio frequency (RF) weighing module (or modules).

NOTE: This menu only appears for wireless systems.

•

COM1 Menu “-C-” COM1 communication parameters.

NOTE: This menu only appears for cabled systems.

Configuration Mode Button Functions

Exit Configuration Menu

Enter Parameter (from Configuration Menu)

–

Show previous Configuration Menu

Show next Configuration Menu

Exit Parameters and return to Configuration Menu

Enter Settings (from Parameters)

–

Show previous Parameter number

Show next Parameter number

Settings Selectable Digits

Increase Digit

Decrease Digit

Accept Value

Shift to next digit, Left

Shift to next digit, Right

Settings Selectable List

–

–

Accept Value

Show previous Setting

Show next Setting

Configuration Menu

Parameters

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Parameters

Accessing The Configuration Menus 1. With the display powered ON, press and hold the “ON/PRINT” button for approximately 20 seconds.

3. Press the "ZERO/OFF" button to view or change the parameter's setting. Refer to the following sections for a list of parameters and available settings: • Setup Menu “-F-” • User Menu “-A-” • Bluetooth Menu “-b-” • COM1 Menu “-C-” 4. A value will show and can be changed using one of the following options:

2. The display will show “-F-”.

3. Press the "ON/PRINT" button to view each available Configuration Menu (“-F-”, “-A-”, “-C-”, or “-b-”). Press the "TARE" button to show the previous menu.

4. Press one of the following buttons:

• Selectable Digit – One digit will flash.

The value can be changed within a set range, one digit at a time.

• Selectable List – The value has a list of settings to choose from.

• "UNITS" – To Exit the Configuration Menu. The display shows "SEt", if changes were made to parameter settings, and then automatically powers off.

• "ZERO/OFF" – To View the parameters of a Configuration Menu.

Configuration Menu Parameters 1. Access and choose a Configuration Menu (“-F-”, “-A-”, “-C-”, or “-b-”).

2. Press the "TARE" and "ON/PRINT" button to view each parameter number.

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5. Press the "NET/GROSS" button to accept a value after it is changed (or viewed).

6. The display will return to the parameter showing the current parameter number after the setting is accepted.

7. Repeat Steps 2 through 6 for each parameter setting to be changed.

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Service Parameters

8. Press the "UNITS" button two times to save and exit Configuration Mode.

Press twice

9. The display will show "SEt".

10. The display will show “oFF” and automatically power off.

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Parameters

Setup Menu “-F-” Parameters Parameter Number

Name

Description

Default Setting

Available Parameter Settings

F1

Graduations

Number of full-scale graduations (capacity / division). The value must be consistent with legal regulations and environmental limits.

2250

100 – 50000

F2

Sampling Rate

Sampling rate in Hertz (per second). Most applications use 10 Hz. For a fast response time, use 80 Hz. Cabled systems only.

10

10, 80

F3

Zero Track Band

Range for scale to automatically zero. Scale must be in standstill to automatically zero.

0.5d

OFF, 0.25d, 0.5d, 1d, 3d, 5d (d = divisions)

F4

Zero Range

Range for scale to accept the display's zero button command. Scale must be in standstill to automatically zero.

100

0 – 100 (percentage)

F5

Motion Band

Motion detection level - When no motion is detected on the scale, printing or zeroing can be performed.

1d

OFF, 0.25d, 0.5d, 1d, 3d, 5d (d = divisions)

F6

Digital Filter

Average weight reading for higher stability. Speed is selected based on application

nnEd

FAST = fast, nnEd = medium, SLo = slow

F7

Overload Limit

Determine the point the display shows overload.

Selections should be based on the primary unit selected in F8.

FS + 2%

FS (FS=Full Scale Capacity), FS + 2%, FS + 5%, FS + 1d, FS + 9d,

F8

Calibration Units

Select the primary base unit to be used in the calibration process. This is also the default unit for normal operation.

1

Primary Unit: 1 = lb, 2 = kg, 3 = oz, 4 = g

F9

Display Divisions

Select the Weight Increments The value must be consistent with legal regulations.

2

1, 2, 5

F10

Decimal Point

Select the location of the decimal point.

0

0, 0.0, 0.00, 0.000, 0.0000, 00

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Service Parameters

Parameter Number

Default Setting

Available Parameter Settings

Select the number of wires on the load cells to be connect to the display.

Cabled systems only.

Raymond

4

4 wires, 6 wires (SENSE)

Percentage Hold Weight

Select the percentage weight change of the displayed hold value before the scale unlocks and relocks onto the new weight.

10%

5%, 10%, 20%, 50%, 75%, 100%

F13

Gravity (g)

Based on location of the scale system, select the gravity (g), in m/s2.

9.797

9.750 – 9.850

F14

Power-On Zero (IZSM)

Enable or disable power-on zero (IZSM).

yES

yES = enable IZSM, no = disable IZSM

F16

Zero Calibration

Perform zero calibration sequence. Refer to “Zero Calibration” on page 43.

F17

Weight (Span) Calibration

Perform weight (span) calibration sequence.

Refer to “Weight (Span) Calibration” on page 44.

F18

View Calibration

View both zero and weight (span) calibration values. The values displayed are valid only after calibration has been successfully completed.

Refer to “View Calibration Values” on page 46.

F19

Key-In Zero

In the event of memory loss, the zero calibration value can be keyed in.

F20

Key-In Weight (Span)

In the event of memory loss, weight (span) calibration value can be keyed in.

F21

Factory Reset (US)

Reset all parameters in the "F" and "A" menus to the default settings.

Calibration data will not be overwritten.

Use with caution.

Refer to “Reset Only Parameter Settings” on page 38.

Name

Description

F11

Number Of Load Cell Wires

F12

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Parameters Parameter Number

Default Setting

Available Parameter Settings

Name

Description

F22

Factory Reset (EU)

Reset all parameters in the "F" and "A" menus to the default settings.

Calibration data will not be overwritten.

Use with caution.

Refer to “Reset Only Parameter Settings” on page 38.

F23

Full Factory Reset

Reset all system parameters to the default settings.

Calibration data will not be overwritten. Use with extreme caution.

Refer to Section “Reset Only Parameter Settings” on page 38.

F24

Fine Tune 4-20 mA

Fine tune the optional 4-20 mA analog output.

F25

Set Point Function

Select the number of set point functions and relay outputs.

0

0 to 10

F26

Multi-Interval Segments

Select the number of multi-interval segments.

1

0 = None (No multi-interval), 1, 2

F27

Number of Scale Divisions WS1

Number of divisions used for Weighing Segment 1 (WS1).

Selections should be based on F1, F9 and F10 settings.

500

100 – 50000

F28

Number of Scale Divisions WS2

Number of divisions used for Weighing Segment 2 (WS2).

Selections should be based on F1, F9 and F10 settings.

5000

100 – 50000

F29

Load Cell Input

Select load cell input source.

AdC

AdC = Internal A/D (cabled), 1rAdlo = One external wireless A/D modules, 2rAdlo = Two external wireless A/D modules, dJb = Digital junction box

F30

Special Application

Select one special application feature. Application must be consistent with legal regulations.

0

0 = None (Gross/Net) 1 = Totaling 2 = Remote Display 3 = Sampling Weight (Piece Count) 5 = Hold 6 = Set Point

30

Raymond does not recommend this parameter get changed.

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Service Parameters

Parameter Number

Name

Description

Default Setting

Available Parameter Settings

F31

Gross Zero Band

Range for scale to automatically clear the tare and switch to gross mode.

Scale must be in standstill.

0

0 –10 divisions (d) 0 = disabled

F32

Center the Zero Band

Range of scale to display Center of Zero annunciator for gross zero.

0.25d

0.25d, 0.5d (d = divisions)

F34

Auto Print Minimum Weight

Select auto print function minimum weight.

1

0 – 100 divisions (d) 0 = disabled

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Parameters

User Menu “-A-” Parameters Parameter Number

Name

Description

Default Setting

Available Parameter Settings

A1

Baud Rate

Select baud rate for data transmission through serial port.

9600

600, 1200, 2400, 4800, 9600,19200, 38400, 57600, 115200

A2

Data Bits, Parity and Stop Bits

Select the number of data bits and parity of serial transmission.

8_n_1

8_n_1 = 8 data bits with no parity and one stop bit, 8_n_2 = 8 data bits with no parity and two stop bits, 7_n_1 = 7 data bits with no parity and one stop bit, 7_n_2 = 7 data bits with no parity and two stop bits, 7_E_1 = 7 data bits with even parity and one stop bit, 7_E_2 = 7 data bits with even parity and two stop bits, 7_o_1 = 7 data bits with odd parity and one stop bit, 7_o_2 = 7 data bits with odd parity and two stop bits

A3

Serial Port Mode

Select the mode of the serial port.

0

0 = Demand Full Duplex, 1 = Continuous Full Duplex, 2 = Auto Print, 3 = RFID, 4 = Test and Measurement, 5 = 0-20 mA output, 6 = 0-10 mA output

A4

MP-20 Print Header

Print header information (MP-20 Printer). A6 selections should be set to "2" or "4".

0

0 = Do not print header 1 = Print header

A5

UNITS Button

Enable or disable "UNITS" button.

NOTE: Ounces and grams (F8) disables the "UNITS" button.

yES

no = Disabled, yES = Enabled

A6

Output String

Select output string for serial port.

0

0 = String Format 1 (Condec Demand), 1 = String Format 2 (Condec Continuous), 2 = Text Print Ticket, 3 = Text Print Ticket with MP-20 Auto Label Feed, 4 = Dot Matrix Printer, 5 = Thermal Receipt Printer, 6 = Label Printer, 7 = Bluetooth Option

A7

ID Number

Enable or disable ID number mode

no

no = Disabled, yES = Enabled

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Service Parameters

Parameter Number

Name

Description

Default Setting

Available Parameter Settings

A8

Set ID Number

Enter in ID number.

123456

0 to 999999

A9

Line Feeds

Enter in the number of line feeds.

08

0 to 99

A10

Display Auto Power Off

Enter the number of minutes that the display and forks are inactive, the display will power off.

5

0 to 30

A11

Hold Mode

Enable automatic, manual or peak hold to capture a weight of an unstable load and lock the value on the display.

Parameter F30 setting "5" must be selected.

0

0 = Off 1 = Automatic 2 = Manual 3 = Peak Hold

A12

Handshaking

Enable or disable hardware handshaking function.

0

0 = Disabled 1 = Enabled

A18

Date

Enable or disable date printout.

no

no = Disabled yES = Enabled

A19

Date Format

Select date format

USA

USA = mm/dd/yy IntL = dd/mm/yy

A20

Set System Time & Date

Set system time and date Refer to “Set (or Change) Display Time and Date” on page 37.

A22

Display Low Battery Auto Power Off

Enter the number of minutes that the display will power off after the low battery display appears.

02

0 to 99

A24

Diagnostics

Test functions, one at a time, from the following list: Refer to “Diagnostic Test Modes” on page 13.

A25

Decimal Point

Select type decimal point character

A30

Upload EID Database

Configure the transmit function for EID database information to go through RFID serial for mode (A3).

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A24-U1 = Display segment test A24-U2 = A/D Converter Test A24-U3 = Input Test A24-U4 = Output Test (all) A24-U5 = Serial Port test (both) A24-U6 = Keyboard Test A24-U7 = NTEP (or OIML) test mode 0

0 = Period ('.')

1 = Comma (',')

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Parameters Parameter Number

Name

Description

A31

Clear EID Database

Clear stored EID database information.

A34

Correction Sensor Setting

Correct sensor

Default Setting

Available Parameter Settings

0

0 = Disable angle sensor, 1 = Compensation with no angle limits, 2 = Compensation with NTEP (or OIML) limits

NOTE: Value 1 is for Non-NTEP only. Setting 1 turns off the Level Sensor.

Value 2 is for NTEP only, Setting 2 turns on the Level Sensor.

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Service Parameters

Bluetooth Menu “-b-” Parameters Parameter Number B1

Name

Description

Adjust Load Cell (Corner) #1

Adjust the digital corner compensation factor for load cell (corner) #1.

Default Setting

Available Parameter Settings

1.0000

0 to 6.5535

1.0000

0 to 6.5535

1.0000

0 to 6.5535

1.0000

0 to 6.5535

3

0 = Always on 1 = 30 minutes 2 = 1 hour 3 = 2 hours

NOTE: Perform Parameter B10 before changing this parameter setting.

B2

Adjust Load Cell (Corner) #2

Adjust the digital corner compensation factor for load cell (corner) #2.

NOTE: Perform Parameter B10 before changing this parameter setting.

B3

Adjust Load Cell (Corner) #3

Adjust the digital corner compensation factor for load cell (corner) #3.

NOTE: Perform Parameter B10 before changing this parameter setting.

B4

Adjust Load Cell (Corner) #4

Adjust the digital corner compensation factor for load cell (corner) #4.

NOTE: Perform Parameter B10 before changing this parameter setting.

B6

Restore Factory Calibration

Restore calibration data to factory settings.

Refer to “View and/or Restore Corner Calibration” on page 42.

B8

Auto Power Off Forks

Select the time for forks automatic power off time out.

B9

Low Battery Force Off Forks

Enter the number of minutes that the forks will power off after the low battery is detected.

B10

Digital Corner Calibration

Perform digital corner calibration sequence.

Refer to “Corner Calibration” on page 41.

B11

Bluetooth Pairing

Pair forks to display.

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Parameters

COM1 Menu “-C-” Parameters Parameter Number

Name

Description

Default Setting

Available Parameter Settings

C1

Baud Rate

Select baud rate for data transmission through serial port.

9600

600, 1200, 2400, 4800, 9600, 19200, 38400, 57600, 115200

C2

Data Bits, Parity and Stop Bits

Select the number of data bits and parity of serial transmission.

8_n_1

8_n_1 = 8 data bits with no parity and one stop bit, 8_n_2 = 8 data bits with no parity and two stop bits, 7_n_1 = 7 data bits with no parity and one stop bit, 7_n_2 = 7 data bits with no parity and two stop bits, 7_E_1 = 7 data bits with even parity and one stop bit, 7_E_2 = 7 data bits with even parity and two stop bits, 7_o_1 = 7 data bits with odd parity and one stop bit, 7_o_2 = 7 data bits with odd parity and two stop bits

C3

Serial Port Mode

Select the mode of the serial port.

0

0 = Demand Full Duplex, 1 = Continuous Full Duplex, 2 = Auto Print, 3 = RFID, 4 = Test and Measurement

C6

Output String

Select output string for serial port.

0

0 = String Format 1 (Condec Demand), 1 = String Format 2 (Condec Continuous), 2 = Text Print Ticket, 3 = Text Print Ticket with MP-20 Auto Label Feed

C9

Line Feeds

Enter in the number of line feeds.

08

0 to 99

C13

Handshaking

Enable or disable hardware handshaking function.

0

0 = Disabled, 1 = Enabled

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Service Parameters

Set (or Change) Display Time and Date

7. The display shows the current month once the day value is accepted, Change the current month to the actual month.

1. Access the Configuration Menu and User Menu "-A-" (refer to “Accessing The Configuration Menus” and “Configuration Menu Parameters”). Navigate to parameter number "A 20".

8. The display shows the current year once the month value is accepted. Change the current year to the actual year,

2. Press the "ZERO/ OFF" button to enter Parameter Setting "A 20".

9. The display reverts to parameters, showing "A 20".

3. The screen will show "ho_XX" where "XX" is the display's current hour (example "03"). One digit will flash.

Press Twice

10. Press the "UNITS" button two times to save and exit the Configuration Menu.

4. Refer to “Configuration Mode Button Functions” on page 25 to change the current hour to the actual hour.

5. The display shows the current minute once the hour value is accepted. Change the current minute to the actual minute.

6. The display shows the current day once the minute value is accepted. Change the current day to the actual day.

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Parameters

Reset Only Parameter Settings NOTE: This procedure resets the parameters but keeps calibration data. This procedure cannot be undone.

1. Access the Configuration Menu and Setup Menu "-F-" (refer to “Accessing The Configuration Menus” and “Configuration Menu Parameters”).

2. Navigate to parameter "F 21".

3. Press the "ZERO/OFF" button to enter parameter "F 21".

4. The display shows "SUrE" to proceed with reset. Press the "ZERO/OFF" button to confirm reset.

5. The display shows "SEt__" for approximately 2 seconds.

6. The display reverts to parameters, showing parameter "F 21".

7. Press the "UNITS" button two times to save and exit the Configuration Menu.

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Reset All Parameter Settings (To Default) and Calibration Data (Full Reset) NOTE: This procedure resets all parameters to default and calibration data. This procedure cannot be undone. Use with extreme caution.

1. Access the Configuration Menu and Setup Menu "-F-" (refer to “Accessing The Configuration Menus” and “Configuration Menu Parameters”).

2. Press the "ZERO/OFF" button to enter parameter "F 23".

3. The display shows "SUrE" to proceed with reset. Press the "ZERO/OFF" button to confirm reset.

4. The display shows "SEt__" for approximately 2 seconds.

5. The display reverts to parameters, showing parameter "F 23".

6. Press the "UNITS" button two times to save and exit the Configuration Menu.

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Service Calibration

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.

•

Corner Calibration – Takes any inconsistency between the load cells (corners) and equalizes them with each other.

•

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

•

Weight Calibration – Determines and sets the weight range for the Mobile Scale Forks system by using a sample of known weight(s).

NOTE: Always perform the corner calibration first, then zero calibration, followed by weight (span) calibration.

NOTE: After calibration is complete, record the zero and weight (span) calibration values. This will eliminate the need for test weights in the field, where calibration information is lost (rare).

Refer to “View Calibration Values” and “Input Calibration Values”.

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:

When to Calibrate

Calibration Procedures

When the Mobile Scale Forks are not within system tolerance.

Perform “Zero Calibration” (page 43) and “Weight (Span) Calibration” (page 44) with at least one known weight

When the weighing range does not meet end user preferences.

Perform “Zero Calibration” (page 43) and “Weight (Span) Calibration” (page 44) with at least one known weight

When the display or wire harness has been replaced. 2

Perform “Corner Calibration” (page 41), “Zero Calibration” (page 43), and “Weight (Span) Calibration” (page 44)

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.

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Always perform the tasks and calibration in the order listed.

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Calibration

Prior to Calibration 1. Determine which fork is the right fork and which fork is the left fork. Each fork is assigned specific load cell (corner) positions.

NOTE: Load cell positions can be found where the fork shoe cap screws are located, as shown in Figure 1-4.

Figure 1-4.

Load Cell Position Identification

Left Fork

Position 1 (near fork base) Position 2 (toward fork tip)

Right Fork

Position 3 (toward fork tip) Position 4 (near fork base)

Corner 4 Corner 3 FK0491.eps

Corner 1 Right Fork

Corner 2 Left Fork

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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Service Calibration

Corner Calibration Corner Calibration is the first 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.

4. Press the “NET/GROSS” button to accept the zero point A/D value.

5. “Corn-1” will show on the display.

6. Place the test weight on the pallet in position 1. Wait five seconds for the load to stabilize.

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.

NOTE: Verify that the primary base unit (lbs. or kg) is determined prior to calibration. To update units, go to Parameter F8. Refer to “Configuration Menu Parameters” and “Bluetooth Menu “-b-” Parameters”.

1. Access the Configuration Menu and Bluetooth Menu "-b-" as described in “Configuration Menu Parameters” and “Bluetooth Menu “-b-” Parameters”.

Navigate to parameter "b 10"..

7. Press the “NET/GROSS” button, to accept the Corner 1 calibration value.

8. “Corn-2” will show on the display.

9. Place the test weight on the pallet in position 2. Wait five seconds for the load to stabilize.

2. Press the “ZERO/OFF” button to enter parameter “b 10”.

10. Press the “NET/GROSS” button, to accept the Corner 2 calibration value.

3. The display will show an A/D count value (example 1063), Verify that the forks are clear of any loads or objects.

11. “Corn-3” will show on the display.

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Calibration 12. Place the test weight on the pallet in position 3. Wait five seconds for the load to stabilize.

18. Press the “NET/GROSS” button, to accept the calibration values and to return to the parameter screen showing “b 10”.

Press Twice

19. Press the "UNITS" button two times to save all changes and exit the Configuration Menu.

FK0713.eps

13. Press the “NET/GROSS” button, to accept the Corner 3 calibration value.

View and/or Restore Corner Calibration Use the following procedure to view or restore corner calibration values.

14. “Corn-4” will show on the display.

15. Place the test weight on the pallet in position 4. Wait five seconds for the load to stabilize.

1. Access the Configuration Menu and Bluetooth Menu "-b-" as described in “Configuration Menu Parameters” and “Bluetooth Menu “-b-” Parameters”.

Navigate to parameter "b 10".

2. Press the “ZERO/OFF” button to enter parameter “b 6”.

16. Press the “NET/GROSS” button, to accept the Corner 4 calibration value.

3. The display will show "F-CAL". Press the "ZERO/OFF" button.

17. The display shows “SEt--”.

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4. The display will show a sequence of the four corner calibration values and then show “F-CAL”.

Corner 1

Corner 3

Corner 2

Corner 4

Zero Calibration Zero Calibration is the second 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. Access the Configuration Menu and Setup Menu "-F-" as described in “Configuration Menu Parameters” and “Setup Menu “-F-” Parameters”. Navigate to parameter "F 16".

2. Press the “ZERO/OFF” button to enter parameter “F 16”.

5. Press one of the following buttons: • "UNITS" – To view weight (span) calibration values. After the display shows the weight and A/D count for each of the three points, "F-CAL" shows.

• "ON/PRINT" – To exit without restoring the factory calibration values. The display reverts to parameters, showing "b 6".

• "NET/GROSS" – Press and hold for 3 seconds to restore factory calibration values. The display briefly shows "dOnE" and then reverts to parameters, showing "b 6".

6. Press the "UNITS" button two times to save all changes and exit the Configuration Menu.

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3. The display shows "C 0" and then an A/D count value (example 3672), Verify that the forks are clear of any loads or objects.

4. Press the "ZERO/OFF" button to zero the displayed value.

5. The display counts down to ending in "- - - - - -" and then a zeroed A/D count value.

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Calibration 6. Press the "NET/GROSS" button accept the new zero point.

7. The display shows "SEt",

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.

1. Access the Configuration Menu and Setup Menu "-F-" as described in “Configuration Menu Parameters” and “Setup Menu “-F-” Parameters”. Navigate to parameter "F 17".

then "EndC0"

2. Press the “ZERO/OFF” button to enter parameter “F 17”. and then reverts to parameters, showing "F 16".

3. The display shows "C 1" 8. Continue to the Weight (Span) Calibration procedure to complete the calibration process.

Weight (Span) Calibration Weight (Span) 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:

and then a value with a flashing digit.

4. Place Weight 1 on the forks so that the weight is centered evenly between the four corner positions.

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)

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5. If required, change the weight shown on the display to match the value on the forks (Weight 1). Refer to “Configuration Mode Button Functions” to change the value.

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NOTE: If using a pallet, the weight entered must include the pallet weight (Weight 1 + Pallet Weight).

10. After entering the value, press the "NET/GROSS" button.

6. After entering the value, press the "NET/GROSS" button.

11. The display shows "EndC2", 7. The display shows "EndC1",

then "C3" then "C2"

and ends with showing a value with a flashing digit. and ends with showing a value with a flashing digit.

8. Place Weight 2 on the forks so that the weight is centered evenly between the four corner positions.

9. If required, change the weight shown on the display to match the value on the forks (Weight 2). Refer to “Configuration Mode Button Functions” to change the value.

NOTE: If using a pallet, the weight entered must include the pallet weight (Weight 2 + Pallet Weight).

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12. Place Weight 3 on the forks so that the weight is centered evenly between the four corner positions.

13. If required, change the weight shown on the display to match the value on the forks (Weight 3). Refer to “Configuration Mode Button Functions” to change the value.

NOTE: If using a pallet, the weight entered must include the pallet weight (Weight 3 + Pallet Weight).

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Calibration 14. After entering the value, press the "NET/GROSS" button.

View Calibration Values Use the following procedure to view calibration values.

1. Access the Configuration Menu and Setup Menu "-F-" as described in “Configuration Menu Parameters” and “Setup Menu “-F-” Parameters”. Navigate to parameter "F 18".

15. The display shows "EndC3" for a moment,

then shows gravity settings.

16. Enter the local gravity factor, if known.

Refer to “Configuration Mode Button Functions” to change the value. When complete (or if unchanged), press the “NET/GROSS” button.

2. Press the “ZERO/OFF” button to enter parameter “F 18”.

3. The display shows “C 0” and then a value.

17. The screen shows “donE”.

Record the value.

Value C0

18. Press the “NET/GROSS” button, to accept the calibration values and to return to the parameter screen showing “F 17”.

4. Press the “ZERO/OFF” button to continue to the next value.

Press Twice

19. Press the "UNITS" button two times to save all changes and exit the Configuration Menu.

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5. The display shows the following sequence: “t 1”,

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the weight,

and the A/D count.

“C 1” (value is in pounds or kilograms)

Record the value.

Value t2 C2

and the A/D count.

8. Press the “ZERO/OFF” button to continue to the next value.

9. The display shows the following sequence: “t 3”,

Record the value.

Value t1

the weight,

C1

6. Press the “ZERO/OFF” button to continue to the next value.

7. The display shows the following sequence: “t 2”,

“C 3” (value is in pounds or kilograms)

the weight,

and the A/D count.

“C 2” (value is in pounds or kilograms)

Record the value.

Value t3 C3

10. Press the “ZERO/OFF” button to continue to the next value.

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Calibration 11. The display reverts to the parameters screen showing “F 18”.

4. Change the value to the recorded “C 0” value in “View Calibration Values”. Refer to “Configuration Mode Button Functions” to change the value.

5. After entering the value, press the "NET/GROSS" button to accept the value.

6. The display shows “E CAL0”.,

Input Calibration Values This procedure is intended for emergency use only on the rare occasion that the memory is lost. Successful calibrations for zero (F16) and weight (span) (F17) must have occurred previously and the values recorded.

Then reverts to the parameters screen showing “F 19”.

1. Access the Configuration Menu and Setup Menu "-F-" as described in “Configuration Menu Parameters” and “Setup Menu “-F-” Parameters”. Navigate to parameter "F 19".

7. Press the “ON/PRINT” button to continue to the next parameter.

8. Press the “ZERO/OFF” button to enter parameter “F 20”.

2. Press the “ZERO/OFF” button to enter parameter “F 19”.

3. The display shows "Cal 0" for a moment,

then “E CAL0”.,

and then “000000” with the far right digit flashing.

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9. The display shows “Et t 1” and then a value. The value should match the “t 1” value recorded in “View Calibration Values”.

10. Change the value, if necessary, to the recorded “t 1” value in “View Calibration Values”. Refer to “Configuration Mode Button Functions” to change the value.

11. After entering the value, press the "NET/GROSS" button to accept the value.

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12. Repeat steps 9, 10, and 11 for each of the following codes: • Et C1 - Use the “C 1” value recorded in “View Calibration Values” • Et t2 - Use the “t 2” value recorded in “View Calibration Values” • Et C2 - Use the “C 2” value recorded in “View Calibration Values” • Et t3 - Use the “t 3” value recorded in “View Calibration Values” • Et C3 - Use the “C 3” value recorded in “View Calibration Values” 13. The display reverts to the parameters screen showing “F 20” after all values are entered.

Press Twice

14. Press the "UNITS" button two times to save all changes and exit the Configuration Menu.

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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 Cell and Level Sensor Removal

Load Cells

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

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.

NOTE: Taking a photo of the routing is recommended.

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

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Load Cell & Level Sensor Installation

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.

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.

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

FK0502.eps

Use the following steps to install the load cells 1. Remove the old load cells as described in “Load Cell and Level Sensor Removal” on page 50.

4. Perform the correct Wiring procedures for this type of truck. Refer to “Load Cell and Level Sensor Cable Routing” on page 53.

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

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)

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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 52 ft. lbs. (70 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 “Calibration” on page 39.

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 Wire Routing – Under Battery Box

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

A

A

C

6

1 A = Secure cables with cable ties in these locations.

5

4

3

2

Load Cell and Level Sensor Locations/Wire Routing Legend 1

Load Cell 1

2

Load Cell 2

3

Load Cell 3

4

Load Cell 4

5

Load Cell 5

6

Load Cell 6

C

Level Sensor (NTEP trucks only)

A

Secure cables under tab in these locations

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1. Route Load Cell 2 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 3 cable through the channel along 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.

3. Create a 1 to 1.5 in. loop in the Load Cell 1 cable. Push the loop into the guide channel. Continue routing the cable between Load Cell 1 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 1 and 3 under the tab on the inner fork carriage with a cable tie.

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Wiring 4. Route Load Cell 5 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 right side of the truck. Secure the cable under the tab on the fork carriage with a cable tie.

5. Route Load Cell 4 cable through the channel along 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 6 cable. Push the loop into the guide channel. Continue routing the cable between Load Cell 6 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 6 and 4 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 5 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 Load Cell cables (1, 3, 4, and 6) 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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9. Continue to route the four Load Cell cables to the right side of the truck.

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.

10. Route the four Load Cell cables along with the Load Cell 5 cable and level sensor cable (if equipped) up the bulkhead to just above the lift motor on the right side of the truck (Figure 1-7).

Figure 1-7.

Wire Routing – Tractor Compartment and from Junction Box

A A

A

A A

A

A

A = Secure cables with cable ties in these locations.

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Figure 1-8.

Wire Routing, Tractor Right Side

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

12. Route Load Cell 2 cable up the left side of the truck, across the top of the tractor compartment to the right side of the tractor compartment (Figure 1-7).

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Junction Box, Display, and Voltage Filter

Junction Box, Display, and Voltage Filter 1. Attach the Voltage Spike Filter to the underside of the accessory bar on the right side closest to the load backrest. Make sure the red and black wires face the right side of the truck.

2. Attach the junction box to the underside of the accessory bar on the right side.

3. Route the cables from the junction box down the inside of the accessory bar to through the hole with the load backrest at the top right of the tractor compartment.

4. Connect each Load Cell cable to the corresponding cable from the junction box. Make sure to align the red dots on the

connector then push together to prevent damage to the connector.

Cable from Load Cell 2

Cables from Junction Box

Cables from Load Cells

5. Install the display in the ram mount attached to the accessory bar.

6. Connect the power cord (connector has 2 pins) to the display. Make sure to line up the two small red dots and press the connector together until it clicks.

7. Connect the power cord (connector has 7 pins) to the Junction Box. Make sure to line up the two small red dots and press the connector together until it clicks.

NOTE: Attempting to connect the wrong end of the power cord at either the Display or the Junction box will require

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replacement of the junction box and/or the power cord.

will be between the power amplifier and behind the cover bracket.

8. Connect the power harness to the voltage spike filter connector at JE1.

9. Route the power harness to the left toward the load backrest. Continue routing the power harness down through the hole for the load backrest, and into the tractor compartment.

12. Attach the TPA B– (white) wire to the lower left terminal on the power amplifier on top of the other wires. Make sure the wires are spaced so that the power amplifier status LED is visible.

10. Secure the power harness to the center of the load backrest arm using the cable tie cutouts. Make sure the wire is in the middle of the load backrest arm (not off to the side).

13. Route the MPC-(+) (black) wire under the contactors. Connect to the + terminal on the right side of the MPC.

11. Route the white wire down the side of the panel, behind the cover bracket. The cable

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1329468/001A Printed by the Digital Print Center, The Raymond Corporation, Greene, NY