Rice Lake CLS-M3 Installation & Service Manual
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Rice Lake CLS-M3 Installation & Service Manual

Rice Lake CLS-M3 Installation & Service Manual

Cargo lift scale
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CLS-M3
Cargo Lift Scale
Installation & Service
Manual
157393 Rev F

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Summary of Contents for Rice Lake CLS-M3

  • Page 1 CLS-M3 Cargo Lift Scale Installation & Service Manual 157393 Rev F...

  • Page 3: Table Of Contents

    1.3 CLS-M3 Power and PC Connection ........
  • Page 4 8.3 Troubleshooting iQube2 LEDs ........... 53 Rice Lake continually offers web-based video training on a growing selection of product-related topics at no cost.

  • Page 5: Introduction

    The Cargo Lift Scale is a rugged, dependable cargo lift scale that can withstand many years of repeated use. When mounted on a forklift, the CLS-M3 saves time and money by allowing you to weigh loads immediately instead of carrying the load to a floor scale.

  • Page 6: Considerations Before Installation

    CLS Classes and ID Plates During the initial sale or installation of the CLS-M3, remind the customer that they must have an updated ID plate on the forklift stating the new lifting capacity and center of gravity information. This is require3d per OSHA rules and regulations.

  • Page 7: Forklift Battery And Cls Installation

    PN 166161 – Power Line Filter, CLS (for static protection) CLS-M3 Power and PC Connection The CLS-M3 receives power from a mobile PC through the RS-232 port, this eliminates the need for a Communication/Power box. The iQube2 j-box interfaces to Virtui software that has been pre-installed on the mobile PCs operating system.

  • Page 8: Scale Base Installation

    Scale Base Installation This section describes procedures for installing the Cargo Lift Scale base. Take all necessary safety precautions when installing the scale carriage, including wearing safety shoes WARNING and protective eyewear, and using the proper tools, which are listed in Section 2.4. The Cargo Lift Scale is shipped from the factory with the scale already calibrated and all settings stored in the j- box.

  • Page 9: Unpacking

    Unpacking The CLS is shipped upright on a sealed pallet with one or two scales per pallet, as shown in Figure 2-1. Hardware component boxes Figure 2-1. CLS-M Packaging Upon receipt of the shipping pallet, inspect it for any visible signs of damage. Immediately after unpacking, visually inspect the contents to ensure all components are included and undamaged.
  • Page 10 Scale Hardware component box Protective wood covering Wood shipping pallet Front pallet support Exploded view of components Hardware component box plastic banding Front pallet Protective wood covering Step 3: Remove front pallet support Step 1: Clip plastic band securing hardware component box Step 2: Remove protective wood covering Plastic banding securing...

  • Page 11: Unpacking A Two Scale Configuration

    2.3.2 Unpacking a Two Scale Configuration The scales are shipped in an upright position as illustrated in Figure 2-3. The upright position allows for ease of installation. The power/communication box and accessories are located in a hardware component box. When installing from a two scale configuration, complete all of steps for scale one before clipping plastic WARNING bands securing second scale to the shipping pallet.
  • Page 12 Scale Hardware component boxes Protective wood covering Protective wood covering Wood shipping pallet Exploded view of components Plastic banding Plastic banding Protective wood covering Step 1: Clip top plastic bands Step 2: Clip plastic band to release hardware component boxes Step 3: Remove hardware component boxes Step 4: Clip plastic bands from first scale Step 5: Remove protective wood covering for first...

  • Page 13: Scale Base Installation

    Scale Base Installation Use the following steps to install the scale base to the forklift. Anti-shift centering pin Top cleat location Shim bolt hole location(s) Figure 2-4. Anti-shift Centering Pin, Shim Bolts and Top Cleat Locations (One Scale Configuration Shown) Verify that the shim bolts are flush with the back plate of the scale.
  • Page 14 Illustration shown is with part of the flexure removed to show shim bolt Shim bolts location. Forklift carriage Bottom cleat retaining bolts Insert a feeler gauge to measure a 0.020-inch thickness between bottom cleat and forklift carriage. Bottom cleat Scale carriage 3/16-inch gap max, for installation on forklift to prevent side shifting.

  • Page 15: Connect The Coiled Interface Cable To J-Box

    Connect the Coiled Interface Cable to J-Box Bolt Washer Loop Clamp Loop Clamp Assembly PN 150720 Used with Scale Cover Assembly PN 97118 Washer Scale Cover Assembly Coiled Cable Loop Clamp Assembly PN 167250 Used with Scale Cover Assembly PN 162340 Figure 2-6.

  • Page 16: Cable Connections

    Cable Connections Figure 3-1. Coiled Interface Cable 3.1 Routing Coiled Interface Cable Special care should be taken when routing the coiled interface cable. To ensure that the cable is installed properly and away from situations that could cause it harm use the following steps: 1.

  • Page 17: Pre-Installed Rs-232 Adapter Cable

    3.2 Pre-installed RS-232 Adapter Cable The RS-232 adapter cable (coiled cable to 9-pin RS-232) may be pre-installed from the factory onto the mobile PC. 1. Ensure the mobile PC is OFF 2. Connect the coiled cable to RS-232 adapter cable, secure with tie wraps RS-232 Adapter Cable to reduce accidental damage.

  • Page 18: Revolution® Interface To Cls-M

    Revolution Interface to CLS-M ® Revolution is a tool to display weight, diagnostics and calibration (if required) of the CLS-M3 scale using a Windows ® based computer. 4.1 Connect Scale to Revolution 1. Open the Revolution program on the computer.
  • Page 19 5. Once selected, the main screen shown in Figure 4-3 is displayed. Figure 4-3. Expanded Pitch Angle Selection 6. Go to Tools/Options (Figure 4-4 A) and select (B), then choose the (C). Settings PC Comm Port 7. Select available RS-232 Comm port. 8.

  • Page 20: Live Weight Data

    (Figure 4-7). Live Weight Data Weight data packet screen shows output format of CLS-M3. Other displays include weight, pitch angle, roll angle, cell 1 & 2mV. (Figure 4-7). This is the information that will be sent to the customer supplied hand-held device when attached through Bluetooth.

  • Page 21: Leveling Forklift Forks

    Figure 4-7. Revolution Live Weight Data screen. A. Weight Data Packet - output format/displays the output protocol of the CLS-M3. B. Auto Refresh - when checked it starts continuous streaming of data in the weight data packet. C. Zero - used to zero the scale.
  • Page 22 Figure 4-8. Zero Forks Forks should be level when testing calibration. A degree of tilt in either direction can cause errors in the use of the scale. Cargo Lift Scale Series...

  • Page 23: Calibration

    4.4 Calibration The carriage j-box will need to be in setup mode (See Section 5.3) 1. Select (Figure 4-9 B) Standard Calibration 2. Press (Figure 4-9 C). Next Figure 4-9. Enter Calibration 3. Enter test weight value to be used and press (Figure 4-10 A).
  • Page 24 4. Corner Match Scale Calibration screen appears. Press (Figure 4-11 A). Calibrate Zero 5. When message in the lower left corner of message box reads press Zero Calibration Complete Next (Figure 4-11 B). Wait for Zero Calibrate Complete to appear before pressing next.
  • Page 25 8. Press (Figure 4-13 A). Measure Figure 4-13. Load Cell Calibration 9. Load Cell #1 Status will read (Figure 4-13 B) and Load Cell #2 Measure will become available. Success Repeat steps 9-11 for Load Cell #2. 10. When both load cells have been calibrated (status reads Success for both Cell #1 & #2, Figure 4-13 B) and message appears (Figure 4-13 C) press (Figure 4-13 D).

  • Page 26: Reading Data In Live Weight Screen

    4.4.1 Reading Data In Live Weight Screen Once calibration is complete, select the tab. Live Weight Data Weight value with weight applied to forks Values update Figure 4-15. Revolution Live Weight Data Screen. 1. Place calibration switch into the closed position (Figure 5-1), toward the left hand side of j-box when standing in front of the scale (toward load cell #1).

  • Page 27: Ez Setup/Upload Unit Serial Number

    4.5 EZ Setup/Upload Unit Serial Number Figure 4-16 appears with three tabs, will be used for Setup Live Weight Data Serial Number Serial Number entering the current serial number of the scale in the following sections. All settings have been preset at the factory for communication with the hand-held device. DO NOT alter these settings, it will cause communication failure with the hand-held device.

  • Page 28: Diagnostics

    4.6 Diagnostics Diagnostics works in setup or normal operating mode. 1. On EZ Setup screen select Diagnostics. Selecting Auto refresh will continuously display data communications for each screen. Diagnostics Figure 4-17. Select Diagnostics Power Supply: Not Applicable to CLS M software Slave Communications: Not applicable to CLS M software Cargo Lift Scale Series...
  • Page 29 Excitation: Not Applicable to CLS M software Cell Connection: Tests correct load cell cable connections Scans each load cell to display connection issues If one load cell connection error is found, will flash between “No cell connection problems” and Scale: SC1 Cell:1 or 2.
  • Page 30 Cell drift: Not Applicable to CLS M software Underloaded Load cell: If error occurs displays mV level of the underloaded load cell. At 5000lbs the mV rating is 1.5 Cell Noise: Not Applicable to CLS M software Unbalanced Cell: Not Applicable to CLS M software Cargo Lift Scale Series...

  • Page 31: Calibration

    Calibration When hanging weights from the forks make sure to note the weight of hanging device and add to test weight value (Figure 5-4). Make sure forks are level before beginning calibration (See Section 4.3). Suggested test weight is 500lb minimum. Always shut forklift off when calibrating, high vibration can cause inaccuracies.

  • Page 32: Calibrate Scale Using Revolution

    5.3 Calibrate Scale Using Revolution 1. Connect computer to adapter on the coiled interface cable (see Section 3.3). 2. Level forks (see Section 5.2). 3. In set-up select (Figure 5-3 A). Calibration 4. Select (Figure 5-3 B) Standard Calibration 5. Press (Figure 5-3 C).
  • Page 33 screen appears. Press (Figure 5-5 A). Corner Match Scale Calibration Calibrate Zero 8. When the message in the lower left corner of message box reads press Zero Calibration Complete Next (Figure 5-5 B). Wait for zero calibrate complete to appear before pressing next.
  • Page 34 11. Press (Figure 5-7 A). Measure Figure 5-7. Load Cell Calibration 12. Load Cell #1 status will read (Figure 5-7 B) and Load Cell #2 will become available. Success Measure Repeat steps 9-11 for Load Cell #2. 13. When both load cells have been calibrated (status reads for both Cell #1 &...

  • Page 35: Reading Data In Live Weight Screen

    5.3.1 Reading Data In Live Weight Screen Once calibration is complete select the screen. Live Weight Data Weight value with weight applied to forks Values update Figure 5-9. Revolution Live Weight Data screen. 1. Place calibration switch into the closed position (Figure 5-1), toward the left hand side of j-box when standing in front of the scale (toward load cell #1).

  • Page 36: Weights And Measures Sealing

    5.4 Weights and Measures Sealing Weights and Measures personnel will inspect the j-box for proper sealing once installed on the forklift. The j-box must have the proper serial tag affixed to the box and lead wire sealing on the j-box. View from back of scale Weights and Measure seals Weights and Measures sealing location...

  • Page 37: Load Cell Replacement And Flexure Troubleshooting

    Load Cell Replacement and Flexure Troubleshooting This section describes procedures for replacing a load cell. The CLS-M Cargo Lift Scale uses Rice Lake’s load cell, PN 125543. The following instructions must be followed exactly to allow for seamless and easy load cell replacement.

  • Page 38: Load Cell Replacement

    6.2 Load Cell Replacement A replacement parts kit is available (PN 97883), which contains all of the component parts shown in Figure 6-1. #1 Upper Hex Nut #2 Upper Hex Nut #3 Spherical Washer Set #4 Upper Block #5 Spherical Washer Set #6 Hex Nut #7 Jam Nut #8 Flexure Rod...
  • Page 39 Use the following steps to replace a load cell. 1. Raise the forklift carriage just slightly for fork removal. 2. Slide the forks to the center of the carriage to allow for removal. Set forks aside. Slide forks to the middle of scale carriage Figure 6-2.
  • Page 40 Figure 6-4. Loosen and Remove Bottom Hex Nut (#18 and #19 on Parts Breakdown) It’s okay if the load cell slightly rotates up against the front or back plate of the scale. 8. Remove the bottom hex nuts (#18 and #19) and the bottom spherical washer set (#17). 9.
  • Page 41 Detach load cell clip from back plate of scale using a large screwdriver. Figure 6-6. Load Cell Cable Clips 18. Position a new load cell with its cable facing towards the center and opening of the S-beam facing the flexure's. Load cell cable should face towards the center of the scale.
  • Page 42 19. Install the top and bottom flexure rod with hardware, ensuring that the flexure rod be oriented with the short thread of the rod facing nearest the load cell. Short threads facing nearest the load cell. Figure 6-8. Installing Flexure into Scale 20.
  • Page 43 Figure 6-10. Install Spherical Washer Set 25. Install a flat-bladed screwdriver in the upper mounting block between the hole and the flexure rod, forcing the flexure rod in the same direction of the flexures. Insert the flat-blade screwdriver here to help center the flexure rod.
  • Page 44 Figure 6-13. Tightening the Lower Hex Nut 27. Use the special modified box wrench to tighten the jam nut (#13) on the lower block. 28. Remove the flat-bladed screwdriver as used in Step 25 and inspect the flexure rod. The flexure rod needs to be in the center of the hole.

  • Page 45: Forklift Flexure Troubleshooting - 28" And 34" Models

    6.3 Forklift Flexure Troubleshooting - 28" and 34" Models For Part Number 92828 The forklift flexure is designed to protect the load cell from damage in the forklift environment. Use the following steps if the forklift scale is out of tolerance or unable to return to zero on a consistent basis. 1.

  • Page 46: Iqube2® J-Box

    J-Box The iQube2 j-box designed for use with the Rice Lake CLS-M series forklift scales and is a replacement for the j-box used on early models of the scale. Load cell connectors have been updated to improve serviceability. iQube2 J-Box Replacement The j-box is located between the front and back panel of the scale and is covered by a metal cover plate on the top of the scale.
  • Page 47 Load Cell 5 Pin Male Connector Wiring Pin # Wire Color Function Green +SIG White -SIG +EXC Black -EXC Yellow Ground Table 7-1. Load Cell Wiring Load Cell Stripping Wiring Load Cell Wiring Figure 7-3. Load Cell Wiring 13. Add blue Loctite 425 to the two contact points as indicated in Figure 7-3.

  • Page 48: Download The Serial Number To The J-Box

    Download the Serial Number to the J-Box 1. To download the serial number of the scale using Revolution while in the mode, select the Serial EZ Setup Number tab. 2. Enter the new six-digit serial number from the forklift scale (A) and press the Download Serial Number button (B) to save the new serial number.

  • Page 49: Iqube2 Pcb Board Assembly Replacement

    10. Replace cover and secure with four screws, Locktite not required. R109 TP26 TP25 C117 LED1 TVS3 TVS2 TVS4 C110 C115 2+ - C119 Coiled cable RS232_TX RICE LAKE TP14 connection RS232_RX TP15 ALIVE TP16 Vx.xx LED2 LED3 JTAG C121 C120 Right load cell Left load cell...

  • Page 50: Iqube 2.3 Cross References

    2.3 Cross References When identifying the correct j-box cross referenced part number, please provide the serial number of the scale so that the Rice Lake Weighing Systems sales and service departments can track it to the correct top level part number sold.

  • Page 51: Appendix

    Appendix 8.1 Parts Breakout Used with Scale Cover Assembly PN 162340 Used with Scale Cover Assembly PN 97118 Figure 8-1. CLS-M3 Scale Assembly Item No. Part No. Item Description 156294 Scale, CLS-M3 125395 Cable Assy, Coiled 5x18AWG 153296 Adapter 127009...
  • Page 52 Note: Torque 5/8-11 Bolts to 150 ft-lbs (Typ) 1 PER SIDE Figure 8-2. CLS-M3 Scale Parts Item Part No. Item Description 125368 Scale Section Assy 34 15198 Washer, Spherical.53x1.12 92822 Bolt, 1-8NCx2-3/8 Gr 5 92812 Screw, Cap 3/8-16NCx1/2 126770 Cleat, Bottom, Thick for use on worn carraiges 92828 Flexure, 1x3x4.12 17-4PH...
  • Page 53 Included with cable assemblies Included with cable assemblies Figure 8-3. iQube2 J-Box Assembly, PN 164071 Item Part No. Item Description Qty. 162378 Enclosure Assembly 163767 Data Receptacle Cable Assembly 163766 Load Cell Cable Receptacle Assembly 164598 Breather Vent 88734 Nut, Breather Vent Thread 167999 J-Box PCB Assembly 14839...
  • Page 54 THIS PAGE REFERENCE ONLY Supplied w/ J-Box Figure 8-4. J-Box Assembly PN 159589 Item Item Part No. Item Description Part No. Item Description 125942 Gasket,Rubber CLS-M 132726 Board,CLS-M J-Box Rev C 42640 Screw,Mach 1/4-28NF X ¼ 125640 Enclosure,Machined CLS-M 81220 Screw, Mach 6-32NCx1/2 19528 Post Only,Slotted Black...

  • Page 55: Troubleshooting Table

    8.2 Troubleshooting Table Symptom Possible Cause Action Scale displaying negative weight Forks are resting (even slightly) on the floor. Lift forks up off floor. Scale reading high against test Material, like wood debris, between the scale Remove debris. weight. and the forklift carriage. Material, like wood debris, between the front Remove debris.
  • Page 56 Symptom Possible Cause Action Intermittent weight readings, Material, like wood debris, between the scale Remove debris weight reading high and low. and the forklift carriage. Material, like wood debris, between the front Remove debris and back scale plates. Centering pin touching the forklift carriage, Adjust scale carriage, centering pin should causing it to teeter back and forth.

  • Page 57: Troubleshooting Iqube2 Leds

    R109 TP26 TP25 C117 LED1 TVS3 TVS2 TVS4 C110 C115 2+ - C119 RS232_TX RICE LAKE TP14 RS232_RX TP15 ALIVE TP16 Vx.xx LED2 LED3 JTAG C121 C120 D20 - PC board LED 2 - Heartbeat LED 3 - Processor...
  • Page 58 Cargo Lift Scale Series...
  • Page 60 Specifications subject to change without notice. Rice Lake Weighing Systems is an ISO 9001 registered company. 230 W. Coleman St. • Rice Lake, WI 54868 • USA U.S. 800-472-6703 • Canada/Mexico 800-321-6703 • International 715-234-9171 • Europe +31 (0)26 472 1319 www.ricelake.com www.ricelake.mx www.ricelake.eu www.ricelake.co.in...

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