Rice Lake CLS Series Service Manual
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Rice Lake CLS Series Service Manual

Cargo lift scale
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CLS-Series
Cargo Lift Scale
Service Manual
211569 Rev B
January 10, 2022

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Summary of Contents for Rice Lake CLS Series

  • Page 1 CLS-Series Cargo Lift Scale Service Manual 211569 Rev B January 10, 2022...

  • Page 3: Table Of Contents

    Course descriptions and dates can be viewed at www.ricelake.com/training or obtained by calling 715-234-9171 and asking for the training department. © Rice Lake Weighing Systems. All rights reserved. Printed in the United States of America. Specifications subject to change without notice. Version 1.0, May 16, 2013...
  • Page 4 Rice Lake continually offers web-based video training on a growing selection of product-related topics at no cost. Visit www.ricelake.com/webinars. CLS-Series Service Manual...

  • Page 5: About This Manual

    Introduction The CLS Series Cargo Lift scale is a rugged, dependable cargo lift scale that can withstand many years of use. When mounted on a forklift, the CLS Series can weigh, transfer and collect data in one efficient operation. It saves operator time, equipment costs and eliminates the middle step.

  • Page 6: Safety

    Do not operate or work on this equipment unless you have read and understand the instructions and warnings in this manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Rice Lake Weighing Systems dealer for replacement manuals. Proper care is your responsibility.

  • Page 7: Load Cell Replacement

    Required Tools for Replacing a Load Cell The following list of tools is necessary for replacing a load cell on the CLS Series Scale. Ensure that you have these necessary tools handy.
  • Page 8 #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 #9 Jam Nut #10 Load Cell #11 Jam Nut Modified #12 Flexure Rod Wrench #13 Jam Nut #14 Hex Nut...
  • Page 9 5. Loosen jam nut from the upper block using the special modified box wrench (PN 96196 - supplied with load cell replacement kit) shown in Figure 2-2. 6. Loosen jam nut (#13) from the lower block. 7. Remove the top hex nut (#2) and the top spherical washer set (#3). 8.
  • Page 10 18. Oil the spherical washers using a standard machine shop oil. Detach load cell clip away from back plate of scale using a large screwdriver. Figure 2-6. Load Cell Cable Clips 19. Back off upper and lower overload stops using a 1-1/8" wrench. Overload stops looking at top view.
  • Page 11 21. Install the top and bottom flexure rod with hardware ensuring that the flexure rod be oriented with the short thread of rod facing nearest the load cell. Short threads facing nearest the load cell Figure 2-8. Installing Flexure into Scale 22.
  • Page 12 Figure 2-10. Install Spherical Washer Set 27. Install a flat bladed screwdriver in upper mounting block between the hole and the flexure rod, forcing the flexure rod in the direction of the flexures. Insert flat blade screwdriver here to help center the flexure rod Figure 2-11.
  • Page 13 Figure 2-12. Centering the Load Cell Using a Chisel Figure 2-13. Tightening the Lower Hex Nut 29. Use the special modified box wrench to tighten the jam nut (#13) on the lower block. 30. 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 14: Junction Box Replacement

    Junction Box Replacement The CLS Series scale uses a NEMA 4X polycarbonate junction box. The junction 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. Use the following procedures for replacing a junction box on the CLS Series Cargo Lift Scale.
  • Page 15 5. Remove the indicator cable from the junction box (not applicable for wireless models). Remove indicator cable from junction box (if using the wired model) Remove load cell cable from junction Figure 3-3. Junction Box Location Inside the Scale (wireless version shown above) 6.
  • Page 16 9. Reconnect the wires to the bottom board per Figure 3-4, Figure 3-5, and Table 3-1 listed below. J4 Wiring Connector (Cell #1 - the left cell as viewed from the forklift drivers seat) J4 Function + SIGNAL - SIGNAL + EXCITATION - EXCITATION SHIELD...
  • Page 17 POS (red) CLOCK (blue) DATA (brown) TEMP (green) NEG (black) Table 3-2. Top Board Wiring Connections Note J6 wiring is only used in the wireless version of the CLS series and goes directly to the battery box. Junction Box Replacement...
  • Page 18 CLS-Series Service Manual...

  • Page 19: Lithium-Ion Battery Charge And Replacement

    Lithium-Ion Battery Charge and Replacement If using a wireless version of the CLS Series Cargo Lift Scale, the CLS scale uses a supplied lithium-ion battery to supply power to the indicator. The lithium-ion battery is located on the top of the cover plate in a painted enclosure.

  • Page 20: Charging The Lithium-Ion Battery

    4.0.2 Charging the Lithium-Ion Battery The lithium-ion battery comes with a two-bay, level-3 stand alone smart battery charger, a DC power jack, and a AC power cord as shown in Figure 4-2. To calibrate the battery pack, press the button on front label.

  • Page 21: Wireless Battery Option

    Wireless Battery Option Wireless technology eliminates the need for the coiled interface cable. The reinforced battery box is welded onto the cover plate. There is an On/Off switch to conserve the life of the battery and an LED to indicate when the battery is on.

  • Page 22: Battery Disposal

    Battery Disposal When using Lithium-ion batteries, be sure to observe the following precautions for disposal as stated in the material safety data sheet regarding lithium-ion batteries. CLS-Series Service Manual...

  • Page 23: Board Replacement

    Board Replacement Use the following procedures in the event that the CPU board on either the 420 or the 920i need to be replaced. Board replacement for the 420 indicator is covered in Section 5.1 and board replacement for the 920i indicator is covered in Section 5.2.
  • Page 24 Figure 5-2. CPU and Power Supply Board with Analog Output Option Card Figure 5-3. 420 DC Power Supply CLS-Series Service Manual...

  • Page 25: Dc Power Wiring Guidelines

    5.1.2 DC Power Wiring Guidelines Based on: • 8 x 350 • Analog output installed • Digital outputs sourcing 20mA each • Drawing maximum current at 7.5 VDC from the DC/DC power supply DC power wiring to the indicator should be 18 AWG to 14 AWG for DC+, DC-, and earth ground conductors. Note The indicator will be connected directly to the battery of the forklift.

  • Page 26: Serial Communications

    5.1.3 Serial Communications Using on of the six-position connectors, provided in the parts kit, wire the serial communications cables to J4. Connector J3 provides connections for the EDP/RS-232 port. Connect communications cables to connectors J3 and J4 as shown in Table 5-2. Once cables are attached, reconnect J3 and J4 to the headers on the board (see Figure 5-2).

  • Page 27: Cls-920I Cpu Board Replacement

    CLS-920i CPU Board Replacement 5.2.1 Enclosure Disassembly The 920i indicator enclosure must be opened to install option cards and to connect cables for installed option cards. 920i has no on/off switch. Before opening the unit, ensure the power cord is disconnected from the WARNING forklift power source.

  • Page 28: Serial Communications

    5.2.4 Serial Communications The four communications ports on the 920i CPU board support full duplex RS-232, 20 mA output, or RS-485 communications at up to 115200 bps. To attach serial communications cables, route the cable through the cord grip and ground the shield wire as described in Section 5.2.3 on page 25.
  • Page 29 Figure 5-6. 920i CPU Board, Showing Option Card Locations Board Replacement...

  • Page 30: Digital I/O

    5.2.5 Digital I/O Digital inputs can be set to provide many indicator functions, including all keypad functions. Digital inputs are active low (0 VDC), inactive high (5 VDC). Digital outputs are typically used to control relays that drive other equipment. Outputs are designed to sink, rather than source, switching current.
  • Page 31 Wireless Antenna INDICATES OPTION CARD CABLE TIES PULSE INPUT CARD DUAL A/D CARD Memory Card Wi-Port Serial Card Installing on CPU Board Installed Showing Secured Cables Figure 5-7. Installing Option Cards The 920i automatically recognizes all installed option cards when the unit is powered on. No hardware-specific configuration is required to identify the newly-installed card to the system.

  • Page 32: Enclosure Reassembly

    5.2.7 Enclosure Reassembly Once cabling is complete, position the backplate over the enclosure and reinstall the backplate screws. Use the torque pattern shown in Figure 5-8 to prevent distorting the backplate gasket. Torque screws to 15 in-lb (1.7 N-m). T o r qu e b ac k pl at e s cr ew s to 1 5 i n - l b (1 .7 N - m) Figure 5-8.

  • Page 33: Fuse Replacement

    5.2.9 Fuse Replacement Fuses for the universal and deep enclosure models of the 920i are located under a cover plate on the outside of the enclosure. Remove the cover plate, replace the fuses, and reinstall the cover plate (see Figure 5-9). CAUTION To protect against the risk of fire, replace fuses only with same type and rating fuse.

  • Page 34: Downloading Cls Configuration And User Program Software

    Description 15665 Reducing glands for 1/2 NPT cord grips (2) 15887 6-position screw terminal for load cell connection (1–single A/D, 2–dual A/D) 19538 Cord grip plugs (4–single A/D, 3–dual A/D) 42350 Capacity label (1–single A/D, 2–dual A/D) 53075 Cable shield ground clamps (4) 70599 6-position screw terminals for J2 and J10 (2) 71126...

  • Page 35: Replacement Parts

    Replacement Parts Figure 6-1. CLS Forklift Scale Parts Illustration Item No. Part No. Description 111234 Front Plate 100073 Angle Protective WLDT 109953 Screw, Cap 5/8-11NCx3 97883 Load Cell Replacement Kit (see Figure 6-2) 109976 Flexure 92829 Screw Cap 5/8-11NCx1-1/4 109952 Screw, Cap 5/8-11NCx2-1/2 109961 Washer Black Steel 5/8...
  • Page 36 Figure 6-2. Load Cell Replacement Kit Parts Illustration Item No. Part No. Description 97883 Load Cell Replacement Kit (inc items 1, 2, 5, 4, 6 & 8) 109958 Hex Nut 15198 Spherical Washer Set Upper Block 92827 Flexure Rod 14665 Jam Nut 96198 Load Cell...
  • Page 37 CLS-420 Indicator CLS-920i Indicator Figure 6-3. Indicator Mounting Bracket Parts Illustration Item No. Part No. Description 14656 Nut, 3/8-16NC Hex 15159 Washer, Lock, 3/8 Regular 96929 Clamp Plate, Indicator 14984 Screw, Cap 1/4-20NCx1-3/4 44676 Washer, Bonded Sealing 96928 Mount Plate,Indicator 14634 Nut, Lock 1/4-20NC Hex 98537...

  • Page 38: Cls 420 Indicator Replacement Parts

    6.0.1 CLS 420 Indicator Replacement Parts Ground Wire to Backplate Ground Wire from Power Assembly Zigbee Wireless Option From Power Supply Cable Assembly 31 25 To Power Supply Detail AA Figure 6-4. CLS-420 Indicator Parts Illustration CLS-Series Service Manual...
  • Page 39 Bracket, Power Supply 420 99479 Power Supply, 25W DC/DC 53307 Label,4.000x2.875 84397 Overlay, 420 Indicator 68216 Nameplate, Rice Lake 85151 Cable Assy, Power Supply 16892 Label, Earth Ground 15134 Washer, Lock NO 8 Type A 45043 Wire, Ground 4in W/No.8 53308 Label,1.25x1.25 8000T...

  • Page 40: Cls-920 Replacement Parts

    6.0.2 CLS-920 Replacement Parts Optional Wireless Communication Module From Power Supply Cable Assembly Attaches to Backplate Optional Zigbee Wireless Module 34 27 29 38 Section A-A Ground Wire to Backplate Ground Wire From Power Connector Ground Stud Stackup Detail B Figure 6-5.
  • Page 41 Cable, Ribbon Interface 67614 Display, LCD Module 920i 16892 Label, Earth Ground 67886 Standoff, Male-FEM 4-40NC 68216 Nameplate, Rice Lake 68661 Standoff, Male-FEM 4-40NC 80331 Connector,T ap and Run 109549 Board Assy, CPU 920i 57241 Gasket, MS Conn Shell Size...

  • Page 42: Cls-Series Specifications

    CLS-Series Specifications Cargo Lift Scale Scale Capacity: 5,000 lb Safe Overload: 200% Ultimate Overload: 5:1 capacity Scale Power: Wired Version: supplied by coiled interface cable from indicator Wireless Version: supplied by one lithium-ion Smart battery (SMBus revision 1.1 fully compliant) Material/Finish: Painted mild steel Scale Warranty:...
  • Page 44 Rice Lake Weighing Systems January 10, 2022 PN 211569...

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