with FLI 225 Instrument Installation Instructions

Transcription

1 QTLTSC Forklift Scale with FLI 225 Instrument Installation Instructions AWT Issue AB August 2009

2 Avery Weigh-Tronix, LLC All rights reserved. No part of this publication may be reproduced, stored in an electronic retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise without the prior written consent of the copyright owner, or as permitted by law or under license. Full acknowledgment of the source must be given. Avery Weigh-Tronix is a registered trade mark of the Avery Weigh-Tronix, LLC. This publication was correct at the time of going to print however, Avery Weigh-Tronix, LLC reserves the right to alter without notice the specification, design, price or conditions of supply of any product or service at any time. All third party brands and product names used within this document are trademarks or registered trademarks of their respective holders. QTLTSC_FLI225_i_en_ book

3 Table of Contents Manual Revision History... 4 Chapter 1 General information and warnings... 5 About this manual... 5 Text conventions... 5 Special messages... 5 Installation... 6 Safe handling of equipment with batteries... 6 Routine maintenance... 6 Cleaning the machine... 7 Training... 7 Sharp objects... 7 FCC and EMC declarations of compliance... 7 Chapter 2 Installation Unpacking and Inspecting Installing the QTLTSC Carriage De-rating the Forklift Capacity Mounting the FLI 225 Instrument Routing the Signal Cable Power Connections Power Connections Using the FLP 100 Power Conditioner Chapter 3 Extras Making a Ramp for Tilting the Forklift De-rating Forklift Capacity Available Carriages page QTLTSC w/fli 225 Installation Instructions 3

4 Manual Revision History Current Issue Date Created Details of Changes AA August 2008 Issue new manual AB August 2009 Added notes on using thread locking compound on bolts for both the carriage and the instrument on pages 10 and 14. Updated the safety and warnings information. Updated copyright statement. Added CE statement on pages 8 and 9. Updated drawing and measurements of ramp on p QTLTSC w/fli 225 Installation Instructions

5 About this manual 1 General information and warnings 1.1 About this manual This manual is divided into chapters by the chapter number and the large text at the top of a page. Subsections are labeled as shown by the 1 and 1.1 headings shown above. The names of the chapter and the next subsection level appear at the top of alternating pages of the manual to remind you of where you are in the manual. The manual name and page numbers appear at the bottom of the pages. This manual covers the general user instructions for the FLI 225 instrument for multiple regions worldwide Text conventions Key names are shown in bold and reflect the case of the key being described. This applies to hard keys and onscreen or soft keys. Displayed messages appear in bold italic type and reflect the case of the displayed message Special messages Examples of special messages you will see in this manual are defined below. The signal words have specific meanings to alert you to additional information or the relative level of hazard. ELECTRICAL WARNING! THIS IS AN ELECTRICAL WARNING SYMBOL. ELECTRICAL WARNINGS MEAN THAT FAILURE TO FOLLOW SPECIFIC PRACTICES OR PROCEDURES MAY RESULT IN ELECTROCUTION, ARC BURNS, EXPLOSIONS OR OTHER HAZARDS THAT MAY CAUSE INJURY OR DEATH. CAUTION! This is a Caution symbol. Cautions give information about procedures that, if not observed, could result in damage to equipment or corruption to and loss of data. NOTE: This is a Note symbol. Notes give additional and important information, hints and tips that help you to use your product. FLI 225 User Instructions 5

6 General information and warnings 1.2 Installation DANGER: RISK OF ELECTRICAL SHOCK. NO USER SERVICEABLE PARTS. REFER TO QUALIFIED SERVICE PERSONNEL FOR SERVICE Safe handling of equipment with batteries CAUTION: Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent type recommended by the manufacturer. Dispose of used batteries according to the manufacturer s instructions. ATTENTION: Il y a danger d'explosion s'il y a remplacement incorrect de la batterie, remplacer uniquement avec une batterie du même type ou d'un type équivalent recommandé par le constructeur. Mettre au rebut les batteries usagées conformément aux instructions du fabricant. 1.3 Routine maintenance IMPORTANT: This equipment must be routinely checked for proper operation and calibration. Application and usage will determine the frequency of calibration required for safe operation. Always turn off the machine and isolate from the power supply before starting any routine maintenance to avoid the possibility of electric shock. Make sure that it is placed securely on a flat and level surface. 6 FLI 225 User Instructions

7 Cleaning the machine 1.4 Cleaning the machine Table 1.1 Cleaning DOs and DON Ts DO DO NOT Wipe down the outside of standard products Attempt to clean the inside of the machine with a clean cloth, moistened with water and Use harsh abrasives, solvents, scouring cleaners or a small amount of mild detergent alkaline cleaning solutions 1.5 Training Do not attempt to operate or complete any procedure on a machine unless you have received the appropriate training or read the instruction books. To avoid the risk of RSI (Repetitive Strain Injury), place the machine on a surface which is ergonomically satisfactory to the user. Take frequent breaks during prolonged usage. 1.6 Sharp objects Do not use sharp objects such as screwdrivers or long fingernails to operate the keys. 1.7 FCC and EMC declarations of compliance This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense. European Countries WARNING: This is a Class A product. In a domestic environment, this product may cause radio interference in which the user may be required to take adequate measures. FLI 225 User Instructions 7

8 General information and warnings 8 FLI 225 User Instructions

9 FCC and EMC declarations of compliance FLI 225 User Instructions 9

10 Installation 2 Installation This scale system is made up of the QTLTSC scale carriage and the FLI 225 instrument and is shipped as a precalibrated system. To function within the requirements of a legalfor-trade scale, it must be tested. If the scale performs outside the acceptable tolerance, adjustments and calibrations must be made. The following steps will help the technician to successfully install and test the system. Calibration procedures are covered in the Calibration Instructions as well as the Service Manual. CAUTION: Please, always keep safety first in your mind as you install your Avery Weigh-Tronix forklift scale and operate any forklift. Take all necessary safety precautions as you install the QTLTSC scale. This includes wearing safety shoes, protective eyewear, and using proper tools. Included in this section are instructions for: l Unpacking and Inspecting on page 10 l Installing the QTLTSC Carriage on page 11 l Mounting the FLI 225 Instrument on page 13 l Routing the Signal Cable on page 14 l Power Connections on page 16 l Power Connections Using the FLP 100 Power Conditioner on page Unpacking and Inspecting 1. Inspect the shipping container as soon as it is received. If the container appears damaged, closely inspect the contents. 2. Open the shipping container. You will find the QTLTSC carriage, interface cable, mounting hardware, power cable and other electrical connectors, User and Installation Instructions and the FLI 225 instrument. These items may be packed in various boxes. 3. Inspect the QTLTSC carriage and the interface cable for damage. A supply of Loctite is included in the shipped items. If any bolts are removed to gain access to the junction box or to move cable routing, use the Loctite (or an equivalent substitute) when replacing the bolts. 10 QTLTSC w/fli 225 Installation Instructions

11 Installing the QTLTSC Carriage 2.2 Installing the QTLTSC Carriage Refer to figure 2.1 and the following instructions to install the QTLTSC carriage. The centering pin on the scale can be unbolted and flipped over to make a snug fit if the carriage notch is worn. 1. Remove the customer's forks. Figure 2.1 QTLTSC and mounting hooks 2. Check the forks for wear or damage and make any necessary repairs. 3. Clean and inspect the customer's forklift carriage. Both the upper and lower sections of the carriage must be flat and not twisted or bent out of shape. It is especially important that the upper carriage notches are not excessively worn. 4. Repair any damage before installing the QTLTSC carriage or the system will not function properly. The QTLTSC system comes precalibrated from Avery Weigh-Tronix. Calibration will be affected if the scale is attached to a damaged carriage. 5. Cut the shipping straps holding the carriage to the pallet. 6. Remove the two bottom mounting hooks. 7. With an assistant, raise the QTLTSC carriage to a vertical position and set it near the edge of the pallet. 8. Drive the forklift into a position where it can pick up the QTLTSC carriage. 9. Align the QTLTSC centering pin, refer to figure 2.1, with the center notch in the forklift carriage. The top mounting blocks of the QTLTSC must be over the top of the customer's forklift carriage lip and seated firmly in place. QTLTSC w/fli 225 Installation Instructions 11

12 Installation 10. Raise the carriage and back the forklift away with the QTLTSC in place. 11. Pull the top of QTLTSC as far forward as possible for proper seating of the hooks. 12. Raise the forklift carriage with QTLTSC to a convenient height for attaching the two mounting hooks on the bottom of the QTLTSC. 13. Make certain the customer's carriage is clean where the hooks will be positioned. 14. Attach the mounting hooks. 15. Tighten the bolts to 70 foot pounds. 16. Thread the supplied sealing wire through the bolt heads of the mounting hook to stop the bolts from vibrating loose. If needed, loosen the bolts just enough to align the holes in the bolt heads. See figure 2.2. Figure 2.2 Sealing wire placement 17. Mount the customer s forks on the Quik-Tach in the same way they attach to the regular forklift carriage. 18. Move the forks into the positions they will be used during normal operation. 19. Make sure all carriage components are firmly and safely secured in place. Figure 2.3 Side view of the QTLTSC and customer s carriage 12 QTLTSC w/fli 225 Installation Instructions

13 De-rating the Forklift Capacity As a minimum, there must be a 1/32 gap between the back of the scale and the customer s carriage except at the bosses. Make sure the bosses on the Quik-Tach carriage make contact with the customer s forklift when both forks are seated. If there is a gap between the bosses and the customer s carriage (see Figure 2.3) when the forks are seated, use the included shims as necessary to close the gap on either end. Then bend the tabs over to hold them in place as shown in Figure 2.1. There are three shim thicknesses. If you have to stack more than two shims on either end, your carriage is bent and needs to be fixed or replaced. There must be to space between the customer s carriage and the mounting hooks of the Quik-Tach scale. See Hook Clearance in figure 2.3. These parts must not touch or the scale will not weigh correctly. Use the spacer plates as needed to be sure this space exists. You must also be sure the forks contact the scale only at the positions shown in figure 2.3. Repair or replace the forks if they are bent or have protrusions which contact the face of the scale. 2.3 De-rating the Forklift Capacity A calculation formula is provided in De-rating Forklift Capacity on page 21. It is the customer s responsibility to contact their forklift manufacturer / distributor with this information to obtain a new ID plate stating the new lifting capacity and center of gravity information of the forklift. Always comply with local rules and regulations. 2.4 Mounting the FLI 225 Instrument Inside the shipping box, you will find the parts necessary to mount the FLI 225 instrument to your forklift. Refer to figure 2.4. Upper Mounting Plate Lower Mounting Plate FLI 225 Mounting Bracket Isomount between lower mounting plate and FLI 225 mounting bracket Figure 2.4 Instrument Mounting Hardware Be sure to consider operator safety when determining placement of the instrument. Place the instrument out of the operator s way so as to maximize the field of view. QTLTSC w/fli 225 Installation Instructions 13

14 Installation The instrument comes attached to the mounting bracket and the mounting bracket is attached to the lower mounting plate with isomounts. Follow these steps to complete installing the unit to the forklift: 1. Determine the best location for the FLI 225. The tilt position is adjustable. You may pick the best viewing angle for your operators now or after you fully install the FLI Use the long bolts, lock washers and nuts to sandwich the top of the roll cage between the upper and lower mounting plates. CAUTION: Be sure to use the supplied thread locking compound on all threaded parts as you assemble the instrument bracket and hang it from the forklift roll cage. 3. Adjust the position of the instrument for best viewing and tighten all hardware to prevent movement. 2.5 Routing the Signal Cable The signal cable has a 12 pin connector on each end. You may need to be creative in finding the ideal routing for the signal cable on your model of forklift due to differing mast styles and installed options among the different manufacturers. 1. Connect one end of the signal cable to the junction box on the scale carriage. Place a bead of silicone (RTV) across the connector parts to reduce the effects of vibration. 2. Route the other end of the cable to the FLI 225 instrument. Two mounting brackets and cable clamps are supplied with the system. If needed, mount them where they will best support the signal cable without interfering with mast movement. Cable tie the cable where necessary to prevent snagging and to secure the cable in place. If possible, position the cable between the mast uprights and over any side-shifter cylinder hoses. 14 QTLTSC w/fli 225 Installation Instructions

15 Routing the Signal Cable See figure 2.5 for an illustration of one suggested routing of the signal cable on one type of forklift. Figure 2.5 Sample routing of signal cable Routing the interface cable up the center of the mast will prolong the cable life. Attach the signal interface cable to the connector on the back of the FLI 225. See figure 2.6. Figure 2.6 Back of the FLI 225 Note the alignment pin and slot in the connectors. Plug them together and tighten the collar. QTLTSC w/fli 225 Installation Instructions 15

16 Installation After all connections are made, check the cable routing. Lower the forks to the fully lowered position then raise the forks to full height and back down again. Watch the cable as the carriage moves and adjust the cable length if necessary. Tilt the mast forward and back. Be sure the cable allows for the full movement of the mast. Tuck and cable tie any excess signal cable out of the way. 2.6 Power Connections The FLI 225 can use voltages between 9 and 36 volts. Most propane and diesel powered forklifts supply voltages in this range and connections can be made using the steps below. If you have an electric forklift, your voltage may need to be adjusted using the optional FLP 100 power conditioner available through your Avery Weigh-Tronix dealer. The conditioner can handle voltages from 24 to 72 volts and convert it for use by the FLI 225. If you use the FLP 100 power conditioner see the instructions in Power Connections Using the FLP 100 Power Conditioner on page Disconnect the negative wire from the battery terminal of the forklift before performing any electrical work. 2. Temporarily attach the connector end of the power cable to the rear of the FLI 225 instrument. Secure the cable with cable ties near the instrument. 3. Route the cable to the desired power source connection point. If possible, run the power cable through existing holes and channels so that it will be out of the way and cannot be damaged by any of the forklift s moving parts. Be sure to keep the cable from running near a distributor cap, the spark plugs or wires, or the alternator on the motor. Keep the cable around the periphery of the engine compartment whenever possible. CAUTION: DO NOT connect directly to the battery of an electric forklift. This will damage the power conditioner when the forklift is charging. Connect power leads to terminals attached to the battery but can be disconnected when charging. For non-electric forklifts the power source must make a direct connection to the battery. Do not make the power connection through the On/Off switch of the forklift. 4. Disconnect the power connector from the back of the instrument. 5. Install the fuse kit between the power cable and the connection point by following these steps: The fuse in the in-line fuse kit (item 4 in figure 2.8) is a 3AMP 3AG SLOW-BLOW fuse (p/n AWT ). 16 QTLTSC w/fli 225 Installation Instructions

17 Power Connections 5a. Cut the wire on the fuse holder where indicated in figure 2.7. Figure 2.7 Fuse holder CAUTION: Non-approved power connections may void warranty. 5b. Using the supplied butt splice connector (item 6 if figure 2.8) and heat shrink tubing, (item 5 in figure 2.8) connect wire from the fuse holder to the white wire from the power supply cable. The smaller diameter wire from the power cable should be inserted into the red striped end of the butt splice connector. Insert the wire from the fuse holder into the other end (no stripe) of the butt splice connector. The heat shrink tubing should be placed over the butt splice connector. 5c. Cut the heat shrink tubing (item 2 in figure 2.8) in half and place one piece on the black wire from the power supply cable and one piece on the loose wire from the fuse holder. 5d. Crimp the ring terminals (item 1) onto the wires as shown in figure e. Using a heat gun, shrink all three pieces of heat shrink tubing, item 5 in figure 2.8, in place. 5f. If the battery terminals have bolts to which you can connect the ring terminals, do so. If not, skip to step 6. The ring terminal connected to the fuse holder should be attached to the positive (+) terminal. The ring terminal connected to the black wire should be attached to the negative (-) terminal. Skip to step 12. Figure 2.8 Fuse wiring After wiring the fuse kit, continue with the rest of the electrical installation. QTLTSC w/fli 225 Installation Instructions 17

18 Installation 6. Connect the white power cable as close as possible to the battery's positive voltage terminal without attaching it directly to the battery terminal. In other words, the first place the positive terminal is connected to is where you should tap in with the white power cable for the instrument. 7. Connect the black ground cable as close as possible to the battery's negative terminal without attaching it directly to the battery. In other words, the first place the negative terminal is connected to is where you should tap in with the black ground cable for the instrument. The chassis may not provide the proper ground potential. Check with the forklift manufacturer to determine if battery ground is isolated from chassis ground. 8. Plug the 2-conductor power cable into the two pin connector on the back of the FLI Reconnect battery power. 10. Press and hold the STANDBY key on the FLI 225 for one second to see that the instrument powers up. 11. Raise the forks a few inches off the floor and zero the instrument by pressing the ZERO key. 12. Place a known test weight on the forks and make sure the instrument displays the correct weight. 2.7 Power Connections Using the FLP 100 Power Conditioner For forklifts with power too high for the FLI 225, use the optional power conditioner, FLP 100 (AWT PN AWT ). The kit part number is AWT which includes the cable for the run between the power conditioner and the FLI 225. Securely mount the FLP 100 module out of harms way. Follow these steps to make the electrical connections. 1. Disconnect the negative wire from the battery terminal of the forklift before performing any electrical work. 2. Cable tie the connector end of the power cable (the one which comes with the FLP 100) near the FLI 225 instrument. Leave enough slack to make the connection to the instrument later in the procedure. 3. Route the cable to the power conditioner. If possible, run the power cable through existing holes and channels so that it will be out of the way and cannot be damaged by any of the forklift s moving parts. 4. Plug the 4 pin connector to the appropriate receptacle on the power conditioner and finish running the bare lead end of the cable to the desired power source connection point. CAUTION: DO NOT connect directly to the battery of an electric forklift. This will damage the power conditioner when the forklift is charging. Connect power leads to terminals attached to the battery but can be disconnected when charging. 5. Install the fuse kit between the power cable and the connection point as described in steps 5a through 5f on pages 16 and QTLTSC w/fli 225 Installation Instructions

19 Power Connections Using the FLP 100 Power Conditioner 6. Connect the white power cable as close as possible to the battery's positive voltage terminal without attaching it directly to the battery terminal. In other words, the first place the positive terminal is connected to is where you should tap in with the white power cable for the instrument. 7. Connect the black ground cable as close as possible to the battery's negative terminal without attaching it directly to the battery. In other words, the first place the negative terminal is connected to is where you should tap in with the black ground cable for the instrument. The chassis may not provide the proper ground potential. 8. Plug the 2-conductor power cable into the two pin connector on the back of the FLI 225. See figure Reconnect battery power. Press and hold the ON/OFF key on the FLI 225 for one second. Check to see that the instrument powers up. 10. Raise the forks a few inches off the floor and zero the instrument by pressing the ZERO key. Place a known test weight on the forks and make sure the instrument displays the correct weight. 11. Connect any other peripheral equipment you will be using to the back of the FLI 225 Your scale is now installed and ready for use. Forklifts will experience a 12% to 14% reduction in lifting capacity with the QTLTSC installed. See De-rating Forklift Capacity on page 21 for more information. If you have any problems during installation of your QTLTSC forklift scale, please contact your local Avery Weigh-Tronix representative. QTLTSC w/fli 225 Installation Instructions 19

20 Extras 3 Extras 3.1 Making a Ramp for Tilting the Forklift The following drawing and dimensions will help you build a set of ramps that you can use to facilitate rolling the forklift left and right. You will need to build a minimum of two ramps (one for the front wheel and one for the rear). Ramps are constructed of 1/2 plywood.total height (H) is 3 inches (76.2 mm). Table 3.1 Ramp board dimensions Board H (in inches) W (in inches) L (in inches) Board H W L (in inches) A 0.5 in / 12.7 mm 8 in / mm 24 in / mm B 0.5 in / 12.7 mm 8 in / mm 22 in / mm C 0.5 in / 12.7 mm 8 in / mm 20 in / mm D 0.5 in / 12.7 mm 8 in / mm 18 in / mm E 0.5 in / 12.7 mm 8 in / mm 16 in / mm 20 QTLTSC w/fli 225 Installation Instructions

21 De-rating Forklift Capacity 3.2 De-rating Forklift Capacity Installing the QTLTSC on your customer s forklift reduces the forklift s capacity by up to 14%. The information in this section is provided to help you determine the new capacity. Check with the local governing authorities for information on having the ID plate on the forklift updated with the new lifting capacity and center of gravity information. It is the customer s responsibility to contact their forklift manufacturer / distributor with this information to obtain the new ID plate. The formula for calculating the new lift capacity is: Refer to the figure and table below for the dimensions. No scale installed Scale installed l l l l l A = Forklift Capacity in pounds B = Inches from front wheel center line to fork face C = Inches from fork face to truck rating point (usually 24") D = Weight of scale in pounds E = Inches from front wheel center line to carriage face l l l l l F = Inches from carriage face to scale center of gravity (CG) G = J + K (inches from carriage face to rear face of load) H = Inches from fork face to new truck rating point J = Thickness of fork K = Thickness of scale Figure 3.1 Formula & Dimensions for Calculating New Lift Capacity QTLTSC w/fli 225 Installation Instructions 21

22 Extras 3.3 Available Carriages The QTLTS forklift scale is available in ITA Class II (16 high, 5,000 lb) and ITA Class III (20 high, 5,000 lb and 10,000 lb) models. Figure 3.2 Class II and III Carriages Each class comes in several widths for cleat type carriages. Measure the height and width of the forklift carriage. Refer to the following tables and select the width that best meets the dimensions of the forklift carriage. Table 3.2 Class II 5,000 Pound Models Width Weight D DIM F DIM K 30.0" 337 lb 2.0" " 368 lb 2.0" " 378 lb 2.0" " 399 lb 2.0" " 403 lb 2.0" " 408 lb 2.0" " 439 lb 2.0" " 448 lb 2.0" 4.0 Table 3.3 Class III 5,000 Pound Models Width Weight D DIM F DIM K 36.0" " 4.00" 37.0" " 4.00" 38.0" " 4.00" 40.0" " 4.00" 42.0" " 4.00" 44.0" " 4.00" 46.0" " 4.00" 48.0" " 4.00" Table 3.4 Class III 10,000 lb Models Width Weight "D" DIM "F" DIM "K" 40.0" " 5.50" 42.0" " 5.50" 44.0" " 5.50" 47.0" " 5.50" 48.0" " 5.50" 52.0" " 5.50" 56.0" " 5.50" 60.0" " 5.50" 22 QTLTSC w/fli 225 Installation Instructions

23 Available Carriages Table 3.5 Class IV 10,000 lb Models Width Weight "D" DIM "F" DIM "K" 38.0" " 5.50" 40.0" " 5.50" 42.0" " 5.50" 44.0" " 5.50" 46.0" " 5.50" 48.0" " 5.50" 50.0" " 5.50" 52.0" " 5.50" 54.0" " 5.50" 56.0" " 5.50" 58.0" " 5.50" 60.0" " 5.50" Table 3.6 Class IV 16,000 lb Models Width Weight "D" DIM "F" DIM "K" 38.0" " 6.13" 40.0" " 6.13" 42.0" " 6.13" 44.0" " 6.13" 46.0" " 6.13" 48.0" " 6.13" 50.0" " 6.13" 52.0" " 6.13" 54.0" " 6.13" 56.0" " 6.13" 58.0" " 6.13" 60.0" " 6.13" 62.0" " 6.13" 64.0" " 6.13" 66.0" " 6.13" 68.0" " 6.13" 70.0" " 6.13" 72.0" " 6.13" QTLTSC w/fli 225 Installation Instructions 23

24 Extras 24 QTLTSC w/fli 225 Installation Instructions

25

26 Avery Weigh-Tronix USA 1000 Armstrong Dr. Fairmont MN USA Tel: Fax: Avery Weigh-Tronix UK Foundry Lane, Smethwick, West Midlands, England B66 2LP Tel:+44 (0) Fax: +44 (0)