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FORK SCALE INSTALLATION MANUAL - Vulcan On

1. Tack weld to Mounting Block re after fastening N l Connector Guard H S F i pe H 5 16 24UNF X 1 Hex Cap Screw ain E Washer Wire Tie and Locknut Fastening Holes Add 5 16 lock washers SE under existing fasteners 2 Places Figure 7 G April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Electronics Installation April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 STRESS TEK INC 2008 42 Doc 44 10112 001 Rev Manual Control Kit Installation 43 8 0 MANUAL CONTROL KIT A01 INSTALLATION 8 1 ELECTRICAL DIAGRAMS 8 1 1 METER WIRE CONNECTION DIAGRAM Stress Tek Inc Kent WA USA O oh Jo o o RS 232 4 12345678 White Ls 12 24 Vdc White VSL Accessory Port Use only 2A fast blow fuses in power leads POWER O POWER GREEN gt lt WHITE 5 PIN 5 PIN 8 PIN VSL VULCODER POWER Th COMMUNICATION CABLE CABLE GREY COMM LINK ORANGE d ORANGE CABLE FROM WEIGHT CAPTURE BUTTON p WEIGHT CAPTURE BUTTON L_ Figure 8 A Route the grey power cable from the truck battery to the meter in the cab Route through the cab hinge point The fuses must be at the battery end of the cable April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Manual Control Kit Installation 44 In the truck cab strain re
2. Red Black 4 White w BIk stripe ie Relay rs 9 HE Accessory port ES 8 pin connector Green on back of meter Stress Tek orange cable vou EL AWN Cab mounted Black ni _Brown Jet Blue Yellow light Vulcan V600 Meter showing that Stress Tek trigger has grey cable been detected fused Stress Tek Red grey cable fused Proximity switch Battery cut off switch shown off Mounting Stress Tek D bracket 4 orange cable Torque tube that Gieb White arms rotate on behind truck cab a 12 Vdc Truck battery From Vulcoder Rotation direction NOTE when lifting bin Proximity trigger location Red ring terminals are provided with with cross tube six feet proximity switch Fasten these terminals above ground to both proximity switch and grey power cable wires where connected in junction box Figure 10 I April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Weigh In Motion With Lift Control Kit Installation 76 1 Mount the junction box in a protected location on the truck body structure 2 Route and secure the proximity switch cables to the junction box For trucks that tip to eject and tip for service route and secure the orange and grey cables through the body rear hinge point to the junction box 3 The junction box comes with the relay alre
3. Stress Tek orange cable White Green From Vulcoder Red ring terminals are provided with proximity switch Fasten these terminals to both proximity switch and grey power cable wires where connected in junction box Figure 9 G VULCAN ON BOARD SCALES 1 800 237 0022 STRESS TEK INC 2008 Doc 44 10112 001 Rev Static Weigh In Motion Control Kit Installation 56 1 Mount the junction box in a protected location on the truck body structure 2 Route and secure the proximity switch wires to the junction box For trucks that tip to eject and tip for service route and secure the orange and grey cables through the body rear hinge point to the junction box 3 The junction box comes with the relay already wired to the proper terminals Wire the orange and grey cables to the junction box as shown in Figure 9 G 9 2 2 METER WIRE CONNECTION DIAGRAM O Stress Tek Inc Kent WA U S A O o Je RS 232 4 t La 12345678 12 24 Vde White vst Eo ei Accessory Port O Use only 2A fast blow fuses in power leads Sooo oood Pin 8 VSL Vulcoder Power Cable a Oren c ton grey able Comm Link Junction Box orange Figure 9 H Route the grey power cable from the truck battery to the meter in the cab Route through the cab hinge point The fuses must be at the battery end of the cable In the truck cab strain relief and cut the VSL Vulcoder cable meter
4. 13 10 SYSTEM TEST MENU Note When trying to enter the SYSTEM TEST menu if the lower display shows Password with the cursor blinking the Driver Lockout Password feature is activated and the Configure System Setup Calibrate Sequence Channels and System Test menus are not accessible Refer to section 13 1 to unlock the system Five diagnostic tests are available with the Vulcan V600 Meter The tests are called Test Keypad which performs the keypad test Test Leds which performs the LED display test Test Memory which performs a test on the storage memory inside the meter Test VSL Comm which performs the VSL communications test To Enter the Meter Program Menu ES Press the PWR MENU button to turn on the meter Let it complete its startup routine Note If the PWR MENU button is held too long the meter will display all 8 s and the meter will turn off EA Press the PWR MENU button to enter the program menu m Press the CYCLE button until SYSTEM TEST is displayed E Press the ENTER button to select the SYSTEM TEST menu April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Troubleshooting And Repair 130 13 10 1 TEST KEYPAD TEST KEYPAD the keypad test can be used to determine whether all of the keys on the keypad are operating properly Procedure to Test the Keypad Enter the SYSTEM TEST menu section 13 10 oa Press the
5. but this should be verified ES Press the PWR MENU button to turn on the meter ES After the meter has completed its startup routine and is running press the PWR MENU button to enter the program menu If the meter display shows Ready To Lift the meter is in BASIC mode SR Press the CYCLE button until CONFIGURE SYSTEM is displayed E Press the ENTER button to select the CONFIGURE SYSTEM menu m Press the CYCLE button until CONF CUST MODE is displayed April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Troubleshooting And Repair 10 E Press the ENTER button to select the CONF CUST MODE option D OR KR Press either the UP or DOWN ARROW buttons to turn the CUSTOMER mode to OFF or ONI Press the PWR MENU button twice to exit and the meter will return to normal operation in BASIC mode and it is now ready to weigh See the Vulcan V600 Fork Scale User Manual for a description of customer mode 13 3 RE SEQUENCE THE VULCODER BA Press the PWR MENU button to turn on the meter E After the meter has completed its start up routine and is running press the PWR MENU button to enter the program menu E Press the CYCLE button until SEQUENCE CHANLS is displayed E Press the ENTER button to select the SEQUENCE CHANLS option m Press the CYCLE button to start the channel sequence process April 2008 VULCAN ON BOARD SCALES
6. section 13 6 1 April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Troubleshooting And Repair 116 5 Check the fork scales Check by disconnecting one fork scale at a time When the faulty fork scale has been disconnected the meter will read a number instead of the error code 13 8 5 CONDITION Not advancing to next customer or not computing net weight Possible Causes 1 Proximity switch sensor needs adjustment 2 Proximity switch sensor has failed 3 Holding the manual Weight Capture button down too long What to Do 1 Check the correct trip location for the proximity sensor 2 Failed proximity sensor Replace the proximity sensor 3 Review the operational procedure or the driver card for correct lift procedure Manual System section 8 4 Static System section 9 5 Weigh In Motion System section 10 6 13 8 6 CONDITION Meter displays LO LO If the meter encounters a low voltage situation either on the power input lead or the VSL line the meter will display LO LO and then switch to 1 90 1 indicates the input power is low and the 90 being the amount of voltage 9 0 Vdc being read by the meter If the meter displays LO LO and then switches to 2 0 2 indicates the VSL line is low and the other number being the amount of voltage read by the meter Possible Causes For LO LO and 1 XX 1 Corroded fuses or corroded bad meter cable c
7. then dump the full bin e Lower the empty bin and stop within the 6 weigh zone with level forks press the weight capture button wait for a two beep audible signal from the meter then gently return empty bin to the ground e When the meter emits two beeps the weight has been captured e f picking a bin from a dock bring it down within the 6 weigh zone before pressing the weight capture button VULCAN CUSTOMER SERVICE 1 800 237 0022 HOURS 7 30 a m 5 00 p m PACIFIC TIME UP AND DOWN LIFT CYCLE Level container in weighing zone i zone zar LE INSTALLATION NOTE DRIVER NOTE Please wire tie this driver card to the Please place this driver card on visor or Vulcan V600 Meter bracket clipboard to use as a quick reference guide April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Static Weigh In Motion Control Kit Installation 9 0 STATIC WEIGH IN MOTION CONTROL KIT A04 INSTALLATION 9 1 PROXIMITY SWITCH INSTALLATION Torque tube Cross tube Fork scale Area where the weight is measured Recess proximity switch in nut up to 1 8 Body structure Height adjustment S d screws a Proximity switch MUST point to the center of the torque tube AW 1 0 Tightening screw Lock washer for hose clamp Mechanical stop oF gt Rotati f N l ASOEMBLED ne PROXIMITY SWITCH when arms IN BRACKET
8. 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Troubleshooting And Repair 10 The channel in now re sequenced Press the PWR MENU button twice to return to the normal operation mode The scale system is now ready to weigh 13 4 LOOSE BOLT TEST Loose bolt test To see if the fork mounting bolts are loose a loaded bin 2000 Ib or more is lifted up and down several times The meter should return to zero within 50 Ib If not the fork mounting bolts need to be torqued to 1000 ft lb Forks level April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Troubleshooting And Repair 103 Obtain a bin that weighs at least 2000 Ib Et Press the PWR MENU button to turn on the meter e Forks must be down level and ready to stab a bin Be sure the meter reads zero with no load on the forks If the meter does not read zero then press the TARE ZERO button No ground A contact e Pick up the bin so that the bin is off of the ground completely Do not dump bin Return bin to the ground Lift the bin 2 more times e Return the bin to the ground and completely disengage the forks keeping the forks level e The meter display should read zero within 50 lb e f not torque the bolts to 1000 ft lb and re test e Call Vulcan Scales if problem continues April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10
9. 13 2 L Driver Lockout Password feature is activated This prevents the driver from modifying the scale systems setup parameters section 13 1 11 2 1 MANUAL METHOD WEIGH SYSTEMS Accessory port is wired correctly for the Weight Capture button section 8 1 1 L Weight Capture button is in a desirable location and is strain relieved 11 2 2 STATIC WEIGH IN MOTION METHOD WEIGH SYSTEMS L Accessory port is wired correctly section 9 2 2 and Figure 9 G L Proximity switch triggers in the proper location section 9 1 z Junction box wires are routed through the body s tipping hinge point section 9 2 1 April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Final Inspection Checklist 91 L Proximity switch is mechanically protected inside the protective mounting bracket nut section 9 1 and Figure 9 E 11 2 3 WEIGH IN MOTION WITH LIFT CONTROL METHOD WEIGH SYSTEMS EI Accessory port is wired correctly section 10 3 2 and Figure 10 J L Proximity switch triggers in the proper location section 10 1 and Figure 10 F L Junction box wires are routed through the body s tipping hinge point section 10 3 1 and Figure 10 E E Proximity switch is mechanically protected inside the protective mounting bracket nut section 10 1 L Hydraulic valve engages and disengages only in the proximity trigger area determined by the proximity switch and the arms move smoothly through this
10. 16 wall is adequate size The orange cable can be pulled through using weld wire A wire pulling lubricant can also be used to make it easier to pull the cable through Small clamps can be welded to the arm to hold the steel tube in place The orange cable can also be routed inside the tube arm for protection Protect the cable inside an air line or hydraulic line when running inside the arm Route the orange cable to the inside of the arm when meeting the cross tube The cable is more vulnerable to damage if routed on the outside of the arm For bodies that tip for service the orange cable must be routed from the arm pivot point through the rear hinge pin and to the cab Follow existing wire harness where possible If the cab is a front tilt model route the cables through the hinge point to enter the cab preferably through a grommet April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Electronics Installation 41 Full Up Position 2 Wire Orange VSL Vulcoder Cable in steel tube Clamps to hold tube in place Full Down Position No Loop Small Loop Full Up Position Full Down Position Figure 7 F 7 6 INSTALL CONNECTOR GUARDS 7 6 1 Install connector guards on each of the two forks as shown in Figure 7 G Mounting Block a Fork Scale
11. 2008 Install Scale Ready Cross Tube 18 4 2 INSTALLING THE SCALE READY CROSS TUBE Unbolt and drop out the existing fork cross tube Keep the cap plates matched to the sides where they came from They are a matched pair and may not be interchangeable Inspect bushings for excessive wear Replace as required Grease bushings before installing scale ready cross tube Bolt in the scale ready cross tube Align and torque all bolts to secure new cross tube After bolting on the cross tube assembly go to section 6 0 Install Fork Assembly on Cross Tube and complete the fork installation April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Install Fork Mounting Clamps On Existing Cross Tube 19 5 0 INSTALL FORK MOUNTING CLAMPS ON EXISTING CROSS TUBE 5 1 PREINSTALLATION MEASUREMENTS 5 1 1 Measure the existing cross tube cross section to ensure the proper fork mounting kit was ordered If the tube is round measure the diameter If the tube is square measure one side refer to Figure 5 A 5 1 2 Verify the new fork assembly when installed still dumps the bin contents without overshooting refer back to Figures 2 B through 2 F This is especially important if lifting 10 yard containers Although all trucks do not have the same size forks the Vulcan Front Fork is designed to be similar to the typical OEM fork dimensions 5 1 3 If the installation of the Front Fork System is on a new truc
12. 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Static Weigh In Motion Control Kit Installation 65 DAILY DRIVER OPERATING GUIDE FRONT FORK STATIC WEIGH IN MOTION SYSTEM GUIDELINES TO MAXIMIZE PICKUP WEIGHT ACCURACY e Just before bin engagement with forks in level position if the meter reads more than 50 Ib press the TARE ZERO button to rezero e Lift the full bin completely off of the ground smoothly stop the forks in a level position within the 6 weigh zone Wait for a two beep audible signal from the meter indicating weight capture then dump the full bin e Lower the empty bin and stop within the 6 weigh zone with level forks wait for a two beep audible signal indicating weight capture and return empty bin to the ground e f continuous beeping occurs while lifting the bin to dump or setting it on the ground bring the bin back into the weighing zone and wait for the two beep signal e f maneuvering a bin to get in the lifting position momentarily set the bin back on the ground before weighing This will reset the weighing cycle e f picking a bin from a dock bring it down within the 6 weigh zone and wait for the two beep audible signal before dumping VULCAN CUSTOMER SERVICE 1 800 237 0022 HOURS 7 30 a m 5 00 p m PACIFIC TIME UP AND DOWN LIFT CYCLE Level container in weighing zone j No ground Weighing zone contact en E E INSTALLATI
13. C D E April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Install Fork Mounting Clamps On Existing Cross Tube 22 5 3 REMOVE EXISTING FORKS AND RELATED HARDWARE Note Instead of removing the existing fork some operations remove the existing cross tube and fork assembly to use as a Spare This is replaced with just the OEM cross tube which these mounting clamps are then welded to 5 3 1 It is recommended to remove the existing factory mounted fork assemblies from the cross tube by using an air arc carbon arc Note Removing the cross tube and fork assembly from the truck before starting the work is recommended This allows the fork mounting clamps to be welded in a flat position creating a better weld This also protects the truck from cutting and welding splatter and other damage 5 3 2 Prepare the cross tube for installing the Front Fork Mounting Kit by grinding smooth any excess welds slag or burrs If the cross tube s structural integrity is diminished due to gouging or other actions during the removal of fork components the cross tube must be replaced 5 3 3 Most truck body manufacturers use a reinforcement coupler support between the fork and coupler plate There are various types of coupler supports being installed by OEM s The two most common types are illustrated below refer to Figure 5 D This coupler support will need to be removed to allow welding access when installing th
14. CYCLE button until TEST KEYPAD is displayed Press the ENTER button to begin the selected TEST KEYPAD test A 0 will be displayed indicating that no buttons are being pushed The buttons keys are labeled 1 through 6 with 1 being the PWR MENU button and 6 being the CYCLE button Press each button one at a time the corresponding number should be displayed indicating the button key is functioning The small alpha numeric display will also indicate which button is being pressed D AND e Dress the UP and DOWN ARROW buttons at the same time to exit and i return to the TEST KEYPAD menu option SR Press the CYCLE button to advance to the next SYSTEM TEST menu option April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Troubleshooting And Repair 131 13 10 2 TEST LEDs TEST LEDs can be used to determine if the LEDs are operating properly Procedure To Test The LEDs Enter the SYSTEM TEST menu section 13 10 E Press the CYCLE button until TEST LEDs is displayed E Press the ENTER button to begin the selected TEST LEDs test This tests all the combinations of segment on off conditions which might produce an error in the display There are several patterns which are run If seeing any deviation from this pattern contact your Vulcan dealer E gt Press the TARE ZERO button to exit and return to the TEST LEDs menu option oa Pres
15. Connector guard and fasteners Manual button weigh method Static Weigh In Motion weigh method Weigh In Motion with lift control weigh method Description Cross tube cable guard required by Vulcan Scales Heil scale ready cross tube 4 5 McNeilus scale ready cross tube 3 5 Atlantic body style Printer with signal and power cable Printer mounting bracket Doc 44 10112 001 Rev STRESS TEK INC 2008 System Layout And Tools Required 11 2 3 REPLACEMENT PARTS Stock or P N Description H55 Cross tube cable guard 59 30042 001 Connector guard 59 30042 002 Vulcoder guard 59 30045 001 Proximity switch A04R Static proximity switch upgrade kit AO2R W I M proximity switch upgrade kit 21 10003 001 Relay for proximity switch static and W I M 2 4 SERVICE REPAIR PARTS Stock or P N Description 59 30050 001 Fork connector replacement kit 59 20223 001 Fork connector O ring replacement kit 7 O rings 53 20130 001 Vulcoder connector replacement pigtail kit 59 20370 001 Black Vulcoder cable splice kit 27 10086 001 Orange VSL cable displacement connector 2 5 INSTALLATION TOOLS Stock or P N Description 47 10192 001 3 4 Drive torque wrench 47 10105 001 Torque multiplier 30 90024 001 Threaded insert 47 10211 001 Threaded insertion tool 47 10217 001 Threaded insert tap drill 21 Threaded insert replacement kit 6 threaded inserts insertion tool thread tap drill 2 5 1 SHOP TOOLS REQUIRED FOR MOUNTING A FORK SYSTEM WI
16. INC 2008 Fork Scale Troubleshooting And Repair 115 2 Verify fork operation Manual System section 8 2 3 Static System section 9 3 6 Weigh In Motion System section 10 4 5 3 For a single trip to the landfill every lift must be recorded before comparing to the landfill weight 4 Fine tune the calibration see V600 Fork Scale User Manual 13 8 3 CONDITION Weight not returning to zero after lifting a bin Possible Causes 1 Fork mounting bolts are loose 2 Not zeroing the scale properly 3 Not following the lift procedure What to Do 1 Retorque fork mounting bolts to 1000 ft lb 2 Review the operational procedure in the V600 Fork Scale User manual or the driver card for correct lift procedure and how to zero the display properly 13 8 4 CONDITION Meter displays ERR 6 or ERR 1 Indicates the VSL Vulcoder is processing an out of range signal This means the fork scale output is beyond the limits the VSL Vulcoder will accept Possible Causes There is moisture in a fork scale connector One of the black VSL Vulcoder to fork scale cables has been damaged No fork scales are connected to the VSL Vulcoder A fork scale has a large preload number A fork scale is faulty Or E Oe What to Do 1 Check to see the fork scales are properly connected to the VSL Vulcoder 2 Clean connectors with isopropyl alcohol and dry with a hair dryer 3 Perform the Tare Test section 13 6 2 4 Perform the Leakage Test
17. Lifting eceeeeeeeeeeeeeeeeeee 115 13 8 4 Meter Displays ERR 6 Or ERR 1 115 13 8 5 Not Advancing To Next Customer Or Not Computing Net Weight 116 13 8 6 Meter Displays LO LO ss 116 13 8 7 Unable To Enter Tare Or Calibration Numbers ssssssseeenneeeeeeeenne 118 13 8 8 No Indicator Display Or Function Uobts 118 13 8 9 IDLE Next Cust n EEN 119 13 810 PASSWOrd KE 119 13 9 Repair Techniques Ee 121 13 9 1 How To Repair The Black Vulcoder Cable 121 13 9 2 How To Repair The Orange VSL CGable 122 13 9 3 Fork Scale Connector Replacement cccccececeeeeeeeeeeeeeeeeteeees 124 13 9 4 Fork GcaleO nmngbReplacement 126 13 9 5 How To Repair A Vulcoder Connector sssssssssseeeeeeeeeeeeeeeeeeeeeeeeene 127 13 10 System TES EM NEES ee 129 13 10 1 Test ee DEE 130 13 102 Deet 131 1321023 Leer M MONNR ES ee EES 131 110 TeSt VSL ORT tege 132 13 10 5 Exiting The Program Menu nn 133 April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Table Of Contents April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Introduction o 7 1 0 INTRODUCTION The Vulcan Front Fork Weighing System consists of two weight measuring forks two mounting kits welded to the cross tube V600 electronics package and associated accessories for protecting the system Itis designed to measure individual commercial collection weights and
18. MENU button before pressing the ENTER button will cancel that configuration change Disconnect one fork scale from the VSL Vulcoder of the channel to be tested The meter will display the still connected fork scale preload number The preload number should not exceed 2 000 Ib to 2 000 Ib If the preload number is between 2 000 Ib to 2 000 Ib the fork scale is within specification Test the other fork scale using the same method If the preload number is within specification for both fork scales reconnect and secure all fork scale leads Reset the Tare weight if required Note If the preload number is out of specification clean the fork scale connector and cable connector with cotton swabs and isopropyl alcohol and dry thoroughly with a hair dryer DO NOT OVERHEAT the connector This procedure will remove any moisture that may have been causing the problem Check the electrical isolation of the fork scale by performing the Leakage Test section 13 6 1 Check the preload number again to see if it is within the 2 000 Ib to 2 000 Ib range If the fork scale is still out of range it may be faulty Perform the Resistance Test section 13 6 3 If the fork scale cannot be brought to Vulcan specifications contact Vulcan customer service your Vulcan dealer April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Troubleshooting And Repair 109 13 6 3 RESISTANCE TEST PROCED
19. SE Torque tube Proximity Stainless steel hose clamp trigger Figure 9 A April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Static Weigh In Motion Control Kit Installation 52 1 Raise the cross tube until it is six feet above the ground Locate a position on the truck body structure near the torque tube where the supplied bracket can be installed Proximity switch must be installed on truck body not on truck chassis The base of the nut must be 1 from the surface of the torque tube Scribe line Drawn center line on body structure along this edge Align tick marks on bracket with drawn center line Ba 2 Torque tube Torque tube Center line locating tool Figure 9 B Figure 9 C 2 Remove the Center Line Locating Tool pattern from section 9 6 Place the Center Line Locating Tool on the torque tube and mark a line on the body structure where the bracket will be installed see Figure 9 B 3 Use the tick marks on the angle bracket to align it with the line drawn on the truck structure This aligns the center of the bracket with the center of the torque tube The base of the nut must be 1 from the surface of the torque tube The bracket can be cut down or additional bracketry can be welded to it so it fits properly in the desired area see figure 9 C April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2
20. The scales should read the amount of weight on each fork 1 Run the lift arms up and down and make sure they are slow and smooth in the weighing range If not e Check the hydraulic valve setting It should be 1 3 4 turns open see section 10 2 e Hydraulic trip point should be about 6 feet off the ground and should be the same spot going up and down e Check to see where the hydraulics engages on the up cycle e f arms are moving too fast turn hydraulic valve setting 4 turn clockwise cw and retest April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Weigh In Motion With Lift Control Kit Installation 85 2 Lift a bin with weight is preferred but empty is OK through the up and down cycle 5 times without dumping and check the repeatability of the meter s computed readings Note each up and down reading the meter computes All up readings should be close to the same within 50 Ib and all down readings should be close to the same within 50 Ib although they may not be equal to the exact pound or kilogram 3 Activate the Driver Lockout Password feature Vulcan Scales recommends the activation of this password feature to prohibit the driver from changing the scale system set up parameters See section 13 1 to activate this feature 10 5 CALIBRATION The Front Fork Scale comes calibrated from the factory There is no need for further calibration by the installer Once the syst
21. a different channel The display will show n in the left most position and you should see a number on the right hand side which will be counting up As you press the UP or DOWN arrow keys you will cycle through the various readings listed below Number of transmission attempts Number of buffer overruns detected Number of framing errors detected Number of timeouts detected Number of checksum errors detected OTn1OS Note Intermittent communications such as a bad cable connection while running the truck will show up by the number of timeouts detected for example t 6 Some errors are inherent in any communication system The VSL system is designed to recover from most error conditions If the error rate becomes excessive greater than 1 of the total transmissions contact your Vulcan dealer Press the TARE ZERO button to exit and return to the TEST VSL COMM menu option SR Press the CYCLE button to advance to the next SYSTEM TEST menu item 13 10 5 EXITING THE PROGRAM MENU To Exit the Meter Program Menu E Press the PWR MENU button once to exit from the main program menu at any time to return to the normal operating mode Note If the PWR MENU button is held too long the meter will display all 8 s and the meter will turn off April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008
22. are attached correctly at the 12 Volt power source and to the green connector at the back of the meter Check the battery connections for corrosion 4 If a spare meter is available the quickest and easiest next step is to exchange the meter If the new meter works try the old meter again If the old meter now works the problem was likely the meter s internal circuit breaker If both the old meter and the new meter do not work the problem is most likely in the power source battery meter power cable or fuses If the new meter works but the old one doesn t the old meter is faulty If you do not have a spare meter disconnect then reconnect the green power plug on the back of the meter If the meter doesn t work then check the power source battery meter power cable or fuses If the power source checks out OK then the meter is faulty 13 8 9 IDLE Next Cust n IDLE Next Cust n is not an error condition It indicates the system is ready to download data To download data from the V600 Meter the forks must be out of the weigh zone and have less than 200 lb on the display Data cannot be downloaded without these conditions being met When these conditions are met the meter will display IDLE Next Cust n indicating data can be downloaded The word IDLE will be flashing Refer to the V600 Fork Scale User Manual for details on how to download data from the V600 Meter 13 8 10 PASSWORD Password
23. for cracking to be performed a minimum of 48 hours after weld completion 5 No thermal stress relieving permitted April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Install Fork Mounting Clamps On Existing Cross Tube 25 5 5 WELDING MOUNTING CLAMPS TO CROSS TUBE Bolt the Front Fork Scales to the mounting clamps and the cross tube using the 1 14 X 3 Grade 8 cap screws and the hardened steel washer plate The cap screws do not have to be tightened to their specified torque 400 500 ft lb is sufficient to create enough clamping force between the mounting clamps and the fork Note This is the alignment stage of the assembly The bolts will be torqued to specification during final assembly Use the dimensions B C D and E taken from the factory fork assembly refer to Figure 5 C to position the Front Fork Scales in the same location and check for squareness Make sure both forks are level The mounting clamps should fit snug around the cross tube when bolted in place Shimming should not be required Note Do not shim between Mounting Clamps and Front Fork Scales refer to Figure 5 E SSeS Cross Tube Bell Crank Mounting Clamp No shimming between Se Front Fork Scale and Front Fork Scale Mounting Clamp Bolted to Mounting Clamp 1 1 2 Figure 5 E 5 5 2 It is recommended to build a weld jig for holding the forks together and creating good alignment betw
24. gap Proximity Stainless steel hose clamp trigger Figure 10 A April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Weigh In Motion With Lift Control Kit Installation 70 1 Raise the cross tube until it is six feet above the ground Locate a position on the truck body structure near the torque tube where the supplied bracket can be installed Proximity switch must be installed on truck body not on truck chassis The base of the nut must be 1 from the surface of the torque tube Scribe line Drawn center line on body structure along this edge Align tick marks on bracket with drawn center line we 2 Torque tube Torque tube Center line locating tool Figure 10 B Figure 10 C 2 Remove the Center Line Locating Tool pattern from the section 10 7 Place the Center Line Locating Tool on the torque tube and mark a line on the body structure where the bracket will be installed see Figure 10 B 3 Use the tick marks on the angle bracket to align it with the line drawn on the truck structure This aligns the center of the bracket with the center of the torque tube The base of the nut must be 1 from the surface of the torque tube The bracket can be cut down or additional bracketry can be welded to it so it fits properly in the desired area see Figure 10 C April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2
25. is damaged Replace VSL Vulcoder 6 Meter is damaged Replace meter 13 7 4 Err 04 Indicates the VSL Vulcoder is not calibrated Possible Causes 1 Calibration or Tare number is not entered What to Do 1 Check and reset the Calibration number and Tare weight 13 7 5 Err 05 Indicates the VSL Vulcoder has a hardware problem Possible Causes 1 VSL Vulcoder hardware component is damaged April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Troubleshooting And Repair 112 What to do 1 Press and hold the PWR MENU button to turn the meter off and then press PWR MENU again to turn it on This may reset the meter and eliminate the error 2 Inspect VSL Vulcoder communication line for cut or broken wires 3 VSL Vulcoder is damaged Replace VSL Vulcoder 13 7 6 Err06 Indicates the VSL Vulcoder is processing an under ranged signal An under ranged signal means the fork scale output is less than the minimum the VSL Vulcoder will accept Possible Causes 1 There is moisture in a fork scale connector 2 One of the black VSL Vulcoder to fork scale cables has been damaged 3 No fork scales are connected to the VSL Vulcoder 4 A fork scale is faulty What to Do 1 Check to see that the fork scales are properly connected to the VSL Vulcoder 2 Clean fork scale connectors with isopropyl alcohol and dry with a hair dryer 3 Perform the Tare Test sectio
26. showing on the lower display is not an error condition It indicates the Driver Password Lockout feature is activated It prohibits modification of any of the Configure System Setup Calibrate Sequence Channels or the System Test menus without entering the proper password The meter comes from the factory with the password lock inactive To return to the normal operating mode if password is not known RW Press the ENTER button BE Press the PWR MENU button to return to the normal operating mode The scale system is now ready to weigh For activating and deactivating the Driver Lockout Password feature see section 13 1 April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Troubleshooting And Repair 120 April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Troubleshooting And Repair 121 13 9 REPAIR TECHNIQUES 13 9 1 HOW TO REPAIR THE BLACK VULCODER CABLE How To Repair The Black Vulcoder Cable This black cable runs between the Vulcoder and the fork scales Vulcan has a splice kit available with all the parts required 4 wire splice kit p n 59 20370 001 Caution Make certain power to the system is turned off before beginning splice procedure Cut cable to remove damaged section Remove approx 2 of outer jacket being careful not to cut individual wire insulation Pull back shield s from splice area S
27. use 0 for a Tare weight this step can be omitted Current Tare Weight April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Troubleshooting And Repair 107 ES Press the PWR MENU button to enter the program menu Note If the PWR MENU button is held too long the meter display will display all 8 s and the meter will turn off m Press the CYCLE button until SETUP CALIBRATE is displayed Note When trying to enter the SETUP CALIBRATE menu if the lower display shows Password with the cursor blinking the Driver Lock Password feature is activated and the Configure System Setup Calibrate Sequence Channels and System Test menus are not accessible Refer to section 13 1 to unlock the system E Press the ENTER button to select the SETUP CALIBRATE menu option m Press the CYCLE button until SET TARE WEIGHT is displayed E Press the ENTER button to select the SET TARE WEIGHT option Example 20 000 Ib Tare weight is shown D OR KR Press either the UP or DOWN ARROW buttons to adjust the number to 0 Press the ENTER button to save the new Tare weight and return to the SET TARE WEIGHT menu option April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Troubleshooting And Repair 108 ES Press the PWR MENU button twice to go directly to the normal operating mode Note Pressing the PWR
28. 008 Static Weigh In Motion Control Kit Installation 5 Proximity switch Torque tube Torque tube Recess switch up to 1 8 inside protection nut Figure 9 D Figure 9 E 4 Weld bracket to the truck structure and set a 1 gap between the nut and torque tube see Figure 9 D 5 Install the proximity switch in the bracket nut Tighten in place so the sensor is recessed in the nut up to 1 8 maximum see Figure 9 E April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Static Weigh In Motion Control Kit Installation 5 Align proximity trigger under the proximity switch as shown Proximity switch Proximity trigger Torque tube IMPORTANT Arrow indicates rotation of torque tube as arms are lowered Torque tube Stainless steel The above figure shows the Rose claps position of the proximity trigger when the fork cross tube is 6 above ground and is being lowered Figure 9 F 6 The proximity trigger will be mounted directly below the proximity switch on the torque tube Clean off grease and debris from the torque tube in this area Use the hose clamps to fasten the proximity trigger to the torque tube Verify the cross tube is six feet off the ground before final alignment Align the trigger with the proximity switch and set up the final installed distances as shown in Figure 9 F 7 As the arms are raised and lowered the gap betwee
29. 008 Weigh In Motion With Lift Control Kit Installation 7 Proximity switch Torque tube Torque tube Recess switch up to 1 8 inside protection nut Figure 10 D Figure 10 E 4 Weld bracket to the truck structure and set a 1 gap between the nut and torque tube see Figure 10 D 5 Install the proximity switch in the bracket nut Tighten in place so the sensor is recessed in the nut up to 1 8 maximum see Figure 10 E April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Weigh In Motion With Lift Control Kit Installation 72 Align proximity trigger under the proximity switch as shown Proximity switch Proximity trigger Torque tube IMPORTANT Arrow indicates rotation of torque tube as arms are lowered Torque tube Stainless steel The above figure shows the nose Clamps position of the proximity trigger when the fork cross tube is 6 above ground and is being lowered Figure 10 F 7 The proximity trigger will be mounted directly below the proximity switch on the torque tube Clean off grease and debris from the torque tube in this area Use the hose clamps to fasten the proximity trigger to the torque tube Verify the cross tube is six feet off the ground before final alignment Align the trigger with the proximity switch and set up the final installed distances as shown in Figure 10 F 8 As the arms are raised and lowered the gap betw
30. 1 START UP DISPLAY METER Note If there are any problems with the following quick system tests contact Vulcan Customer Service 1 Start the truck Bring the arms down and put the forks in a level position Level Forks Figure 8 C 45 April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Manual Control Kit Installation 46 2 Turn the meter on and let it complete its startup routine RB Press the PWR MENU button for less than 2 seconds After the meter has completed its startup routine the meter will display READY TO LIFT If the meter does not have the display shown above but instead has the display shown below the meter is not in BASIC mode it is in CUSTOMER mode See section 13 2 for instructions on how to put the meter back into BASIC mode before continuing See the Vulcan V600 Fork Scale User Manual for a description of customer mode Below is the display shown when the meter is in CUSTOMER mode 8 2 2 ERASING THE METER AND VULCODER ES Press the PWR MENU button to enter the Program menu SR Press the CYCLE button until SEQUENCE CHANLS is displayed April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Manual Control Kit Installation 47 Note When trying to SEQUENCE CHANLS if the lower display shows Password with the cursor blinking the Driver Lock Password
31. 112 001 Rev STRESS TEK INC 2008 Fork Scale Troubleshooting And Repair 104 13 5 VULCAN CHECK OUT BOX The Vulcan Check Out Box can be used to check the fork scales and electronics It works as an extension to bring fork scale connector pins to the side of truck where readings can be conveniently made It can also simulate an applied load to the VSL Vulcoder The Check Out Box is an optional equipment item for the Leakage and Resistance Tests Vulcan Scales recommends every installer and troubleshooter has one Before using the Check Out Box make sure the meter fuses are good Use a multi meter to ensure there is a minimum of 10 4 Vdc from the input power connections at the back of the meter when the system is running Make sure the green plug is plugged in and the meter is turned on If there are any error messages displayed refer to section 13 7 V600 Meter Error Codes To order a Check Out Box P N S22 contact your Vulcan dealer o o oo CONNECTOR oo ch o 8 o TO VULCODER OFF ON o4 RED DOT WHITE BLACK GREEN RED 8 RED LOAD SWITCH CHECK OUT BOX CONNECTOR TO LOAD CELL CABLE 4 FEET Figure 13 A Vulcan Check Out Box April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Troubleshooting And Repair 105 13 6 FORK SCALE EVALUATION TESTS The tests listed below will help identify and locate any prob
32. BLACK AND ORANGE CABLES 7 5 1 There are two black cable lengths a short one and a longer one The shorter length cable is to be connected to the Front Fork Scale where the VSL Vulcoder is mounted The longer black cable is routed along the backside of the cross tube to the fork opposite of the VSL Vulcoder This cable has an added jacket for protection Do not trim nick or cut the black cables to length 7 5 2 A mechanical cable guard must be installed to protect the black cable as it runs across the cross tube A cable guard can be made by the installer or purchased from Vulcan Scales P N H55 Figure 7 E illustrates the cable guard that can be purchased from Vulcan Scales Cross Tube Weld Cable Guard H55 Vulcoder connector cable Weld Cable Guard in place Use weld tabs designed into the Cable Guard Position Cable Guard for adequate clearance to allow passage of the Vulcoder TEON connector cable assembly Route Vulcoder cable inside Cable Guard x Be Grind burs Cable Guard 67 Long 2 ee is Cut to shorter length as needed rind burs Weld to cross tube using weld tabs Figure 7 E April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Electronics Installation 40 7 5 3 7 5 4 7 5 5 Inspect the connectors on the VSL Vulcoder black cables by doing the following verify the connector has an O ring check the connectors on the F
33. BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Troubleshooting And Repair 98 13 1 DRIVER LOCKOUT PASSWORD FEATURE This feature locks the meter and allows drivers to access the Driver Entries menu only It prohibits modification of any of the Configure System Setup Calibrate Sequence Channels or the System Test menus without entering the proper password All meters have the same password The meter comes from the factory with the password lock inactive Vulcan Scales recommends the activation of this password feature after the installation and setup process is complete How the Password works in BASIC mode if not in BASIC mode refer to section 13 2 ES Press the PWR MENU button to turn on the meter E gt After the meter has completed its startup routine and is running press the PWR MENU button to enter the program menu If the password feature is active the display now shows Password with the cursor blinking Without entering the correct password there is no access to other menu options To return to the normal operating mode if password is not known vi Press the ENTER button E Press the PWR MENU button to return to the normal operating mode The scale system is now ready to weigh To Activate or Deactivate the Driver Lockout Password Feature EA Press the PWR MENU button to turn on the meter E After the meter has completed its startup routine an
34. DED BY VULCAN Scale ready cross tubes can be purchased from Stress Tek Inc for both McNeilus and Heil front loader vehicles The scale ready cross tube for McNeilus is for the Atlantic Coast truck model The Pacific Coast truck model is designed for the California market specifically and has a 9000 Ib capacity fork vs a 10 000 lb capacity fork used on the Atlantic model Other OEM s may sell a scale ready cross tube as well 4 1 WHAT IS A SCALE READY CROSS TUBE A Scale ready cross tube includes Fork mounting clamps 2 places April 2008 Complete cross tube sub assembly with the fork mounting clamps welded to the cross tube for the Heil and McNeilus front loaders Strengthening coupler tube welded between the fork mounting clamp and bell crank A cross tube cable protector for running cable between the fork scales Complete assembly is painted with an industrial primer finish Assembly is a direct bolt in replacement all the major welding and alignment is done for you by Vulcan Scales Once this assembly is installed the fork scales are simply bolted to it The scale ready cross tube simplifies the installation and saves 8 10 hours by eliminating fabrication and welding steps It also assures the scale system is properly aligned Cross tube cable protector Strengthening coupler tube 2 places Figure 4 A Scale Ready Cross Tube VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC
35. EK INC 2008 Static Weigh In Motion Control Kit Installation 5 9 3 METER SETUP AND SYSTEM TEST 9 3 1 OPERATIONAL CHECK OF PROXIMITY SWITCH Range where no weights are taken js Range in which the weight is captured in both the up and down motions A two beep audible signal indicates weight capture The yellow indicator light in the switch housing illuminates when the switch is activated 3 16 gap and the forks are in the weigh zone Stainless steel bands are tight Rotation of torque tube when arms are lowered Proximity switch Torque tube Proximity trigger Figure 9 J April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Static Weigh In Motion Control Kit Installation 59 9 3 2 START UP DISPLAY METER Note If there are any problems with the following quick system tests contact Vulcan Customer Service 1 Start the truck Bring the arms down and put the forks in a level position Level Forks Figure 9 K April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Static Weigh In Motion Control Kit Installation 2 Turn the meter on and let it complete its startup routine Et Press the PWR MENU button for less than 2 seconds After the meter has completed its startup routine the meter will display READY TO LIFT If the meter does not have the display shown above
36. ER IN CAB 7 3 1 Find a suitable location to mount the meter in the cab that is visible and accessible to the driver and does not block any mirrors or controls Secure the meter mounting bracket in place and fasten meter to it Figure 7 B April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Electronics Installation 38 7 4 MOUNT VULCODER AND VULCODER GUARD 7 4 1 Tape the exposed ends of the Vulcoder connector sockets prior to routing the cables to avoid contamination Mount Vulcoder on the back side of the bumper plate using the two 20 tapped holes provided refer to Figure 7 C Verify steel bushings are d a in each mounting hole oe Ke S SC Bumper Plate L Tape this area Figure 7 C 7 4 2 Add protective Vulcoder guard to the bumper plate where Vulcoder is mounted The Vulcoder guard is packaged with the Vulcoder The bumper must be removed to install the Vulcoder guard Mounting Block Fork Scale Via Ee Vulcoder Guard Vulcoder Guard m LE C G SE oy 3 D e IS Exitsing Bumper Fasteners 4X 1 2 13UNC X 3 5 Figure 7 D April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Electronics Installation 39 7 5 ROUTE VULCODER
37. ES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Weigh In Motion With Lift Control Kit Installation 82 If the meter does not have the display shown above but instead has the display shown below the meter is not in BASIC mode it is in CUSTOMER mode See section 13 2 for instructions on how to put the meter back into BASIC mode before continuing See the Vulcan V600 Fork Scale User Manual for a description of customer mode Below is the display shown when the meter is in CUSTOMER mode 10 4 3 ERASING THE METER AND VULCODER E gt Press the PWR MENU button to enter the Program menu m Press the CYCLE button until SEQUENCE CHANLS is displayed Note When trying to SEQUENCE CHANL GT if the lower display shows Password with the cursor blinking the Driver Lock Password feature is activated and the Configure System Setup Calibrate Sequence Channels and System Test menus are not accessible Refer to section 13 1 to unlock the system er Press the ENTER button to select the SEQUENCE CHANLS menu option April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Weigh In Motion With Lift Control Kit Installation 83 Press the ENTER button to enter the DISPLAY SEQUENCE menu option The meter will display the truck Vulcoder as a rear lt R gt designator Press and hold the ENTER button for two seconds to erase the Vu
38. INC 2008 Manual Control Kit Installation 49 8 3 CALIBRATION The Front Fork Scale comes calibrated from the factory There is no need for further calibration by the installer Once the system is working in the field fine tuning the calibration may be desired to obtain a higher accuracy This can only be done after the system is working in the field The V600 Fork Scale User Manual P N 44 10115 001 has complete details on the calibration methods 8 4 MANUAL CONTROL KIT DRIVER CARD The following page has a copy of the driver card used for the Manual Control Kit This driver card also comes packaged with the Manual Control Kit P N A01 If driver card cannot be found copy this page fold in half and laminate Put this card in the truck for the driver to reference as needed This driver card is also available from the Vulcan website at www vulcanscales com April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Manual Control Kit Installation 50 DAILY DRIVER OPERATING GUIDE FRONT FORK MANUAL GUIDELINES TO MAXIMIZE PICKUP WEIGHT ACCURACY e Just before bin engagement with forks in level position if the meter reads more than 50 Ib press the TARE ZERO button to rezero e Lift the full bin completely off of the ground smoothly stop the forks in a level position within the 6 weigh zone Press the weight capture button wait for a two beep audible signal from the meter
39. KIT INSTALLATION een 51 9 1 Proximity Switch Installation 51 9 2 Electrical Schematics Dagrams 55 9 2 1 Static Weigh In Motion System Electrical Schematic 55 9 2 2 Meter Wire Connection Diagram 56 9 2 3 Connection To Truck Battery 57 9 3 Meter Setup And System Test 58 9 3 1 Operation Check Of Proximity Switch 58 April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Table Of Contents 9 3 2 Startr Up Display Mere eege 59 9 3 3 Erasing The Meter And Vulcoder 60 9 3 4 Using the Static System as Weigh in Motion ssseeeeeeeeeeeee 62 9 3 5 Meter Setup For Static Or Weigh In Motion sssseeesessseeeenneeseeeenne 63 9 3 6 Verify Fork Operation DE 64 Sigk CEET 64 9 5 Static Weigh In Motion Control Kit Driver Card 64 9 6 Centerline Locating Tobin er canne pd eet 67 10 0 WEIGH IN MOTION WITH LIFT CONTROL KIT INSTALLATION 69 10 1 Proximity Switch E Ee EE 69 10 2 Hydraulic Flow Control Valve Installation And Confouration 73 10 3 Electrical Schematics Diagrams 75 10 3 1 Weigh In Motion With Lift Control System Electrical Schematic 75 10 3 2 Meter Wire Connection Diagram 76 10 3 3 Hydraulic Valve Wire Connection Diagram cceceeeee
40. ON NOTE DRIVER NOTE Please wire tie this driver card to the Please place this driver card on visor or Vulcan V600 Meter bracket clipboard to use as a quick reference guide April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Static Weigh In Motion Control Kit Installation 66 April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Static Weigh In Motion Control Kit Installation 67 9 6 CENTERLINE LOCATING TOOL CUT ALONG OUT April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Static Weigh In Motion Control Kit Installation 68 April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Weigh In Motion With Lift Control Kit Installation 10 0 WEIGH IN MOTION WITH LIFT CONTROL KIT A02 INSTALLATION 10 1 PROXIMITY SWITCH INSTALLATION Arm Torque tube Cross tube Fork scale Ls Area where the weight is measured Recess proximity switch in nut up to 1 8 Body structure Height adjustment ae screws Tightening screw Lock washer for hose clamp Proximity switch MUST point to the center of the torque tube XN RS SCH Mechanical stop Rotation of KOCH ASSEMBLED torque tube SEA PROXIMITY SWITCH ae Fa are lowered IN BRACKET 1 4
41. S Figure 2 A 2 1 SYSTEM COMPONENTS Item Quantity stock Description 1 1 M60 V600 meter 2 1 V33 VSL Vulcoder 1 VSL Vulcoder 1 Vulcoder guard 3 2 L38 Fork scale Fork scale Bumper plate 7 8 14 hex cap screws Rubber bumper and mounting fasteners 1 1 3 1 1 Connector guard and fasteners April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 System Layout And Tools Required 10 Item Quantity stock Description Mounting Kit Options One set of either through hole or threaded kit is required Threaded Mounting Clamp 4 2 H41R L H42R L H44R L Through Hole Mounting Clamp 4 2 H31 H36 H53 H35 Electronic Kit Options One required 5 1 AO A04 A02 2 2 ACCESSORIES Item Quantity Stock or P N 6 1 H55 7 1 H56 7 1 H57 1 59 30030 001 1 59 30029 002 April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 3 1 2 Round mounting kit right and left 4 Round mounting kit right and left 4 1 2 Round mounting kit right and left All mounting kits include 2 Cross tube mounting clamps 6 1 14 Grade 8 hex cap screws 1 Hardened steel washer plate 1 Connector guard and fasteners 3 1 2 Round mounting kit 4 Square mounting kit 5 Square mounting kit Universal mounting kit All mounting kits include 2 Cross tube mounting clamps 6 1 14 Grade 8 hex cap screws 6 1 14 Grade C hex nuts 1 Hardened steel washer plate 2
42. S 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Table Of Contents 6 0 INSTALL FORK ASSEMBLY ON CROSS UBE sssssssnnnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 29 6 1 Install Forks To Mounting Clamps With Washer Plate 29 6 2 Assemble Bumper Plate and Bumper 29 6 3 Minimum Maintenance Requirement 31 6 4 Check Cab Guard Clearance EE 32 6 5 Check Exhaust Port Clearance c ccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeneeeeeeeeeeeeneee 33 7 0 FORK SCALE ELECTRONICS INSTALLATION eee 35 7 1 Electronics System OVEMWVIEW sense er tet kate ken et en kee 35 7 2 Descriptions of The Three Electronics Options For The Fork Scale 35 7 3 Mount Meter In Cab scan tas tea tal ta oth tea ER bin AN es State nh nt a 37 7 4 Mount Vulcoder And Vulcoder Guard 38 7 5 Route Vulcoder Black And Orange Cables sosonssnnnneeesseeeenrrnrnrenseerrrrrnnn 39 7 6 Install Connector EI EE 41 8 0 MANUAL CONTROL KIT INSTALLATION seememmeememmeemeennes 43 8 1 Electrical SEH Ee E eech E eat ta ess 43 8 1 2 Connection To Truck Battery ccccceeeeeeeeeeeeeeeeeeneeeeeeeeeeeeeeneneeees 44 8 2 Meter Setup And System Test 45 8 2 1 Start Up Display Meter nine he eee 45 8 2 2 Erasing the Meter and Vulcoder AEN 46 8 2 3 Verify Fork Operation ed ans nine Net 48 Bes e Te EE 49 8 4 Manual Control Kit Driver Card sister nine nie 49 9 0 STATIC WEIGH IN MOTION CONTROL
43. ST be electrically isolated from the vehicle chassis April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Weigh In Motion With Lift Control Kit Installation 80 10 4 METER SETUP AND SYSTEM TEST 10 4 1 OPERATIONAL CHECK OF PROXIMITY SWITCH AND HYDRAULIC VALVE Arms at normal rt Ee in this range Range in which the arms may be slowed by the hydraulic control valve in both the up and down motions The yellow indicator light in the switch housing illuminates when the switch is activated the hydraulic valve is engaged and the motion of the arms is slowed 3 16 gap Stainless steel bands are tight Rotation of torque tube when arms are lowered Proximity switch Torque tube Proximity trigger Figure 10 M April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Weigh In Motion With Lift Control Kit Installation 81 10 4 2 START UP DISPLAY METER Note If there are any problems with the following quick system tests contact Vulcan Customer Service 1 Start the truck Bring the arms down and put the forks in a level position Level Forks Figure 10 N 2 Turn the meter on and let it go through its startup routine ES Press the PWR MENU button for less than 2 seconds After the meter has completed its startup routine the meter will display READY TO LIFT April 2008 VULCAN ON BOARD SCAL
44. TEK INC 2008 Fork Scale Maintenance April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 STRESS TEK INC 2008 96 Doc 44 10112 001 Rev Fork Scale Troubleshooting And Repair 97 13 0 FORK SCALE TROUBLESHOOTING AND REPAIR FORK SCALE TROUBLESHOOTING In general troubleshooting is a systematic process of testing and eliminating potential problem sources until the one that is causing the problem is found The problem can then be fixed by repairing or replacing the faulty part With a little knowledge and by following a step by step procedure most of the problems that you may encounter will be easy to diagnose and solve In this section you will find guidelines on how to troubleshoot the system some characteristics of a properly functioning system and where to look when certain problems occur Occasionally someone has a problem that is not described here By approaching the problem systematically you will be able to eliminate potential sources of trouble until you find the one that is causing the problem The following section covers an explanation of V600 Test Procedures Fork Scale Evaluation Test Procedures and Vulcan Error Codes Recommended equipment for complete system troubleshooting Stock or P N Description S20 Multi Meter S22 Check Out Box 56 30066 001 VSL Zero Offset Plug Isopropyl Alcohol Cotton Swabs Hair Dryer Indicates part is available only from Vulcan On Board Scales April 2008 VULCAN ON
45. TH A SCALE READY CROSS TUBE 1000 ft lb torquing capabilities A typical well stocked shop no special shop equipment required 2 5 2 SHOP TOOLS REQUIRED FOR MOUNTING A FORK SYSTEM ON AN EXISTING CROSS TUBE ASSEMBLY 1000 ft lb torquing capabilities Structural steel welding and cutting capabilities and a typical well stocked shop April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 System Layout And Tools Required 12 2 6 TROUBLESHOOTING EQUIPMENT Stock or P N Description 20 Multi meter 22 Check Out Box 56 30066 001 VSL Zero Offset Plug 2 7 VULCAN FORK SCALE DIMENSIONS WHEN MOUNTED TO DIFFERENT CROSS TUBES The Vulcan Front Fork Scale is designed to mount directly to a front loader cross tube The Front Fork Mounting Kit is used in conjunction with the Front Fork Scale replacing the original manufacturer s front fork There are currently mounting kits for five different standard cross tube dimensions Three mounting kits were designed for round cross tubes 3 1 2 4 and 4 1 2 Mounting kits were also designed for a 4 and 5 square cross tube The kits have either a bolt nut through hole fastening configuration or a bolt threaded insert fastening configuration In addition a universal mounting kit is designed for through hole mounting only The installer can configure this kit as required to meet the geometry needs of special installations All forks are 1 1 2 thick and
46. Table Of Contents r FRONT FORK SCALE INSTALLATION amp SERVICE MANUAL Table Of Contents LEE INTRODUCTION seed 7 Tt System Specifications sanaan a a a a aa ia 8 2 0 SYSTEM LAYOUT PARTS ACCESSORIES AND TOOLG cssssesssecesseecsseseeseeens 9 2 1 System Components 9 PA PCC ESS ONES ES MR de da de ds As AS ds ts 10 2 3 Replacement PASSER ek CUT Ce ee te eat nr Re re 11 2 4 Service Repair Parts An nn nn An Ann ets 11 25 Installation Leger eege men ns pee ee Ne piesa Mn end ne ne ns ne 11 2 5 1 Shop Tools Required For Mounting A Fork System With A Scale Ready Cross EE 11 2 5 2 Shop Tools Required For Mounting A Fork System On An Existing El SSSR nn naa ent 11 2 6 Troubleshooting Equipment ss 12 2 7 Vulcan Fork Scale Dimensions When Mounted To Different Cross Tubes 12 3 0 HECKER 15 3A Unpacking dE 15 3 2 How To Identify And Use The Two Types Of 1 inch 14 Nuts Supplied 15 4 0 INSTALL SCALE READY CROSS TUBE RECOMMENDED BY VULCAN 17 4 1 What Is A Scale Ready Cross Tube 17 4 2 Installing The Scale Ready Cross Tube 18 5 0 INSTALL FORK MOUNTING CLAMPS ON EXISTING CROSS TUBE 2 2000000 19 5 1 Preinstallation EE 19 5 2 Measure Existing Configuration einen 20 5 3 Remove Existing Forks And Related Hardware ccccceeeeeeeeeeeeeteeeeeeees 22 5 4 Recommended Procedure For Welding Fork Mounting Clamps 0 24 5 5 Welding Mounting Clamps To Cross Tube 25 April 2008 VULCAN ON BOARD SCALE
47. URE Required Equipment Digital Multi Meter With Conductivity Scale Optional Equipment Vulcan Check Out Box Please refer to drawing below in setting up the Resistance Test The resistance in the pins should correspond to the Vulcan specifications listed below Refer to acceptable resistance ranges as shown below OR MULTI METER i MULTI METER CHECK OUT BOX 1 Eat FORK SCALE Y FORK Figure 13 C Resistance Test Pins Terminal Acceptable Color Code Resistance Range A to D Red to Black 349 to 450 Ohms BtoC Green to White 349 to 352 Ohms Pin B Green to Pin A Red should be the same number as Pin B Green to Pin D Black within 1 Ohm Pin C White to Pin A Red should be the same number as Pin C White to Pin D Black within 1 Ohm If the fork scale is not within Vulcan specifications contact Vulcan customer service or your Vulcan dealer April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Troubleshooting And Repair 110 13 7 V600 METER ERROR CODES 13 7 1 Err 01 Indicates that the VSL Vulcoder is processing an over ranged signal An over ranged signal means the fork scale output is greater than the maximum the VSL Vulcoder will accept Possible Causes The fork scales are being overloaded There is moisture in a fork scale connector One of the black VSL Vulcoder to fork scale cables has been dam
48. ady wired to the proper terminals Wire the orange and grey cables to the junction box as shown in Figure 10 I 10 3 2 METER WIRE CONNECTION DIAGRAM O Stress Tek Inc Kent WA U S A O of Je RS 232 4 L whi 12345678 12 24 Vde cet tE White jet 1 Accessory Port O Use only 2A fast blow fuses in power leads S00S000 Pin 8 VSL Vulcoder Power Cable Communication Orange Cable from grey Cable Junction Box Comm Link orange Figure 10 J April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Weigh In Motion With Lift Control Kit Installation 77 Route the grey power cable from the truck battery to the meter in the cab Route through the cab hinge point The fuses must be at the battery end of the cable In the truck cab strain relief and cut the VSL Vulcoder cable meter power cable and junction box cables to ideal lengths Unplug the terminal blocks from the back of the meter strip the wires and connect to the terminal block refer to Figure 10 J Be careful that stray wires DO NOT contact adjacent terminals Twist conductor strands together refer to Figure 10 K Do not plug the terminal block into the meter at this time D 1 4 Twist Tightly Do Not Solder Figure 10 K April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Weigh In Motion With Lift Control Kit Install
49. aged A fork scale has a large preload number A fork scale is faulty Ol ee Ons What to Do 1 Inspect Vulcoder cables 2 Clean connectors with isopropyl alcohol and dry with a hair dryer 3 Perform the Tare Test section 13 6 2 4 Perform the Leakage Test section 13 6 1 5 Check the fork scales Check by disconnecting one fork scale at a time When the faulty fork scale has been disconnected the meter will read a number instead of the error code 13 7 2 Err 02 Indicates the reading to be displayed is beyond the limitations of the meter s display Possible Causes 1 Calibration number set too high 2 Tare weight set too high What to Do 1 Check and reset the Calibration number and Tare weight April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Troubleshooting And Repair 111 13 7 3 Err 03 Indicates that the meter is not receiving a weight from the VSL Vulcoder Possible Causes Break in the orange cable Green and white leads reversed on VSL Vulcoder line where connected to the meter Vulcoder is not sequenced Faulty VSL Vulcoder Faulty meter Ke CNE What to Do 1 Reconnect any cables that have become disconnected 2 Re sequence Vulcoder section 13 3 3 Inspect VSL Vulcoder communication line for cut or broken wires Inspect the pivot point on the fork cross tube area 4 Inspect and clean meter connectors 5 VSL Vulcoder
50. ale e o Proximity Switch A01 Static System A04 Weigh In Motion A02 V600 Meter VSL Vulcoder 6 o o o o o l Front Fork Scale Figure 7 A Truck Battery Il 10 5 29 Vdc 7 2 DESCRIPTIONS OF THE THREE ELECTRONICS OPTIONS FOR THE FORK SCALE All Vulcan Front Fork Scales include a V600 Meter VSL Vulcoder and offer three control options for the scale system 7 2 1 THE MANUAL METHOD P N A01 The Manual Method requires the installation of a Weight Capture button The driver lifts and levels a full bin then presses the Weight Capture button to tell the meter to take a weight reading Similarly on lowering the bin before placing it on the ground the driver levels the empty bin and once again presses the Weight Capture button Both the up and down weights are captured and the net weight is calculated and displayed This allows the driver to take weights on all customers or complete audits on specific customers This system is recommended for auditing routes where not every customer is weighed The A01 kit comes with the Weight Capture button and all required parts April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Electronics Installation 36 7 2 2 THE STATIC METHOD P N A04 The Static Method requires the installation of a proximity switch to tell the meter when a bin is lifted The driver controls the fork speed to allow a weight to be taken T
51. also have scale ready cross tubes available This installation manual details mounting a fork system with both a scale ready cross tube and mounting a fork system on an existing cross tube assembly A CD is included with this manual It contains a PDF version of this manual There is also a second CD which contains the V600 Fork Scale User Manual and A video of How to Download Data from the V600 meter This Installation Manual is available from the Vulcan website at www vulcanscales com April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Introduction 1 1 SYSTEM SPECIFICATIONS e SYSTEM CAPACITY 10 000 Ib e FORK SCALE Material ASTM A514 heat treated high strength alloy steel Finish Plated for corrosion resistance Operating Temperature 40 to 140 F Mounting Fasteners Grade 8 hex cap screws e FORK MOUNTING CLAMPS Through Hole Design Material ASTM A36 mild steel Threaded Hole Design Material ASTM A514 heat treated high strength alloy steel All mounting blocks are painted with a weld through primer e VULCODER Operating Temperature 40 to 180 F Environment Sealed for environmental protection e METER Operating Temperature 40 to 180 F Input Voltage Requirement 10 5 to 29 Vdc April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 System Layout And Tools Required 2 0 SYSTEM LAYOUT PARTS ACCESSORIES AND TOOL
52. alve to a larger piece of steel angle or tube then bolt or weld the angle or tube to the truck body structure April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Weigh In Motion With Lift Control Kit Installation Flow control screw 1 4 hex key required Locknut Hydraulic valve Figure 10 H Factory recommended setting for Weigh In Motion Flow control screw open 1 3 4 turns counterclockwise Procedure for adjusting flow control screw to factory recommended setting Step 1 Loosen the flow control screw locknut Step 2 Turn the flow control screw clockwise until tight This fully closes the valve Step 3 Turn the flow control screw counterclockwise 1 3 4 turns and tighten the locknut The flow control valve is now at the recommended setting of open 1 3 4 turns April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Weigh In Motion With Lift Control Kit Installation 75 10 3 ELECTRICAL SCHEMATICS DIAGRAMS 10 3 1 WEIGH IN MOTION WITH LIFT CONTROL SYSTEM ELECTRICAL SCHEMATIC Use clamp and fasteners Junction Box included with enclosure Lid not shown Relay to secure all cables in location shown o Or Ore CHE O res White Use a black wire to Hydraulic H _ Black SE Junction box hold other wires in place as shown
53. aneuvering a bin into the lifting position momentarily set the bin back on the ground before lifting to dump This will reset the weigh cycle e f picking a bin from a dock bring it down to a few feet off the ground this will reset the weighing cycle e f continuous beeping occurs while lifting the bin to dump bring the bin back into the weigh zone until the meter emits a single or double beep VULCAN CUSTOMER SERVICE 1 800 237 0022 HOURS 7 30 a m 5 00 p m PACIFIC TIME UP AND DOWN LIFT CYCLE Non weighing a no Arms at normal speed Weighing zone e Arms slowed e Forks level e Smooth motion INSTALLATION NOTE DRIVER NOTE Please wire tie this driver card to the Please place this driver card on visor or Vulcan V600 Meter bracket clipboard to use as a quick reference guide April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 gt SS m N o GER Z Q gt Sy Z NN KR 5 EE Ge CD MONYL AYYN E E D Ze e Se Fe gt g z ke O et 9 o a SE u S z d g 2 o O gt E Be DO Weigh In Motion With Lift Control Kit Installation 88 April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Final Inspection Checklist 89 11 0 FORK SCALE FINAL INSPECTION CHECKLIST This section can be pho
54. area section 10 4 1 L Hydraulic valve flow control screw is set correctly section 10 2 Figure 10 H 11 3 DOCUMENTATION LJ Appropriate driver card Manual Static Weigh In Motion or Weigh In Motion with lift control is sent with the truck C V600 Fork Scale User Manual P N 44 10115 001 is sent with truck L Warranty cards are sent with the truck if not filled out by dealer April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Final Inspection Checklist 92 April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Maintenance 93 12 0 FORK SCALE MAINTENANCE This section can be photocopied and used repeatedly as a checklist for maintenance inspections Preventative Maintenance In order to keep any system functioning properly it is important that the system be properly maintained This includes daily vehicle inspection and preventative maintenance during regular scheduled maintenance periods Certain minimum maintenance will be necessary to claim warranty of fork scales and other scale components 12 1 FRONT FORK SCALE ASSEMBLY E Check all Front Fork Scale fastener torques after the first week of operation and then periodically and whenever the truck is being serviced C Torque fork mounting bolts 1 14 Grade 8 hex cap screws and Grade G locking flange nuts 1000 ft lb L Torque bumper block
55. as Recommend a weld machine with a 450A minimum capacity Use a 3 stringer minimum weld pass configuration No weave pattern allowed All welds shall be free of cracks overlaps and unacceptable profiles shown in Figure 5 4 in AWS D1 1 2006 Acceptable weld profiles are shown in this figure Full weld penetration required 6 Preheat weld area to 250 F to remove all moisture from weld area 7 Parts must be free of moisture organic compounds oils rust and other welding contaminates prior to welding 8 Grind off mill scale on mounting clamps in the weld area 9 Welding shall not be done when the immediate environment temperature is below 32 F 10 Itis recommended to remove the cross tube for welding fork mounting clamps and stand on end to create a flat welding condition St 0 5 4 2 Additional specific recommendations for low hydrogen welding on ASTM A514 T 1 steel This is for mounting clamps with threaded inserts 1 Follow AWS D1 1 2006 for procedures workmanship technique inspection and contractor obligations for low hydrogen welding on ASTM A514 T 1 steel 2 The weld wire is usable for only 7 days after sealed package is opened Once removed from original package wire shall be protected and stored in a moisture free environment so the welded metal properties are not negatively affected 3 Minimum preheat temperature for ASTM A514 steel is 250 F Maximum interpass temperature is 450 F 4 Subsequent weld inspection
56. atchdog circuit system is not running Possible Causes 1 New or recently repaired meter April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Troubleshooting And Repair 114 What to Do 1 Turn the meter off and then back on to cycle power in system 3 If Err 11 is still displayed replace meter 13 8 SYSTEM MALFUNCTIONS 13 8 1 CONDITION Meter displays ERR 3 Indicates the meter is not receiving a weight from the VSL Vulcoder Possible Causes Break in the orange cable Green and white leads reversed on VSL Vulcoder line where connected to the meter Vulcoder is not sequenced Faulty VSL Vulcoder Faulty meter Oe DU TS What to Do 1 Reconnect any cables that have become disconnected 2 Re sequence the Vulcoder section 13 3 3 Inspect VSL Vulcoder communication line for cut or broken wires Inspect the pivot point on the fork cross tube area 4 Inspect and clean meter connectors 5 VSL Vulcoder is damaged Replace VSL Vulcoder 6 Meter is damaged Replace meter 13 8 2 CONDITION Sum of the pickup weights don t match the landfill Possible Causes 1 Fork mounting bolts are loose 2 Further calibration is required 3 Not following the lift procedure 4 Pickups not being recorded What to Do 1 Retorque fork mounting bolts to 1000 ft lb April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK
57. ation 10 3 3 HYDRAULIC VALVE WIRE CONNECTION DIAGRAM Pl ge Plastic housing Blue cable Trim cable jacket 1 Terminal block Contact pins Rubber gasket Hydraulic control valve Not used Connect power leads to these terminals TOP VIEW Electrical polarity is not significant TERMINAL BLOCK Figure 10 L April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Weigh In Motion With Lift Control Kit Installation 79 Connect the cable from the junction box to the hydraulic control valve terminal block refer to Figure 10 L Electrical polarity is not significant on the hydraulic terminal block 10 3 4 CONNECTION TO TRUCK BATTERY Disassemble the positive fuse holder red wire Apply grease to the positive connector at the battery post to inhibit corrosion Crimp ringed terminals to the power leads Connect fused power leads directly to battery posts for best operation Power must be connected directly to battery Maximum power is 29 Vdc Note The Vulcan V600 meter is configured to be used in a 12 Vde system using 2 amp fast blow fuses in both leads Do not connect the power cable to a power source activated by the key switch Remember Turn meter off while making any wire connections WARNING If installing the meter in a vehicle with a positive ground electrical system the meter chassis mounting bracket and mounting fasteners MU
58. back of the meter If the meter doesn t work then check the power source battery meter power cable or fuses If the power source checks out OK then the meter is faulty Possible Causes For LO LO and 2 X 1 VSL line orange cable is pinched or shorted 2 VSL line incorrectly wired 3 Damaged VSL plug or receptacle What to Do 1 Using a multi meter check the voltage at the back of the meter when the meter is turned on and off The power should not change more than 1 2 Volt Turn off the meter either by the key or truck battery switch for a few seconds and then turn on again If the meter still shows the error proceed to step 2 2 Check the fuses for both negative and positive leads Use 2 amp fast blow fuses for 12 Vdc applications and 1 amp fast blow fuses for 24 Vdc applications Blown fuses could indicate a shorted VSL line Check for a shorted line by disconnecting the green and white wire from the back of the meter Measure the resistance between the green and white wire It should be greater than 1000 Ohms 3 Faulty meter Replace meter April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Troubleshooting And Repair 118 13 8 7 CONDITION Unable To Enter Tare Or Calibration Numbers Possible Causes 1 Meter may be in the Driver Lockout Password mode which does not allow the Tare weight Cal number or Cal weight to be changed 2 Faulty Meter Wha
59. but instead has the display shown below the meter is not in BASIC mode it is in CUSTOMER mode See section 13 2 for instructions on how to put the meter back into BASIC mode before continuing See the Vulcan V600 Fork Scale User Manual for a description of customer mode Below is the display shown when the meter is in CUSTOMER mode 9 3 3 ERASING THE METER AND VULCODER ES Press the PWR MENU button to enter the Program menu m Press the CYCLE button until SEQUENCE CHANLS is displayed April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Static Weigh In Motion Control Kit Installation 61 Note When trying to SEQUENCE CHANLS if the lower display shows Password with the cursor blinking the Driver Lock Password feature is activated and the Configure System Setup Calibrate Sequence Channels and System Test menus are not accessible Refer to section 13 1 to unlock the system E Press the ENTER button to select the SEQUENCE CHANLS menu option FPE Press the ENTER button to enter the DISPLAY SEQUENCE menu option The meter will display the truck Vulcoder as a rear lt R gt designator Press and hold the ENTER button for two seconds to erase the Vulcoder The meter will display lt gt This shows that the Vulcoder has been erased Press and hold the ENTER button again to erase the meter The meter will display all dashes on the upp
60. can monitor net or gross weight by summing the pickup weights Commercial pickup weights can be measured each time or by using an audit approach This allows operators to optimize pricing of commercial accounts and improve their competitive position The Front Fork Scale also allow operations to eliminate overweight fines minimize legal liabilities and reduce maintenance expenses by assuring the vehicles are not overloaded The V600 Fork Scale User Manual details how to operate the system This small bound manual comes packaged with the V600 meter and should be included with every installed system There are three types of electronic kits that can be used with the fork scale From the most basic push button auditing system to a complete Weigh In Motion system The three electronic systems are P N Description A01 A simple Manual push button primarily used for specific customer auditing A04 Static weighing method driver pauses the fork motion then the weight is taken automatically A02 Full Weigh In Motion with lift control method no pausing the forks motion weight is taken automatically Vulcan recommends that a scale ready cross tube be used for installation It simplifies the installation process saves 8 10 hours of installation time and better assures a properly aligned system Scale ready cross tubes are available from Vulcan for Heil and McNeilus refuse bodies They can also be purchased from the OEM Other OEM s may
61. cannot be brought to Vulcan specifications contact Vulcan customer service or your Vulcan dealer April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Troubleshooting And Repair 106 Caution Do not touch the multi meter probes with your hands when making measurements This could cause an error in the meter reading A person s body can have 10 times the allowable conductivity of a fork scale MULTI METER gt MULTI METER gt 2000 S 20001 a S E CN AS SS O Q Q WHITE BLACK OO SE OO A O 8 GREEN RED j TT FORK SCALE FORK SCALE fi Figure 13 B Leakage Test Iess lt CHECK OUT BOX Leakage Test Specifications Measure between any pin and an unpainted clean surface of the fork scale or connector body Electrical Isolation must not be greater than 2 0 nS or less than 500 Meg Ohms 13 6 2 TARE TEST PROCEDURE This test checks each fork scale for a high preload number caused by mechanical damage or moisture Both forks must be connected to the Vulcoder With the truck empty and no bin on the forks lower the arms and extend forks to a level position BE Press the PWR MENU button to turn on the meter and let it complete it s startup routine Record the current truck Tare weight The Tare weight is the weight displayed when the vehicle is empty and there is no bin on the forks For trucks that
62. d area and apply heat to shrink e Wrap completed splice with electrical tape Tape the connection and all the wires with the orange insulation stripped off to help seal and prevent wires from chaffing which can cause a wire to short e Fold cable as shown to create strain relief and secure with wire ties April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Troubleshooting And Repair 123 You can also use the Vulcan VSL 3M connectors for making the cable splice These connectors are available from Vulcan Scales p n 27 10086 001 e When using the Vulcan supplied 3M connector do not strip the insulation from each wire e Be sure to insert wires completely into the connector and check their position by looking through the translucent connector body e Crimp the connector cap down flush with the top edge of the connector body ensuring a good connection e Tape the connection and all of the wires with the orange insulation stripped off to help seal and prevent wire chaffing that can cause a wire to short e Wire tie the splice so the connection is strain relieved GREEN ORANGE CABLE April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Troubleshooting And Repair 12 13 9 3 FORK SCALE CONNECTOR REPLACEMENT Fork Scale Connector Replacement Kit p n 59 30050 001 e Remove the four 4 40 screws
63. d is running press the PWR MENU button to enter the program menu E Press the CYCLE button until CONFIGURE SYSTEM is displayed April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Troubleshooting And Repair 99 E Press the ENTER button to select the CONFIGURE SYSTEM menu BR Press the CYCLE button until CONF PASSWORD is displayed With the cycle button depressed press the UP ARROW button to switch between the two options vc Press the ENTER button to save the selection ES Press the PWR MENU button twice to exit and the meter will return to its operating mode The scale system is now ready to weigh April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Troubleshooting And Repair 100 Definition of the Password The password is a series of button presses Press these buttons TARE ZERO CYCLE A Y ENTER in that order Any other sequence of button presses will leave the meter locked Enter this sequence of button presses when prompted by the meter to obtain full access to all the meter s menus If a mistake is made when entering the password code press the ENTER button and restart entering the password code 13 2 SWITCH THE METER BETWEEN BASIC AND CUSTOMER MODE Vulcan Scales recommends the meter be set in BASIC mode The meter factory default setting is BASIC mode
64. e fork mounting clamp on the cross tube This coupler support must be reinstalled on the fork scales so the final fork assembly is equivalent in strength to the original OEM design April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Install Fork Mounting Clamps On Existing Cross Tube VW Bell Crank Coupler support tubular shape Existing Fork Cross Tube Cross Tube a Existing Fork Coupler support tubular shape Ki Bell Crank Coupler support non tubular shape Existing Fork Cross Tube Cross Tube a Existing Fork Coupler support non tubular shape April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Install Fork Mounting Clamps On Existing Cross Tube 24 5 4 RECOMMENDED PROCEDURE FOR WELDING FORK MOUNTING CLAMPS There are two types of fork mounting brackets Threaded insert design made from ASTM A514 T 1 steel Through bolt design made from ASTM A36 steel Below are general welding recommendations for all welding processes and specific welding recommendations for welding on the ASTM A514 T 1 steel parts 5 4 1 General Recommendations 1 Recommended weld process Flux core arc welding FCAW G 2 Recommend weld wire UltraCore 712C 045 minimum diameter larger diameter desirable mfg Lincoln Arc Welding This wire requires using 100 CO g
65. e ground within the weigh zone keeping the forks level It is best if the bin has weight but it s not required Press the Weight Capture button Wait for the two beep audible signal from the meter to verify weight capture The bin weight will be displayed 2 With the bin in the same position again hit the Weight Capture button Wait for the two beep audible signal from the meter to verify weight capture A net weight of about zero should be displayed by the meter If there are no beeps recheck electrical connections per section 8 1 and or call Vulcan Scales 3 Set the bin down and disengage the forks from the bin so there is no contact The meter display should return to zero within 50 Ib 4 Repeat the first 3 steps 2 times to verify the full weights displayed and zero net weights displayed are repeated within 50 Ib 5 All the up weight readings should be close to the same weight within 50 Ib and all the net weights should be close to zero within 50 Ib although they may not be equal to the exact pound or kilogram If not retorque fork mounting bolts per section 12 1 and or call Vulcan Scales 6 Activate the Driver Lockout Password feature Vulcan Scales recommends the activation of this password feature to prohibit the driver from changing the scale system setup parameters See section 13 1 to activate this feature April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK
66. ed DE Washer Plate Se ZS S w A x Ki N Be Se rt S N 5 N d l yy 24 A Torque 700 ft lb 3 Places per fork scale Torque 1000 ft lb 6 Places per fork scale Figure 6 A Note If bolts are not torqued to proper value or thread lubricant is not used scale inaccuracies will result If you cannot obtain a torque multiplier contact Vulcan Customer Service at 800 237 0022 April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Install Fork Assembly On Cross Tube 31 Do not add any support bracing from the backside of the bumper plate to the Cross Tube refer to Figure 6 B This will cause scale inaccuracies Fork Cover Plates Minimum Area For Undercoating Front Fork Scale Bumper Plate NO SUPPORT BRACING between Bumper Plate and Cross Tube Figure 6 B 6 3 MINIMUM MAINTENANCE REQUIREMENT Certain minimum maintenance will be necessary to claim warranty of Front Fork Scales Apply high quality paint to the Front Fork Scales and Mounting Clamps For environments where high concentrations of salts are used on road surfaces undercoating is recommended 3M Universal Rubberized Undercoating 3M P N 8883 Areas between the bumper plate and cross tube are most critical and should be well coated This specifically includes the connector area fork cover plate areas and mounting clamp contact areas N
67. eeeeaeeeeeeeeeeeeeeeeeeaaeeeeeeeeeeeeeeeeaeees 94 12 3 Manual Ela 94 12 4 Static Weigh In Motion System 94 12 5 Weigh In Motion With Lift Control System 95 13 0 FORK SCALE TROUBLESHOOTING AND HERPAIR een 97 13 1 Driver Lockout Password Feature 98 13 2 Switch the Meter Between BASIC and CUSTOMER Mode 100 13 3 Re S quence the Vulcoder 22e nana 101 134 Loose Bolt Tests msananinaninantinandtatiian tat dan tanss 102 13 5 Vulcan Check Out Ee tn tt te 104 13 6 Fork Scale Ee BEE 105 13 6 1 Leakage Test Erol gece 105 13 6 2 Tare Test Procedure 106 13 6 3 Resistance Test Procedure 109 13 7 V600 Meter Error Codes ccccccccceceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 110 JE EE AR ee ee ae head he he ale i Se a he Cn oN 110 TS foe NE U2 EE 110 13 79 ENEE eege 111 137A EE EE EE 111 e AS E LE nana anata ial eel halal anal arial anal AarAaiaas 111 137 0 Eir OO act cxcacncavocsvads int tedevcstadasiees Uacainettadseetinds ertadianesbecutmeuadaseeiiwtians 112 UC EE GE GE ARR RER RER RE ate E 112 WG Err 087 KEE 113 TOO e E 113 LOS ID ETES EE 113 13 8 System Malfunctions EE 114 13 8 1 Meter Displays ERR 83 114 13 8 2 Sum Of The Pickup Weights Don t Match The Landfill 114 April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Table Of Contents 13 8 3 Weight Not Returning to Zero After
68. eeeeeeeeeeees 78 10 3 4 Connection To Truck Battery ceeeeeceeeeeeeeeeeeeeeeeeeeneeeeeeeeeeeeteeee 79 10 4 Meter Setup And System Test 80 10 4 1 Operation Check Of Proximity Switch And Hydraulic Valve 80 10 4 2 Start Up Display Meter sido otis ce nn he oh ke oar 81 10 4 3 Erasing the Meter and Vulcoder 82 10 4 4 Meter Setup For Weigh In Motion 83 10 4 5 Verify Fork Operation 84 Wl EE 85 10 6 Weigh In Motion With Lift Control Kit Driver Card 85 10 7 Centerline Locating TOO nes mass hatin ns ne nas 87 11 0 FORK SCALE FINAL INSPECTION CHECKLIST eee 89 11 1 Front Fork Scale Assembly sssssssnnnnneeessesnennrrrresesrennrnnnnrnserrrrnnnnnnnnneeennne 89 11 2 Electronics EE 89 11 2 1 Manual Method Weigh Systems eeceeeeeeeeeeeeeeeeeeeeeeeeeeeeees 90 11 2 2 Static Weigh In Motion Method Weigh Systems 90 11 2 3 Weigh In Motion With Lift Control Method Weigh Systems 91 April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Table Of Contents 4 1158 DOCUMEN NON icicocscocavastukesractnnctiastuueieacinncivaniaucieqciacieacseacieacinncinaacieetnnels 91 12 0 FORK SCALE MAINTENANCE 0 0 0 0 0 93 12 1 Front Fork Scale Assembly 93 12 2 Electronics Assembly c cecceeeeeeeeeeeeeeeee
69. een the forks and the cross tube An optional method of fork alignment is to tack weld an appropriate length refer to Figure 5 C of bar stock steel to the Front Fork Scale tips to eliminate any possible movement during bracket tack welding refer to Figure 5 F April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Install Fork Mounting Clamps On Existing Cross Tube 26 Front Fork Scale Mounting Clamp Spacer Mounting Clamp Front Fork Scale Figure 5 F 5 5 3 Tack weld the Mounting Clamps to the cross tube refer to Figure 5 G Note DO NOT tack the Front Fork Scale to the mounting clamp Note The tack welds must be sufficient so the Mounting Clamps do not pull out of position during the final welding stage If the Mounting Clamps do not remain square the forks will not mount correctly It is recommended to use a weld jig Caution Arcing on the body of the Front Fork Scale may seriously damage its structural integrity and must NOT be installed if this occurs This also voids manufacturer s warranty It is OK to tack weld installation jigs to the fork tip 1 2 Length Tack Weld 4 Places Per Fork Top View Figure 5 G April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Install Fork Mounting Clamps On Existing Cross Tube 27 5 5 4 Remove the Front Fork Scales from the mounting clamps and completely we
70. een the proximity sensor and the proximity trigger must remain 1 4 If the gap is greater than 1 4 the sensor may not trigger properly 9 When the position is finalized tighten the 2 4 20 fasteners and tack weld the 2 mounting plates together so they will not slip April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Weigh In Motion With Lift Control Kit Installation 73 10 2 HYDRAULIC FLOW CONTROL VALVE INSTALLATION AND CONFIGURATION Install the Vulcan hydraulic control valve between the main valve manifold and the T connection as shown in Figure 10 G The valve must be installed where it can affect both arm hydraulic cylinders It does not matter whether the arm cylinders are single acting or double acting The valve will work for both types On double acting cylinders the valve must be installed in the return line when the cylinder is extending Arm hydraulic actuator Power and or return line Vulcan flow control valve T connection Arm hydraulic actuator Main S A E 16 Port valve manifold Mounting holes 2 Places Flow Hydraulic Flow S A E 16 Port S A E 16 Port BE Lg direction p valve E direction Vulcan Flow direction of oil flow control when lifting bin to dump valve diagram Figure 10 G Use the two holes in the valve manifold to mount the unit to the truck body structure It may be helpful to bolt the v
71. em is working in the field fine tuning the calibration may be desired to obtain a higher accuracy This can only be done after the system is working in the field The V600 Fork Scale User Manual has complete details on the calibration methods 10 6 WEIGH IN MOTION WITH LIFT CONTROL KIT DRIVER CARD The following page has a copy of the driver card used for the Weigh In Motion with Lift Control Kit This driver card also comes packaged with the Weigh In Motion with Lift Control Kit P N A02 If driver card cannot be found copy this page fold in half and laminate Put this card in the truck for the driver to reference as needed This driver card is also available from the Vulcan website at www vulcanscales com April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Weigh In Motion With Lift Control Kit Installation 86 DAILY DRIVER OPERATING GUIDE FRONT FORK WEIGH IN MOTION WITH LIFT CONTROL GUIDELINES TO MAXIMIZE PICKUP WEIGHT ACCURACY e Just before bin engagement with forks in level position if the meter reads more than 50 Ib press the TARE ZERO button to rezero e Lt the full bin off of the ground smoothly and maintain a smooth motion through the 6 weigh zone Lower the empty bin smoothly through the 6 weigh zone e While lifting the bin keep the forks level in the weigh zone until a single or double beep is emitted by the meter e Set the bin down gently on the ground e f m
72. er display and Wait on the lower display Press and hold the PWR MENU button until the meter powers off Once the power is off press the PWR MENU button again to power the meter back up After the meter has completed its startup routine the meter will display READY TO LIFT April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Static Weigh In Motion Control Kit Installation 62 9 3 4 Using the Static System as Weigh In Motion The Static System A04 can be used with the Static meter software or the Weigh In Motion software The user can select either software method If the static scale system is used with the Weigh In Motion software the driver must be careful to make a smooth lift in the weigh zone There is no hydraulic valve to automatically smooth out the arm motion in the weigh zone The hydraulic valve only comes with the Weigh In Motion kit A02 How the Static software system works The driver controls the fork speed to allow a weight to be taken If a successful up or down weight capture is made it is acknowledged by two audible beeps from the meter If the motion of the bin while lifting in the weigh zone is too rough uncontrolled or generally not smooth enough the meter will not capture a weight and will display an error code This condition is acknowledged by multiple audible beeps from the meter when the bin exits the weigh zone Thi
73. erouted exhaust pipe to the center of cab guard d e A New perforation Ke Figure 6 F Figure 6 G View under the cab guard showing Cab guard modification so the exhaust gases the rerouted exhaust pipe are exiting in the center of the cab guard between the forks In this example a welding torch was used to create a perforated exhaust exit in the cab guard April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Install Fork Assembly On Cross Tube 34 The existing exhaust pipe is cut below the cab guard Another section of exhaust pipe is welded to the remaining exhaust system such that the exhaust exits through the cab guard toward the center of the truck between the two forks A new hole is cut in the cab guard to allow the exhaust to exit This new hole must have a screen or use perforated steel to prevent debris from going into it The new exhaust port must be sufficiently large so no backpressure is created on the exhaust system Modifications are only required to those trucks that have exhaust blowing directly in the path of the fork motion April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Electronics Installation 35 7 0 FORK SCALE ELECTRONICS INSTALLATION 7 1 ELECTRONICS SYSTEM OVERVIEW Hydraulic Valve Weigh In Motion A02 Weight Capture Button B Front Fork Scal ront Fork Sc
74. ey are finger tight plus an additional 1 8 of a turn more with channel lock pliers April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Troubleshooting And Repair 127 13 9 5 HOW TO REPAIR A VULCODER CONNECTOR How to Repair a Vulcoder Connector If a Vulcoder connector is damaged it can be replaced without replacing the entire Vulcoder Purchase a Vulcoder Connector Pigtail Replacement Kit form Vulcan Scales p n 53 20130 001 This kit includes a Vulcoder connector completely sealed with the black signal cable A Vulcoder black cable splice kit P N 59 20370 001 is also included as an item in this kit Splice cable Es 9 Replacement E Vulcoder Connector This new connector assembly is then spliced onto the existing Vulcoder s black cable by following the How to Repair the Black Vulcoder Cable section 13 9 1 A bulletin also comes with the cable replacement kit detailing how to properly make the splice April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Troubleshooting And Repair 128 If you need additional assistance parts or service give us a call at VULCAN CUSTOMER SERVICE 1 800 237 0022 HOURS 7 30 a m 5 00 p m PACIFIC TIME April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Troubleshooting And Repair 129
75. f a proximity switch to tell the meter that a bin has been lifted A hydraulic valve is installed in the lift arms hydraulic line which softens the movement of the arms There is no need for the driver to do anything other than a normal lift The V600 Meter will capture the up and down weights automatically while the bin is in motion Both the up and down weights are captured and the net weight is calculated and displayed This is a completely automated system When a successful up or down weight capture is made it is acknowledged by two audible beeps or a single beep from the meter If the motion of the bin while lifting in the weigh zone is too rough uncontrolled or generally not smooth enough the meter will acknowledge this condition by multiple audible beeps when the bin exits the weigh zone In this case the meter will still capture a weight but the weight captured may not be as accurate as it could be if lifted smoothly This same bin can be re entered into the weigh zone to get a potentially more accurate weight reading The Weigh In Motion with Lift Control motion system will always capture a weight value for every customer no matter what the lifting conditions are in the weigh zone April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Electronics Installation 37 The A02 kit comes with the proximity switch hydraulic valve and all required parts 7 3 MOUNT MET
76. feature is activated and the Configure System Setup Calibrate Sequence Channels and System Test menus are not accessible Refer to section 13 1 to unlock the system E Press the ENTER button to select the SEQUENCE CHANLS menu option Press the ENTER button to enter the DISPLAY SEQUENCE menu option The meter will display the truck Vulcoder as a rear lt R gt designator Press and hold the ENTER button for two seconds to erase the Vulcoder The meter will display lt gt This shows that the Vulcoder has been erased Press and hold the ENTER button again to erase the meter The meter will display all dashes on the upper display and Wait on the lower display Press and hold the PWR MENU button until the meter powers off Once the power is off press the PWR MENU button again to power the meter back up TP PP After the meter has completed its startup routine the meter will display READY TO LIFT The meter is now set up in the BASIC mode using the manual method of weighing April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Manual Control Kit Installation 48 8 2 3 VERIFY FORK OPERATION Verify the forks are working by either sitting or standing on each fork The scales should read the amount of weight on each fork Level container in weighing zone o ground Wain zone bes VN E LL Figure 8 D 1 Lift a bin off th
77. here is no button to push to record weights Instead when the driver lifts and levels a full bin the meter detects when the weight is stable takes a reading and produces an audible signal letting the driver know a stable weight has been captured and to continue the lift When returning the empty bin the driver levels the bin before placing it on the ground The meter will once again signal that a stable empty weight has been captured and the driver can set the bin on the ground Both the up and down weights are automatically captured and the net weight is calculated and displayed If the motion of the bin while lifting in the weigh zone is too rough uncontrolled or generally not smooth enough the meter will not capture a weight and will display an error code This condition is acknowledged by multiple audible beeps from the meter when the bin exits the weigh zone This same bin can be re entered into the weigh zone to get a successful weight capture If the bin does not re enter the weigh zone no weight will be recorded for that customer and an error message will be stored in meter memory for that customer The static system will not capture a weight value for a customer if the lift conditions are not steady in the weigh zone The A04 kit comes with the proximity switch and all required parts 7 2 3 THE WEIGH IN MOTION WITH LIFT CONTROL METHOD P N A02 The Weigh In Motion with Lift Control Method requires the installation o
78. ion 63 9 8 5 MEIER SETUP FOR STATIC OR WEIGH IN MOTION With the meter already on and displaying Ready to lift RB Press the PWR MENU button to enter the Program menu m Press the CYCLE button until CONFIGURE SYSTEM is displayed E Press the ENTER button to select the CONFIGURE SYSTEM menu option E Press the CYCLE button until CONF METHOD is displayed E Press the ENTER button to select the CONF METHOD menu option D OR Press either the UP or DOWN ARROW buttons until METHOD STATIC or MOTION is displayed You can choose either method see section 9 3 4 April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Static Weigh In Motion Control Kit Installation 64 E Press the ENTER button to store the method 9 3 6 VERIFY FORK OPERATION Verify the forks are working by either sitting or standing on the each fork The scales should read the amount of weight on each fork 1 With a bin on the forks empty or full run the lift arms up and down and verify the meter gives the two beep signal for weight capture for both up and down directions If not e Verify the proximity switch illuminates its yellow light indicating the detection of the weigh zone e Verify the weigh position of the proximity switch is triggered up to 6 off the ground 2 Lift a bin with weight is preferred but empty is OK through the up and down cycle 5
79. k Scale is rotated in the full up and full down position section 7 5 5 Figure 7 F April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Final Inspection Checklist 90 E Cable from Vulcoder running up the arm is completely protected in steel conduit section 7 5 5 Figure 7 F L Meter is powered from the battery Manual System section 8 1 2 Static System 9 2 3 Weigh In Motion System section 10 3 4 E Orange VSL Vulcoder cable is routed through the rear hinge point of body and through hinge point of front tilt cab use a grommet to protect cable from abrasion section 7 5 5 O Black cable routed from the VSL Vulcoder to the Front Fork Scale on the opposite side of the truck is protected section 7 5 Figure 7 E L If the vehicle has a positive ground electrical system the meter chassis mounting bracket and mounting fasteners must be electrically isolated from the vehicle chassis Manual System section 8 1 2 Static System 9 2 3 Weigh In Motion System section 10 3 4 L Power cable has the fused ends near the battery not by the meter in the cab Manual System section 8 1 2 Static System 9 2 3 Weigh In Motion System section 10 3 4 Meter mounting screws are secure and rear meter connections are in place L V600 meter terminal connections are protected from clipboard use and other in cab equipment L V600 Meter is set in BASIC mode section
80. k without factory forks installed consult body manufacturer for the fork hydraulic extension dimension that is ideal for their truck refer forward to Figure 5 B Diameter Round tube Square tube Figure 5 A Cross Tube measurement April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Install Fork Mounting Clamps On Existing Cross Tube 20 5 2 MEASURE EXISTING CONFIGURATION 5 2 1 Lower arms so the cross tube is waist level Use a level to position the fork ona horizontal plane Measure how far the fork hydraulic cylinder is extended refer to Figure 5 B Record this dimension A This dimension will be used in aligning the fork scale Top Surface of Fork Horizontal Plane Verified with a level Figure 5 B Measuring Fork Cylinder Extension A April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Install Fork Mounting Clamps On Existing Cross Tube 21 5 2 2 Measure the internal dimensions between the two existing forks as shown in Figure 5 C Record each dimension B C D E Note Front fork thickness dimensions vary from manufacturer to manufacturer The Vulcan Front Fork Scale is 1 1 2 thick Be sure to measure the inside dimension of the forks to ensure the forks will fit in all of the container lifting sleeves Existing Fork Cross Tube Existing Fork Figure 5 C Measuring Internal Fork Dimensions B
81. lcoder The meter will display lt gt This shows that the Vulcoder has been erased Press and hold the ENTER button again to erase the meter The meter will display all dashes on the upper display and Wait on the lower display Press and hold the PWR MENU button until the meter powers off Once the power is off press the PWR MENU button again to power the meter back up TPE After the meter has completed its start up routine the meter will display READY TO LIFT 10 4 4 METER SETUP FOR WEIGH IN MOTION ES Press the PWR MENU button to enter the Program menu E Press the CYCLE button until CONFIGURE SYSTEM is displayed RW Press the ENTER button to select the CONFIGURE SYSTEM menu option April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Weigh In Motion With Lift Control Kit Installation 84 m Press the CYCLE button until CONF METHOD is displayed E Press the ENTER button to select the CONF METHOD menu option D OR D Press either the UP or DOWN ARROW buttons until METHOD MOTION is displayed E Press the ENTER button to store the method and return to the CONF METHOD menu option EA Press the PWR MENU button twice to exit and the meter will return to its operating mode The scale system is now ready to weigh 10 4 5 VERIFY FORK OPERATION Verify the forks are working by either sitting or standing on the each fork
82. ld the Mounting Clamps to the cross tube using a minimum three pass 3 8 fillet weld refer to Figures 5 H and 5 l Note Tape up fastener holes in the mounting clamps to prevent weld spatter from entering the fastener holes Lg Weld Leg qh Z Weld Leg Figure 5 H Must have continuous weld beads through this this area 3 Pass Weld No weld starts or stops Must have continuous weld on top and bottom Weld bead must be If necessary deposited continuously Sak SL on the top and bottom here ONLY Top View of mounting clamps Start and stop weld bead on sides as required Figure 5 I April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Install Fork Mounting Clamps On Existing Cross Tube 28 5 5 5 Trim the original coupler support length to fit between the mounting clamp and coupler plate or make a new coupler support Weld coupler supports in place refer to Figure 5 J Both Ends see SN SS Sch ech RS Vv e K d LE fe D Se Figure 5 J April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Install Fork Assembly On Cross Tube 29 6 0 INSTALL FORK ASSEMBLY ON CROSS TUBE 6 1 INSTALL FORKS TO MOUNTING CLAMPS WITH WASHER PLATE Re attach the Front Fork Scales to the mounting clamps using the supplied 1 14 hex cap screws and hardened steel washer plate Tor
83. lem you may encounter with your Vulcan fork scales Leakage Test Tare Test Resistance Test 13 6 1 LEAKAGE TEST PROCEDURE Required Equipment Digital Multi Meter With Conductivity Scale Isopropyl Alcohol Cotton Swabs Hair Dryer Optional Equipment Vulcan Check Out Box The Leakage Test detects the presence of moisture that could cause erratic meter readings The way to measure leakage is to use a digital multi meter that has a conductivity scale Electrical isolation is measured between any pin and an unpainted clean surface on the fork scale or the connector body Electrical isolation must not exceed 2 0 nS nano siemens or be less than 500 Meg Ohms Nano siemens and Meg Ohms are two different units of measure for evaluating electrical leakage Refer to Figure 13 B for the Leakage Test equipment setup For proper operation the power and signal leads from the fork scale must have a very high resistance to the fork scale body An electrical path between the wires and the body would indicate moisture in the fork or shorting to the body This would result in erratic fluctuating or even out of range weight displays If the fork scale fails electrical isolation is greater than 2 0 nS or is less that 500 Meg Ohms check the inside of the fork scale connector with a dry cotton swab to make sure it is clean and dry If not clean with isopropyl alcohol dry with a hair dryer and check the electrical isolation again If the fork scale
84. lief and cut the VSL Vulcoder cable meter power cable and Weight Capture button cable to ideal lengths Unplug the terminal blocks from the back of the meter strip the wires and connect to the terminal blocks refer to Figure 8 A Be careful that stray wires DO NOT contact adjacent terminals Twist conductor strands together refer to Figure 8 B Do not plug the terminal block into the meter at this time 44 Twist Tightly Do Not Solder Figure 8 B 8 1 2 CONNECTION TO TRUCK BATTERY Disassemble the positive fuse holder red wire Apply grease to the positive connector at the battery post to inhibit corrosion Crimp ringed terminals to the power leads Connect fused power leads directly to battery posts for best operation Power must be connected directly to battery Maximum power is 29 Vdc Note The Vulcan V600 meter is configured to be used in a 12 Vdc system using 2 amp fast blow fuses in both power leads Do not connect the power cable to a power source activated by the key switch Remember Turn meter off while making any wire connections WARNING If installing the meter in a vehicle with a positive ground electrical system the meter chassis mounting bracket and mounting fasteners MUST be electrically isolated from the vehicle chassis April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Manual Control Kit Installation 8 2 METER SETUP AND SYSTEM TEST 8 2
85. mounting bolts 7 8 14 Grade 8 hex cap screws 700 ft lb L Inspect rubber bumpers for excessive wear E Verify the connector guard Vulcoder guard and cross tube cable guards are intact and undamaged L Check for signs of overloading in the cross tube bell crank area Ki Check and repaint or undercoat areas that show excessive corrosion and rust L Verify there is adequate clearance between the cross tube fork scale assembly and cab guard during a lift cycle C Torque striping bolts It is recommended to apply torque stripes to bolt heads to make sure they remain properly torqued To apply a torque stripe Use a durable brightly colored paint Paint a stripe crossing the head of the fastener continuing down the fastened structure as shown in Figure 12 A April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Maintenance 94 Figure 12 A Painting a Torque Stripe Verify the Driver Lockout Password feature is activated to prevent the driver from modifying scale system setup parameters 12 2 ELECTRONICS ASSEMBLY L Check the orange cable strain relief loop at the cross tube arm junction to make sure it s not getting damaged L Verify V600 Meter in cab cable routing is strain relieved and secure L Verify cable running up the arm is undamaged and protected in conduit and the conduit is securely in place L Verify orange cable to the meter is routed through the fron
86. n 13 6 2 4 Perform the Leakage Test section 13 6 1 5 Check the fork scales Check by disconnecting one fork scale at a time When the faulty fork scale has been disconnected the meter will read a number instead of the error code 13 7 7 Err 07 Indicates a new VSL Vulcoder has been detected Possible Causes 1 Line noise 2 Faulty Vulcoder April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Troubleshooting And Repair 113 What to Do 1 Vulcoder needs to be manually re sequenced section 13 3 2 Turn the meter off and then back on to cycle power in the system 3 VSL Vulcoder is damaged Replace VSL Vulcoder 13 7 8 Err 08 Err 09 Indicates there is electrical noise in the system Possible Causes 1 Radio frequency interference from other equipment or faulty electrical connections What to Do 1 Re sequence the VSL Vulcoder section 13 3 2 See electronics installation section for proper installation procedure Manual system section 8 0 Static system section 9 0 Weigh In Motion system section 10 0 Check integrity of electrical connections 13 7 9 Err 10 Communication error between the meter and the VSL Vulcoder The VSL Vulcoder is in a locked state Possible Causes 1 Faulty VSL Vulcoder What to Do 1 VSL Comm test from the V600 Meter Test Menu section 13 10 4 2 Replace VSL Vulcoder 13 7 10 Err 11 The meter w
87. n the proximity sensor and the proximity trigger must remain 1 4 If the gap is greater than 1 4 the sensor may not trigger properly 8 When the position is finalized tighten the two 14 20 fasteners and tack weld the two mounting plates together so they will not slip April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Static Weigh In Motion Control Kit Installation 55 9 2 ELECTRICAL SCHEMATICS DIAGRAMS 9 2 1 STATIC WEIGH IN MOTION SYSTEM ELECTRICAL SCHEMATIC Yellow light showing that trigger has been detected Mounting bracket Torque tube that arms rotate on behind truck cab Rotation direction when lifting bin April 2008 Proximity trigger location with cross tube six feet Use clamp and fasteners included with enclosure to secure all cables in Junction Box Lid not shown Relay location shown OOOO O OO Stress Tek orange cable Stress Tek grey cable fused Proximity SCH Black Red Battery cut off switch shown off Truck battery NOTE above ground Use the white wire from the Stress Tek orange cable to hold other wires in place as shown Accessory port 8 pin connector on back of meter Cab mounted Vulcan V600 Meter Stress Tek grey cable fused
88. onnections to the battery 2 Battery is low under 10 5 Volts 3 Damaged power or ground cable 4 Faulty Meter April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Troubleshooting And Repair 117 What to Do 1 Using a multi meter check the power at the back of the meter When the meter is turned on and off the power should not change more than 1 2 Volt Turn off the meter either by the key or truck battery switch for a few seconds and then turn on again If the meter still does not work proceed to step 2 2 Check the fuses for both negative and positive leads Use 2 amp fast blow fuses for 12 Vdc applications and 1 amp fast blow fuses for 24 Vdc applications 3 Check the power supply wires are attached correctly at the 12 or 24 Volt power source and to the green connector at the back of the meter Check the battery connections for corrosion 4 If a spare meter is available the quickest and easiest next step is to exchange the meter If the new meter works try the old meter again If the old meter now works the problem was likely the meter s internal circuit breaker If both the old meter and the new meter do not work the problem is most likely in the power source battery meter power cable or fuses If the new meter works but the old one doesn t the old meter is faulty If you do not have a spare meter disconnect then reconnect the green power plug on the
89. ote Spray undercoating only when Front Fork Scales are fully assembled to the Mounting Clamps and are connected to the electronics April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Install Fork Assembly On Cross Tube 6 4 CHECK CAB GUARD CLEARANCE With the fork scales completely assembled on the cross tube lift the cross tube fork scale assembly and check the clearance between the cab guard and the fork scales refer to Figure 6 C There can be no interference here The cab guard must be modified as required to allow clearance Fork scale Cab guard cross tube assembly aN Q Check for adequate clearance Figure 6 C April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Install Fork Assembly On Cross Tube 33 6 5 CHECK EXHAUST PORT CLEARANCE Check to verify the exhaust is not blowing on the forks where they attach to the cross tube Some trucks have exhaust exit ports on top of the cab guard that blow onto one of the forks when it is in the up position while the truck is being driven Prolonged exposure to hot exhaust gases will damage the fork scale Below figures 6 D through 6 G illustrate one possible modification to redirect the exhaust to avoid exposure to hot exhaust Figure 6 D Figure 6 E Existing condition of exhaust gases View under the cab guard showing the blowing back directly on the fork r
90. over assembly Push the connector back in the housing and secure in place with four mounting screws Apply silicone bead all around connector where it meets the steel bulkhead face e When completely dry put red cap over the connector to protect threads and spray with a rubberized undercoating 8M Universal Rubberized Undercoating 3M p n 8883 April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Troubleshooting And Repair 126 13 9 4 FORK SCALE O RING REPLACEMENT Fork Scale O ring Replacement O ring kit p n 59 20223 001 The O ring is designed to keep the connectors free of moisture O rings shall be replaced anytime the connector is removed for servicing or troubleshooting O RING INSTALLATION ON FORK SCALE CONNECTORS Make sure the old O ring is removed completely Clean both connector ends as required Use cotton swabs and isopropyl alcohol Be sure to dry thoroughly with a hair dryer DO NOT OVERHEAT Slip one O ring over Vulcoder connector barrel see figure below and push down 1 4 to 1 2 O ring will seat itself when connector parts are mated Note There are two types of O rings used a flat ring style and a standard O ring Never use more than one O ring at a time in any connector no matter which type is used Load Cell Connector Vulcoder Connector O Ring RANAN Note Surface must be clean For assembly of connectors make sure th
91. power cable and junction box cables to ideal lengths Unplug the terminal blocks from the back of the meter strip the wires and connect to the terminal blocks refer to Figure 9 H Be careful that stray wires DO NOT contact adjacent terminals Twist conductor strands together refer to Figure 9 l Do not plug the terminal block into the meter at this time April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Static Weigh In Motion Control Kit Installation 57 K 1 4 Twist Tightly Do Not Solder Figure 9 I 9 2 3 CONNECTION TO TRUCK BATTERY Disassemble the positive fuse holder red wire Apply grease to the positive connector at the battery post to inhibit corrosion Crimp ringed terminals to the power leads Connect fused power leads directly to battery posts for best operation Power must be connected directly to battery Maximum power is 29 Vdc Note The Vulcan V600 meter is configured to be used in a 12 Vde system using 2 amp fast blow fuses in both leads Do not connect the power cable to a power source activated by the key switch Remember Turn meter off while making any wire connections WARNING If installing the meter in a vehicle with a positive ground electrical system the meter chassis mounting bracket and mounting fasteners MUST be electrically isolated from the vehicle chassis April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS T
92. que the 1 14 hex cap screws to 1000 ft lb Note Ensure that the Mounting Clamp surfaces are clean and smooth before fastening the fork to it Use Never Seize or equivalent thread lubricant when installing all mounting cap screws refer to Figure 6 A DO NOT use the Never Seize or any other grease on the load cell connectors Note If bolts are not torqued to proper value scale inaccuracies may result Torque stripes are recommended 6 2 ASSEMBLE BUMPER PLATE AND BUMPER 6 2 1 Assemble the bumper plate with the 7 8 14 hex cap screws provided Remember that two of these cap screws were used to package the fork scale to the shipping pallet Use Never Seize or equivalent thread lubricant when installing all mounting fasteners Torque the bumper plate hex cap screws to 700 ft lb refer to Figure 6 A Install the rubber bumpers using the four 2 bolts washers and locking flange nuts Check all fork scale mounting fastener torque values after the first week of operation and periodically using a normal maintenance schedule After torquing the 1 cap screws weld each of the hardened steel washer plates to the cross tube using a 3 16 fillet weld When installing the Vulcoder in section 7 4 2 one of these bumpers must be removed to install a Vulcoder guard April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Install Fork Assembly On Cross Tube 30 Fillet Weld Harden
93. re 2 G Universal Mounting Kit Through Hole Mounting Kit Only H35 April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Unpacking Forks 15 3 0 UNPACKING FORKS 3 1 UNPACKING NOTES When unpacking the Front Fork Scales from the shipping pallet take special note for the following parts 3 1 1 Save the two 7 8 14 bolts that hold the Front Fork Scale to the pallet These will be used later to mount the bumper plate to the Front Fork Scale One more 7 8 14 bolt is packaged with the other fasteners 3 1 2 The 7 8 14 nuts from this packaging assembly are not used and are to be discarded 3 2 HOW TO IDENTIFY AND USE THE TWO TYPES OF 1 14 NUTS SUPPLIED ZA TI FX CO f WE We e Lt 20 GRADE 2 PLAIN NUT NO FINISH GREY COLOR MAXIMUM TORQUE 250 lb ft Used only for initial assembly of forks and mounting clamps for alignment and welding April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 STRESS TEK INC 2008 GRADE G SAE GRADE 8 LOCKING FLANGE NUT ZINC PLATED SILVER COLOR SPECIFIED TORQUE 1000 lb ft Used only for final assembly of forks after mounting clamps are completely welded USE OF TORQUE MULTIPLIER IS REQUIRED Doc 44 10112 001 Rev Unpacking Forks 16 April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Install Scale Ready Cross Tube 17 4 0 INSTALL SCALE READY CROSS TUBE RECOMMEN
94. ront Fork Scale and VSL Vulcoders to make sure they are clean and dry Important Do not get moisture contact cleaner or any other substance inside the connectors Do not grease or lubricate inside the Front Fork Scale connector or VSL Vulcoder connector These components are highly sensitive to foreign substances and inaccurate readings will occur if these components are contaminated Your manufacturer s warranty does not cover the failure of VULCAN components due to contamination use of grease or other conductive substance in either of these component connectors Attach the black VSL Vulcoder cable connectors to the bulkhead connectors on the Front Fork Scales Make sure they are finger tight plus an additional 1 8 turn with channel lock pliers The additional tightening is necessary to correctly compress the O ring This prevents scale errors which can occur from moisture entering through the connector Caution Do not over tighten the connectors as this can damage them Slide the heavy protective jacket up against the connector so the black cable has maximum protection Tape in place Route the 2 wire orange VSL Vulcoder cable from the Front Fork Scale to the arm allowing enough slack for cross tube rotation refer to Figure 7 F Route orange cable by following the arm hydraulic lines to the arm pivot point For extra protection we recommend welding a steel tube to the lift arm and routing the orange cable through it A tube 5 8 with a 1
95. s same bin can be re entered into the weigh zone to get a successful weight capture If the bin does not re enter the weigh zone no weight will be recorded for that customer and an error message will be stored in meter memory for that customer The Static system will not capture a weight value for a customer if the lift conditions are to uncontrolled in the weigh zone How the Weigh In Motion software system works There is no need for the driver to do anything other than a normal lift The V600 Meter will capture the up and down weights automatically while the bin is in motion If a successful up or down weight capture is made it is acknowledged by two audible beeps or a single beep from the meter If the motion of the bin while lifting in the weigh zone is too rough uncontrolled or generally not smooth enough the meter will acknowledge this condition by multiple audible beeps when the bin exits the weigh zone In this case the meter will still capture a weight but the weight captured may not be as accurate as it could be if lifted smoothly This same bin can be re entered into the weigh zone to get a potentially more accurate weight capture The Motion system will always capture a weight value for every customer no matter what the lifting conditions are in the weigh zone April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Static Weigh In Motion Control Kit Installat
96. s the CYCLE button to advance to the next SYSTEM TEST menu item 13 10 38 TEST MEMORY TEST MEMORY performs a test on the internal memory storage on the V600 Meter When the test is finished the meter will display MEMORY TEST OK if each memory location passes the test otherwise an ERROR will be displayed April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Troubleshooting And Repair 132 Procedure To Test The Memory Enter the SYSTEM TEST menu section 13 10 og Press the CYCLE button until TEST MEMORY is displayed E Press the ENTER button to begin the selected TEST MEMORY test Press the TARE ZERO button to exit and return to the TEST MEMORY menu option E Press the CYCLE button to advance to the next SYSTEM TEST menu item 13 10 4 TEST VSL COMM TEST VSL COMM the communications test can be used to determine if the electronics are communicating properly Procedure To Test The VSL COMM Enter the SYSTEM TEST menu section 13 10 E Press the CYCLE button until TEST VSL COMM is displayed April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Troubleshooting And Repair 133 Press the ENTER button to begin the selected TEST VSL COMM communications test The smaller alpha numeric display will indicate which channel is currently monitored RW Press the CYCLE button to advance to
97. t hinge point of the cab through a grommet and is not damaged 12 3 MANUAL WEIGH SYSTEM E Verify Weight Capture button is in a desirable location and is strain relieved L Verify Weight Capture button functions properly and a weight is obtained when used 12 4 STATIC WEIGH IN MOTION SYSTEM E Verify proximity switch triggers in the proper location L Verify junction box wires are routed through the body s tipping hinge point and are undamaged L Verify proximity switch is mechanically protected inside the protective mounting bracket nut L Verify system measures a weight when a bin is dumped April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Maintenance 95 12 5 WEIGH IN MOTION WITH LIFT CONTROL SYSTEM LJ Verify proximity switch triggers in the proper location L Verify junction box wires are routed through the body s tipping hinge point EN Verify proximity switch is mechanically protected inside the protective mounting bracket nut Ei Verify hydraulic valve engages and disengages only in the trigger area determined by the proximity switch and the arms move smoothly through this area L Verify system measures a weight when a bin is dumped If you need additional assistance parts or service give us a call at 1 800 237 0022 HOURS 7 30 a m 5 00 p m PACIFIC TIME April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS
98. t to Do 1 See section 18 1 for setting the Driver Lockout Password feature or call Vulcan Scales at 1 800 237 0022 It is required to be unlocked to change the Cal and Tare numbers 2 Make sure the Vulcoder is connected to both fork scales 3 Unplug the green connector at the back of the meter for a few seconds re plug it in and try to enter the Tare or Cal numbers again 4 Possible faulty meter buttons Run the meter keypad test section 13 10 1 5 Faulty meter Replace meter 13 8 8 CONDITION No indicator display or function lights Possible Causes Power switch turned off Power to the meter has been disconnected Bad meter cable connections to the battery Battery is low under 10 5 Volts A fuse is blown in the power or ground cable Faulty power switch Faulty meter Reversed polarity Oy Ole eg What to Do 1 Check the power to the meter When the meter is turned on and off the power should not change more than 1 2 Volt Turn off the meter either by the key or truck battery switch for a few seconds and then turn on again If the meter still does not work proceed to step 2 2 Check the fuses for both negative and positive leads Use 2 amp fast blow fuses for 12 Vdc applications and 1 amp fast blow fuses for 24 Vdc applications April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Troubleshooting And Repair 119 3 Check the power supply wires
99. that hold the connector in place e Gently pull the connector away from the housing There is 2 3 inches of extra wire inside to allow for connector removal TS a nae Sa eee Fork connector Tae P block bulkhead Remove screws and gently pull out e Trim away the sealant from the 4 pins that are soldered into the connector Use tweezers as required Keep the small circuit board and any resistors intact as they are e Once cleaned use a solder gun to remove the pins from the connector cups Keep track of what pin came from what cup The cups are identified as A B C D Key D A Connector Power Power cups Black Red C B Signal Signal White Green Connector Front Connector Back e Clean all four pins Apply new heat shrink if the existing heat shrink was damaged 4 Cut heat shrink to size as required Fill each of the connector solder cups with solder Solder each connection wire into the correct cup in the new connector e Coat all the new solder joints connector cups and connector back area with silicone sealant April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Troubleshooting And Repair 125 e Clean steel bulkhead face where connector gasket will seat e Remove enough sealant from inside the bulkhead housing so the assembly fits back in easily Too much insertion force will bend the pins e Apply anew gasket by stretching
100. the height tapers from 5 1 2 at the bumper to 2 1 2 towards the tip The height at the end of the tip is 4 Cross tube mounting clamps are shown in the following pictures with dashed lines For 10 yard bins and other very large containers make sure the fork scale configuration will allow the bin contents to be dumped into the hopper without overshooting or undershooting Configuration adjustments may have to be made to correct any problems that may develop from dumping such large containers Spacers can be added to the fork scale bumper blocks as required 3 1 2 ROUND TUBE Figure 2 B 3 1 2 Round Tube Mounting Kit Through Hole Mounting Kit H31 Tapped Hole Mounting Kit H41 Right Left April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 System Layout And Tools Required 4 ROUND TUBE Figure 2 C 4 Round Tube Mounting Kit Tapped Hole Mounting Kit H42 Right Left 4 SQUARE TUBE Figure 2 D 4 Square Tube Mounting Kit Through Hole Mounting Kit H36 4 1 2 ROUND TUBE Figure 2 E 4 1 2 Round Tube Mounting Kit Tapped Hole Mounting Kit H44 Right Left April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 System Layout And Tools Required Figure 2 F 5 Square Tube Mounting Kit Through Hole Mounting Kit H53 7 7 8 UNIVERSAL I f MOUNTING 12 3 8 13 1 16 BLOCK Figu
101. times without dumping and check the repeatability of the meter s computed readings Note each up and down reading the meter computes All up readings should be close to the same weight within 50 Ib and all down readings should be close to the same weight within 50 Ib although they may not be equal to the exact pound or kilogram 3 Activate the Driver Lockout Password feature Vulcan Scales recommends the activation of this password feature to prohibit the driver from changing the scale system set up parameters See section 13 1 to activate this feature 9 4 CALIBRATION The Front Fork Scale comes calibrated from the factory There is no need for further calibration by the installer Once the system is working in the field fine tuning the calibration may be desired to obtain a higher accuracy This can only be done after the system is working in the field The V600 Fork Scale User Manual has complete details on the calibration methods 9 5 STATIC WEIGH IN MOTION CONTROL KIT DRIVER CARD The following page has a copy of the driver card used for the Static Weigh In Motion Control Kit This driver card also comes packaged with the Static Weigh In Motion control kit P N A04 If driver card cannot be found copy this page fold in half and laminate Put this card in the truck for the driver to reference as needed This driver card is also available on the Vulcan website at www vulcanscales com April 2008 VULCAN ON BOARD SCALES 1 800
102. tocopied and used repeatedly as a checklist for inspecting installations 11 1 FRONT FORK SCALE ASSEMBLY L The Front Fork Scales are mounted parallel and square to the cross tube with correct spacing between them section 5 2 2 L The cross tubes structural integrity has not been diminished during the removal of fork components section 5 3 2 LJ Coupler support is installed to meet strength requirements of OEM design section 5 3 3 es There is a complete 3 pass weld wrapped around the Mounting Clamps section 5 5 4 E All mounting cap screws are torqued to specification section 6 1 and 6 2 1 L Rubber bumpers are installed section 6 2 L The Front Fork Scale and Mounting Clamp assembly is painted with a high quality paint section 6 3 L There is adequate clearance between cross tube cab guard and fork scale during lift cycle section 6 4 i System dumps bin in the hopper without overshooting or undershooting especially important for 10 yard bins section 2 7 Connector guard Vulcoder guard and cross tube cable guards are installed section 7 6 7 4 2 7 5 2 L Fork does not pass through truck exhaust when passing above the cab section 6 5 11 2 ELECTRONICS ASSEMBLY L The V600 Meter in the cab does not block mirrors or other in cab equipment Wires have adequate strain relief section 7 3 L There is adequate strain relief for the VSL Vulcoder orange cable between the cross tube and arm when the Front For
103. trip insulation back 1 2 from each wire and gently twist each exposed wire end Slip heat shrink tubing on each wire Twist wire leads together color to color Solder individual twisted wire Slide shrink tubing over soldered area and apply heat gp lt 0 CON UR oe RE Apply butyl rubber moisture barrier over each wire insulating the wires from each other 10 Wrap completed splice with electrical tape 11 Fold cable as shown to create strain relief and secure with tie wraps April 2008 VULCAN ON BOARD SCALES 1 800 237 0022 Doc 44 10112 001 Rev STRESS TEK INC 2008 Fork Scale Troubleshooting And Repair 122 13 9 2 HOW TO REPAIR THE ORANGE VSL CABLE How To Repair The Orange VSL Cable The orange VSL cable can be easily repaired with common wire repair tools and methods Crimp connecting and soldering are both acceptable processes Caution Make sure power to the system is turned off before beginning splicing procedure e Cut the orange cable at least 2 away form each side of the damaged section If cable is too short due to extensive damage common extension cord wire can be used to replace a section 2 e LE slk e Remove 2 of the outer jacket being careful not to cut individual wire insulation e Strip insulation back Le from each wire e f soldering put heat shrink over the wires e Solder or crimp splice the like color wires together e If heat shrink was used slide over soldere

FORK SCALE INSTALLATION MANUAL - Vulcan On

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