Mettler Toledo Heavy PO TE0002 WIRELESS FORKLIFT SCALE User Manual USERS MANUAL

Mettler-Toledo, Inc. Heavy Industrial PO WIRELESS FORKLIFT SCALE USERS MANUAL

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USERS MANUAL

A17082300A

(3/05).00

Preliminary

MCFA

Forklift Scale

Service Manual

No part of this manual may be reproduced or transmitted in any form or by any means, electronic or

mechanical, including photocopying and recording, for any purpose without the express written permission

of Mettler-Toledo, Inc.

U.S. Government Restricted Rights: This documentation is furnished with Restricted Rights.

METTLER TOLEDO

Publication Revision History

An overview of this manual’s revision history is compiled below.

Publication Name: MCFA Forklift Scale Service Manual

Publication Part Number: 17082300A Publication Date: 2/04

Part Number Date Revisions

17082300A(.01) 10/04 Revised load cell calibration procedure on pages 4-15, 7-1, and 7-2. Changed

caution message on page 2-2. Added caution message on page 2-8.

17082300A(.02) 12/04 Changed title on front cover to MCFA Forklift Scale Service Manual. Changed name

of product on page 1-1 to MCFA forklift scale. Added instructions to raise the forks

off the ground to power-up sequence on page 3-1.

A17082300A 3/05 Added information about Triplex version of scale: tools list and installation (Chapter

2), maintenance (Chapter 5), load cell replacement (Chapter 6), and parts list

(Chapter 8). Replaced screen shots in Chapters 3, 4, 6, and 7. Revised parts lists

and added parts for USB port and side shifter options (Chapter 8). Added new

Chapter 9 describing installation of USB port and side shifter options.

INTRODUCTION

This publication is provided solely as a guide for individuals who have received Technical Training in

servicing the METTLER TOLEDO product.

METTLER TOLEDO RESERVES THE RIGHT TO MAKE REFINEMENTS OR

CHANGES WITHOUT NOTICE.

Precautions

WARNING

PERMIT ONLY QUALIFIED PERSONNEL TO SERVICE THIS

EQUIPMENT. EXERCISE CARE WHEN MAKING CHECKS,

TESTS, AND ADJUSTMENTS THAT MUST BE MADE WITH

POWER ON. FAILING TO OBSERVE THESE PRECAUTIONS CAN

RESULT IN BODILY HARM.

READ this manual BEFORE

operating or servicing this

equipment.

FOLLOW these instructions

carefully.

SAVE this manual for future

reference.

DO NOT allow untrained

personnel to operate, clean,

inspect, maintain, service, or

tamper with this equipment.

ALWAYS DISCONNECT this

equipment from the power

source before cleaning or

performing maintenance.

CALL METTLER TOLEDO for parts,

information, and service.

WARNING

FOR CONTINUED PROTECTION AGAINST SHOCK HAZARD,

CONNECT TO PROPERLY GROUNDED OUTLET ONLY. DO NOT

REMOVE THE GROUND PRONG.

WARNING

DISCONNECT ALL POWER TO THIS UNIT BEFORE INSTALLING,

SERVICING, CLEANING, OR REMOVING THE FUSE. FAILURE TO

DO SO COULD RESULT IN BODILY HARM AND/OR PROPERTY

DAMAGE.

WARNING

BEFORE CONNECTING/DISCONNECTING ANY INTERNAL ELECTRONIC COMPONENTS OR

INTERCONNECTING WIRING BETWEEN ELECTRONIC EQUIPMENT, ALWAYS REMOVE

POWER AND WAIT AT LEAST 30 SECONDS. FAILURE TO OBSERVE THESE PRECAUTIONS

COULD RESULT IN BODILY HARM OR DAMAGE TO OR DESTRUCTION OF THE EQUIPMENT.

CAUTION

OBSERVE PRECAUTIONS FOR HANDLING ELECTROSTATIC

SENSITIVE DEVICES.

DANGER

BE SURE TO BLOCK THE LIFT BRACKET WHEN IT IS IN THE

RAISED POSITION. FAILURE TO OBSERVE APPROPRIATE SAFETY

PRECATIONS COULD RESULT IN BODILY HARM OR PROPERTY

DAMAGE.

DANGER

DO NOT REMOVE THE BOLTS FROM MORE THAN ONE FLEXURE

AT A TIME WHILE THE CARRIAGE IS INSTALLED ON THE

FORKLIFT. UNBOLTING MORE THAN ONE FLEXURE COULD

RESULT IN BODILY HARM OR PROPERTY DAMAGE.

DANGER

IF USED IN A HAZARDOUS AREA, THE HAZARDOUS AREA MUST

BE MADE SAFE PRIOR TO INSTALLATION, REPLACEMENT, OR

TROUBLESHOOTING. FAILURE TO COMPLY COULD RESULT IN

PERSONAL INJURY, DEATH, AND/OR PROPERTY DAMAGE.

CAUTION

CHANGES OR MODIFICATIONS NOT EXPRESSLY APPROVED BY METTLER TOLEDO COULD

VOID THE AUTHORITY TO OPERATE THIS EQUIPMENT.

CAUTION

THERE IS A RISK OF EXPLOSION IF A BATTERY IS REPLACED WITH AN INCORRECT TYPE OF

BATTERY. DISPOSE OF BATTERIES ACCORDING TO LOCAL REGULATIONS. FOR DISPOSAL

INFORMATION, REFER TO THE PRODUCT INFORMATION SHEET FOR NICKEL METAL

HYDRIDE BATTERIES (NiMH) AT www.panasonic.com OR REFER TO THE RECHARGEABLE

BATTERY RECYCLING CORPORATION (www.rbrc.org).

Contents

1 Introduction.................................................................................................... 1-1

FCC Notice..........................................................................................................................1-2

2 Installation..................................................................................................... 2-1

General ..............................................................................................................................2-1

Tools.................................................................................................................................... 2-1

Install Scale Controller........................................................................................................2-2

Remove the Forklift Truck’s Lift Bracket.................................................................................2-2

Install the Simplex Scale Carriage.......................................................................................2-6

Install the Triplex Scale Carriage.........................................................................................2-9

Batteries...........................................................................................................................2-12

Geo Index.........................................................................................................................2-13

Shift Adjustment................................................................................................................2-13

3 Scale Operations ............................................................................................ 3-1

Power-up Sequence.............................................................................................................3-1

Weighing Screen.................................................................................................................3-1

Push Buttons......................................................................................................................... 3-2

Weighing Operations...........................................................................................................3-3

Gross Weighing .................................................................................................................... 3-3

Net Weighing with Push Button Tare....................................................................................... 3-4

Net Weighing with Keyboard Tare........................................................................................... 3-4

Accumulating Gross Weights.................................................................................................. 3-5

Accumulating Net Weights..................................................................................................... 3-5

SmartWeigh Transactions...................................................................................................... 3-6

4 Scale Setup.................................................................................................... 4-1

Setup Screens.....................................................................................................................4-1

Scale..................................................................................................................................4-1

Filter.................................................................................................................................... 4-1

Tare ..................................................................................................................................... 4-4

Zero..................................................................................................................................... 4-5

Stability................................................................................................................................4-7

Battery Levels....................................................................................................................... 4-9

Calibration ......................................................................................................................... 4-13

Factory Use......................................................................................................................... 4-19

Reset.................................................................................................................................. 4-20

Application .......................................................................................................................4-21

Accumulate......................................................................................................................... 4-21

SmartWeigh........................................................................................................................ 4-21

Memory.............................................................................................................................. 4-23

Reset.................................................................................................................................. 4-25

Terminal...........................................................................................................................4-25

Date/Time........................................................................................................................... 4-25

Passwords.......................................................................................................................... 4-26

Calibrate Touch................................................................................................................... 4-27

Operating System................................................................................................................ 4-27

Brand Setup........................................................................................................................ 4-29

Reset.................................................................................................................................. 4-30

Communications...............................................................................................................4-30

Scale Radio........................................................................................................................ 4-30

COM1................................................................................................................................. 4-35

Reset.................................................................................................................................. 4-37

Maintenance.....................................................................................................................4-37

Log..................................................................................................................................... 4-37

Diagnostics......................................................................................................................... 4-38

Reset.................................................................................................................................. 4-43

Exit Setup.........................................................................................................................4-43

5 Routine Care and Maintenance........................................................................ 5-1

General ..............................................................................................................................5-1

Cleaning.............................................................................................................................5-2

6 Troubleshooting.............................................................................................. 6-1

General ..............................................................................................................................6-1

Error Messages...................................................................................................................6-2

Scale Controller..................................................................................................................6-4

Check Mechanical Components............................................................................................6-4

Check Overload Gaps ..........................................................................................................6-5

Check Wiring......................................................................................................................6-6

Check Force Data................................................................................................................6-6

Check Load Cells ................................................................................................................6-7

Load Cell Replacement........................................................................................................6-8

Removing a Chain Load Cell (Simplex).................................................................................. 6-8

Installing a New Chain Load Cell (Simplex) ......................................................................... 6-11

Removing a Drag Load Cell (Simplex).................................................................................. 6-12

Installing a New Drag Load Cell (Simplex)........................................................................... 6-13

Removing a Chain Load Cell (Triplex).................................................................................. 6-15

Installing a New Chain Load Cell (Triplex) ........................................................................... 6-18

Removing a Drag Load Cell (Triplex).................................................................................... 6-19

Installing a New Drag Load Cell (Triplex)............................................................................. 6-20

Adjust Load Cell Force.......................................................................................................6-22

7 Calibration..................................................................................................... 7-1

General ..............................................................................................................................7-1

Calibrate Load Cells............................................................................................................7-1

Span Adjustment.................................................................................................................7-3

Calibrate Linearity...............................................................................................................7-5

Calibrate Angles .................................................................................................................7-8

Establish Zero...................................................................................................................7-13

8 Service Parts.................................................................................................. 8-1

Scale Controller..................................................................................................................8-1

Scale Carriage....................................................................................................................8-2

Telemetry Enclosure............................................................................................................8-6

Side Shifter Kit....................................................................................................................8-8

9 Forklift Scale Options...................................................................................... 9-1

USB Port.............................................................................................................................9-1

Side Shifter Kit....................................................................................................................9-2

10 Appendix ..................................................................................................... 10-1

Geo Index.........................................................................................................................10-1

Chapter 1: Introduction

FCC Notice

Introduction

The MCFA forklift scale is a fully electronic scale with a capacity of 5,000 lb (2,000

kg). The scale consists of two components: (1) a scale carriage, which is installed in

place of the forklift truck’s lift bracket, and (2) a scale controller, which is mounted on

the forklift truck’s head guard. The scale carriage and controller communicate by radio,

so there are no wiring connections between them to limit the movement of the forks.

Figure 1-1: Forklift Scale Carriage (Simplex Version)

This manual explains how to install, operate, and service the MCFA forklift scale. If any

information in the manual is incorrect or missing, please use the Publication Suggestion

Report at the back of the manual to tell us about it.

(3/05) 1-1

METTLER TOLEDO MCFA Forklift Scale Service Manual

FCC Notice

MCPC Scale Controller (FCC ID: RITSC0001)

This device complies with Part 15 of the FCC Rules. Operation is subject to the following

two conditions: (1) this device may not cause harmful interference, and (2) this device

must accept any interference received, including interference that may cause undesired

operation.

MCSB Simplex Scale Carriage (FCC ID: RITTE0001)

This device complies with Part 15 of the FCC Rules. Operation is subject to the following

two conditions: (1) this device may not cause harmful interference, and (2) this device

must accept any interference received, including interference that may cause undesired

operation.

MCTB Triplex Scale Carriage (FCC ID: RITTE0002)

This device complies with Part 15 of the FCC Rules. Operation is subject to the following

two conditions: (1) this device may not cause harmful interference, and (2) this device

must accept any interference received, including interference that may cause undesired

operation.

CAUTION

CHANGES OR MODIFICATIONS NOT EXPRESSLY APPROVED BY METTLER TOLEDO COULD

VOID THE AUTHORITY TO OPERATE THIS EQUIPMENT.

(3/05)

1-2

Chapter 2: Installation

General

Installation

General

When you receive your forklift scale, check all items against the shipping bill of lading.

If any items are missing, notify the carrier immediately. Inspect the packing container

and scale for freight damage. If you find damage, contact your freight carrier

immediately in order to collect damages.

Tools The following tools are needed to install and calibrate a forklift scale:

Simplex Version

Crane or lifting device (capacity 2,500 lb)

Torque wrench with 3/8-inch hex bit attachment (flexure bolts)

12-mm wrench (main roller bolts)

14-mm wrench (side roller assembly bolts)

24-mm wrench (chain anchor nuts)

3/4-inch wrench (bumper bolts and drag load cell mounting nuts)

10-mm wrench (bolts for mounting controller)

Triplex Version

Crane or lifting device (capacity 2,500 lb)

Torque wrench with 5/16-, 3/8-, and 1/2-inch hex bit attachments

12-mm wrench (main roller bolts)

16-mm wrench (side roller assembly bolts)

24-mm wrench (chain anchor nuts)

3/4-inch wrench (bumper bolts and drag load cell mounting nuts)

10-mm wrench (bolts for mounting controller)

1.25-inch open-end wrench

(3/05) 2-1

METTLER TOLEDO MCFA Forklift Scale Service Manual

Install Scale Controller 1.

Use a pair of U-bolts to attach the mounting bracket to the forklift truck’s head

guard. Position it so that the driver will be able to view the controller easily.

Bolt the controller to the mounting bracket, using four hexagonal head screws and

washers (see Figure 2-1).

Connect the controller to the forklift truck’s time-delay relay harness. The harness

should be installed according to the manufacturer’s instructions.

U-Bolts

Head Guard

Mounting Bracket

Scale Controller

Figure 2-1: Scale Controller and Mounting Bracket

Remove the Forklift

Truck’s Lift Bracket 1.

Park the forklift truck on a level surface, and make sure the mast is in the vertical

position.

Remove both of the forks.

If the forklift truck is equipped with a load backrest extension, remove the load

backrest extension.

Raise the mast so that the lift bracket is at a comfortable working height (3 or 4 feet

off the ground).

Wrap a sling securely around the lift bracket’s upper fork bar.

Attach the sling to a crane (or other lifting device with a capacity of at least 500

lb), and use the crane to raise the lift bracket so that the chains have some slack in

them.

DANGER

BE SURE TO BLOCK THE LIFT BRACKET WHEN IT IS IN THE

RAISED POSITION. FAILURE TO OBSERVE APPROPRIATE

SAFETY PRECATIONS COULD RESULT IN BODILY HARM OR

PROPERTY DAMAGE.

(3/05)

2-2

Chapter 2: Installation

Remove the Forklift Truck’s Lift Bracket

Disconnect the two chain anchors from the mast by removing the lower jam nut

from each anchor (see Figure 2-2). Keep the nuts with the chain anchor to use

them for installing the scale carriage.

Chain Anchor

Jam Nuts

Mast

Jam Nut

Simplex Version

Jam Nut

Mast

Jam Nuts

Triplex Version

Figure 2-2: Chain Anchor Assembly

Remove the chains from the pulleys at the top of the mast. Then position the chains

over the front of the lift bracket so that they will not interfere with removing the lift

bracket from the mast.

Raise the bottom of the inner mast at least 2 feet off the floor to allow enough room

to remove the lift bracket from the bottom of the mast.

10.

Use the crane to lower the lift bracket to the floor and remove it from the bottom of

the mast.

11.

Place the lift bracket on a stable working surface, with the front side of the lift

bracket facing downward to provide easy access to the rollers and chain mounts.

12.

Disconnect the two chains from the lift bracket. Remove the cotter pin from the

master link that is connected to the 90° joint in each chain (see Figure 2-3). Then

take apart the master link, using a C-clamp or similar device to press the master

link through the link plates. Do not use a hammer or other tool to strike the master

link. It could damage the link. Keep the chains and master links to install on the

scale carriage.

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METTLER TOLEDO MCFA Forklift Scale Service Manual

Master Link

Link Plate (Large Holes)

Cotter Pin

Link Plate (Small Holes)

Figure 2-3: Master Link Assembly

13.

Remove the six main rollers from the lift bracket (see Figure 2-4). The two top

rollers on each side of the lift bracket are secured with screws. The bottom roller on

each side of the lift bracket can be removed by hand. Save the rollers, screws,

washers, and shims so that you can install them on the scale carriage.

Figure 2-4: Remove Main Rollers

14.

Locate the side roller on each side of the lift bracket. Remove the two bolts that

secure each side roller assembly to the lift bracket (see Figure 2-5). Keep these

assemblies together because you will need to install them on the scale carriage.

Note the position of any shims used in the assemblies.

(3/05)

2-4

Chapter 2: Installation

Remove the Forklift Truck’s Lift Bracket

Figure 2-5: Side Roller Assembly

15.

Set the lift bracket aside, and remove the sling from it.

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METTLER TOLEDO MCFA Forklift Scale Service Manual

Install the Simplex

Scale Carriage 1.

Park the forklift truck on a level surface, and make sure the mast is in the vertical

position.

Place the scale carriage on a stable working surface, with the front side of the

carriage facing downward to provide easy access to the rollers and chain load

cells.

Install the two lower main rollers by sliding them onto the roller shafts at the bottom

of each side of the scale carriage (see Figure 2-6). Be sure to install any shims that

were removed from the forklift truck’s lift bracket.

Install the other four main rollers on the scale carriage, securing them with the bolts

that were removed from the lift bracket (see Figure 2-6).

Figure 2-6: Install Main Rollers

Mount the two side roller assemblies (including shims) on the scale carriage (see

Figure 2-7). Do not use the bolts that were removed from the lift bracket. Instead,

use the studs and nuts provided with the scale carriage. Align the two holes in each

side roller assembly with the holes located midway between the two bolted rollers

on each side of the carriage. Insert the studs in the holes and screw them into the

assembly. Then place the washers and nuts on the ends of the studs and tighten

them against the carriage.

(3/05)

2-6

Chapter 2: Installation

Install the Simplex Scale Carriage

Figure 2-7: Side Roller Assembly

Use a master link to connect each chain to one of the chain load cells on the scale

carriage. Assemble the master link as shown in Figure 2-8. Using a C-clamp or

similar device, press the master link assembly together just enough so that you can

insert the cotter pin in the holes. If the link is too tight, it can bind against the load

cell and chain mount. If the link does not rotate freely on the load cell or chain,

press the master link back through the link plates until it rotates freely.

NOTE: When a forklift scale is installed, a standard chain should have 34 links

(including master links). Add or remove links if necessary.

Figure 2-8: Connect Chain to Load Cell with Master Link

Assembled Master Link

Chain Load Cell Master Link

Link Plate

(Large Holes)

Link Plate

(Small Holes) Cotter Pin

Position the chains over the front of the carriage so that they will not interfere when

you install the carriage in the forklift mast.

Raise the bottom of the inner mast at least 2 feet off the floor to allow enough room

to install the carriage from the bottom of the mast.

Wrap a sling securely around the upper part of the scale carriage.

(3/05) 2-7

METTLER TOLEDO MCFA Forklift Scale Service Manual

10.

Attach the sling to a crane (or other lifting device with a capacity of

at least 500

ted

11.

12.

13.

the anchor into the hole in

Figure 2-9: Chain Anchor Assembly

Remove the sling from the scale carriage.

ck on the lift truck, positioning a fork at

17.

the mast are completely

18.

hain anchors so that each chain has 3/4 inch of slack. This will allow

19.

rks

lb), and use the crane to lift the scale carriage. Position the carriage so that its

main rollers fit into the bottom of the mast channel. The chain load cells are loca

on the back side of the scale carriage.

Raise the carriage to a comfortable working position, keeping the main rollers

aligned inside the mast channel. Move the carriage up and down several times

make sure that it moves freely within the mast. If the carriage fits too tightly within

the mast, you might need to remove shims from the bottom rollers or side rollers.

Position two blocks of wood (3 inches high) on the floor under the carriage’s lowe

fork bar. Lower the inner mast and carriage until the fork bar rests on the blocks.

Route the chains over the pulleys at the top of the mast.

14.

Remove the lower nut from each chain anchor and insert

the mast, below and behind the chain pulleys. Place the lower nut on the threaded

anchor and tighten it until both it and the upper nut are tight against the mast (see

Figure 2-9). You will need to adjust the anchors later, so do not tighten the nuts too

much. Make sure there is no slack in the chains, so that the carriage does not drop

when you remove the sling.

Chain Anchor

Jam Nuts

Mast

Jam Nut

16.

Raise the carriage slightly. Put the forks ba

the next to last notch on each side of the carriage.

Lower the carriage to the floor so that the stages of

collapsed.

Adjust the c

room for the chains to adjust when the mast is set at an angle. With the mast in the

vertical position and the carriage fully lowered, the distance between the floor and

the bottom of the scale carriage should be 76 to 80 mm (about 3 inches).

After installing the scale controller and scale carriage, place a pallet on the fo

and exercise the scale to make sure that all components seat properly. Repeatedly

place a test weight on the scale, positioning it on the center of the scale and at

each corner of the scale.

(3/05)

2-8

Chapter 2: Installation

Install the Triplex Scale Carriage

Install the Triplex Scale

Carriage 1.

Park the forklift truck on a level surface, and make sure the mast is in the vertical

position.

Place the scale carriage on a stable working surface, with the front side of the

carriage facing downward to provide easy access to the rollers and chain load

two lower main rollers by sliding them onto the roller shafts at the bottom

the other four main rollers on the scale carriage, securing them with the bolts

Mount the two side roller assemblies (including shims) on the scale carriage (see

Figures 2-10 and 2-11). Align the two holes in each side roller assembly with the

h o bolted rollers on each side of the carriage.

Use two socket head screws and washers to secure each side roller assembly.

cells.

Install the

of each side of the scale carriage (see Figure 2-10). Be sure to install any shim

that were removed from the forklift truck’s lift bracket.

Install

that were removed from the lift bracket (see Figure 2-10).

Figure 2-10: Install Main Rollers

oles located midway between the tw

(3/05) 2-9

METTLER TOLEDO MCFA Forklift Scale Service Manual

Use a master link to connect each chain to one of the chain load cells on the scale

shown in Figure 2-12. Using a C-clamp or

similar device, press the master link assembly together just enough so that you can

insert the cotter pin in the holes. If the link is too tight, it can bind against the load

Figure 2-11: Side Roller Assembly

carriage. Assemble the master link as

cell and chain mount. If the link does not rotate freely on the load cell or chain,

press the master link back through the link plates until it rotates freely.

NOTE: When a forklift scale is installed, a standard chain should have 33 links

(including master links). Add or remove links if necessary.

Chain Load Cell

Master Link

sembled Master Link

Link Plate

es) Cotter Pin

Link Plate

(Large Holes)

(Small Hol

Figure 2-12: Connect C d C nk

Position the chains over the front of the carriage so that they will not interfere when

you insta

Raise the bottom of the inner mast at least 2 feet off the floor to allow enough room

t of the scale carriage.

hain to Loa ell with Master Li

ll the carriage in the forklift mast.

to install the carriage from the bottom of the mast.

Wrap a sling securely around the upper par

(3/05)

2-10

Chapter 2: Installation

Install the Triplex Scale Carriage

ition the carriage so that its

cells are located

ims from the bottom rollers or side rollers.

13.

ht against the mast (see

o do not tighten the nuts

15.

Remove the sling from the scale carriage.

16.

Raise the carriage s , positioning a fork at

the next to last notch on each side of the carriage.

tages of the mast are completely

18.

4 inch of slack. This will allow

r and

f the scale carriage should be 76 to 80 mm (about 3 inches).

10.

Attach the sling to a crane (or other lifting device with a capacity of at least 500

lb), and use the crane to lift the scale carriage. Pos

main rollers fit into the bottom of the mast channel. The chain load

on the back side of the scale carriage.

11.

Raise the carriage to a comfortable working position, keeping the main rollers

aligned inside the mast channel. Move the carriage up and down several times to

make sure that it moves freely within the mast. If the carriage fits too tightly within

the mast, you might need to remove sh

12.

Position two blocks of wood (3 inches high) on the floor under the carriage’s lower

fork bar. Lower the inner mast and carriage until the fork bar rests on the blocks.

Route the chains over the pulleys at the top of the mast.

14.

Remove the lower nut from each chain anchor and insert the anchor into the hole in

the mast, below and behind the chain pulleys. Place the lower nut on the threaded

anchor and tighten it until both it and the upper nut are tig

Figure 2-13). You will need to adjust the anchors later, s

too much. Make sure there is no slack in the chains, so that the carriage does not

drop when you remove the sling.

Figure 2-13: Chain Anchor Assembl

Chain Anchor

Jam Nuts

Mast

Jam Nut

lightly. Put the forks back on the lift truck

17.

Lower the carriage to the floor so that the s

collapsed.

Adjust the chain anchors so that each chain has 3/

room for the chains to adjust when the mast is set at an angle. With the mast in the

vertical position and the carriage fully lowered, the distance between the floo

the bottom o

19.

After installing the scale controller and scale carriage, place a pallet on the forks

and exercise the scale to make sure that all components seat properly. Repeatedly

place a test weight on the scale, positioning it on the center of the scale and at

each corner of the scale.

(3/05) 2-11

METTLER TOLEDO MCFA Forklift Scale Service Manual

Batteries

A 12-volt battery pack is used to power the scale’s load cells and carriage radio. The

scale is supplied with two batteries and a battery charger. New batteries must be

charged before they can be used. A fully charged battery will allow you to operate the

scale for up to 36 hours. The battery level indicator on the scale controller’s main

weighing screen alerts the driver when the battery’s voltage level is low.

CAUTION

THERE IS A RISK OF EXPLOSION IF A BATTERY IS REPLACED WITH AN INCORRECT

TYPE OF BATTERY. DISPOSE OF BATTERIES ACCORDING TO LOCAL REGULATIONS.

FOR DISPOSAL INFORMATION, REF NFORMATION SHEET FOR

NICKEL METAL HYDRIDE BATTERIE sonic.com OR REFER TO

THE RECHARGEABLE BATTERY RECYCLING CORPORATION (www.rbrc.org).

ER TO THE PRODUCT I

S (NiMH) AT www.pana

• tion the

the

To remove a battery, press the plastic tab toward the center of the battery and pull

•

outlet (110 volts). It will take 12 to 16

recharge it. A red light on the battery

To install a battery, insert it in the scale carriage’s battery compartment. Posi

battery so that the metal contacts on its side fit against the metal contacts in

battery compartment.

•

the battery out of the battery compartment.

To charge a battery, insert it in the battery charger (see Figure 2-14). Then plug the

battery charger into a standard electrical

hours to provide the initial charge for a new battery. Once a battery has been used,

it should take no more than 3 to 4 hours to

charger indicates that the battery is being charged. A green light indicates that the

battery is fully charged. When a battery is fully charged, the charger goes into

trickle mode, so there is no danger of damaging a battery by overcharging it.

Figure 2-14: Battery and Batter Charger

(3/05)

2-12

Chapter 2: Installation

Geo Index

To compensate for local gravitational forces, change the geo index to the setting for the

location where the scale will be used. The factory default setting is 16 (the geo index for

Worthington, Ohio, USA). To determine the geo index for a location, refer to the

appendix (Chapter 10). You must know the geographical coordinate for the location

and the elevation above sea level.

To change the geo index, enter the scale controller’s setup mode by touching the

Setup button on the main weighing screen.

Touch the Scale button, touch the Calibration button, and then touch the Where

Used button.

A keypad is used to enter the geo index. Type a number in the data field by

touching the numeric keys on the keypad (the range is 0 to 31). Touch the Clear

button if you wish to clear the data field and start over.

Touch the Enter button to confirm your selection or the Cancel button to cancel any

changes that you made.

Shift Adjustment

Forklift scales are calibrated at the factory and should not need to be recalibrated when

they are installed. You should, however, check the scale after installing it to see if it

needs to be shift adjusted. A correctly adjusted scale will give you the same weight

reading no matter where on the forks you place a test weight. If the weight readings at

the shift test locations are out of tolerance, shift adjust the scale to correct the problem.

Park the forklift truck on a level surface, place a pallet on the forks, raise the forks 12 to

15 inches off the ground, set the mast to the vertical position, and shut off the forklift

truck’s motor. Then check the scale’s repeatability by placing a test weight on the same

location on the pallet several times to make sure that you get the same weight reading

each time.

After verifying the scale’s repeatability, check to see if the scale needs to be shift

adjusted. For shift adjustments, we recommend using test weights equal to one half the

scale’s maximum weighing capacity. The test weights must meet the specified National

Institute of Standards and Technology Handbook 44 accuracy requirements.

NOTE: When performing a shift adjustment, use the weight readings on the data screen

instead of those on the main weighing screen. The weight readings on the data screen

are displayed to two decimal places, although the number in the second decimal place

might not be stable.

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METTLER TOLEDO MCFA Forklift Scale Service Manual

Shift Test Locations

Place a pallet or other flat surface (approximately 4 feet by 4 feet) on the forks and

make sure that it is level. Figure 2-15 shows test weight locations (1, 2, 3, and 4) at

ions.

t reading 1 is greater than 2 → Shim at location A

the center of each quadrant of the pallet. Place the test weight at location 1 and record

the weight reading. Then move the test weight to location 2 and record the weight

reading. Continue until you have taken a weight reading at each of the four locat

Figure 2-15: Shift Adjustment Locations (Simplex Version Shown)

Ideally, the scale will give you the same weight reading at all four locations. The weight

readings at the heel and toe of either or both forks should be within Handbook 44

tolerance requirements (±2.5 lb for weights up to 2,500 lb). If the weight readings are

out of tolerance, you will need to shift adjust the scale. This is done by adding shims to

the flexures at the locations shown in Figure 2-15. To determine where to add shims,

refer to Table 2-1.

If weigh

If weight reading 2 is greater than 1 → Shim at location B

If weight reading 3 is greater than 4 → Shim at location C

If weight reading 4 is greater than 3 → Shim at location D

Table 2-1: Shim Locations

The shims adjust the differences between the weight readings at the heel and toe of an

dividual fork. Adjust the weight readings so that they are as near to equal as possible.

If one weight reading is slightly higher, it should be the reading at the toe of the fork.

Shimming at the front of a flexure (location A) will increase the weight reading at the toe

of the fork (location 2). Because the shim affects the entire fork, it will also slightly

increase the weight reading at the heel (location 1).

Shimming at the back of a flexure (location B) will decrease the weight reading at the

toe of the fork (location 2). Because the shim affects the entire fork, it will also slightly

decrease the weight reading at the heel (location 1).

A pallet places load on both forks. So when a pallet is used, shimming under a flexure

will affect the readings at all four test weight locations. For example, shimming at

Heel Heel Flexure Flexure

2 3

Toe Toe

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Chapter 2: Installation

Shift Adjustment

ange the readings at locations 1 and 2, but it will also change the

o not remove the bolts from more than one flexure at a time. The flexures connect the

o se

ections of t rriage c separate an injury or damage the flex .

location A or B will ch

readings at locations 3 and 4 to a lesser extent.

Keep in mind that, in addition to balancing the weight readings at the heel and toe of

each fork, you are also trying to balance the weight readings of the two forks.

Shimming Procedure

tw ctions of the scale carriage. If you unbolt the two top or bottom flexures, the

s he ca ould d cause ures

DANGER

DO NOT REMOVE THE BOLTS FROM MORE THAN ONE

FLEXURE AT A TIME WHILE THE CARRIAGE IS INSTALLED

N THE FORKLIFT. UNBOLTING MORE THAN ONE FLEXURE

OULD RESULT IN BODILY HARM OR PROPERTY DAMAGE.

Remove the bolts from the side of the flexure where shims will be added.

Loosen the bolts on the opposite side of the flexure.

Place a shim under the flexure, aligning the bolt holes in the sh with those in the

flexure. We recommend starting with the thinnest shim and gradually increasing

the shim thickness as needed to balance the weight readings.

Repl ).

ading at all four test weight locations.

plex Version Shown)

ace the bolts that were removed, and tighten all bolts (torque to 90 ft-lb

Repeat steps 1-4 for the second flexure if needed.

Take new weight readings at all four test weight locations. If the weight readings

are still not equal, repeat the procedure to add additional shimming.

When you have finished shift adjusting the scale, you should get approximately th

same weight re

Figure 2-16: Shimming Procedure (Sim

Remove bolts

to add shim

on opposite

side of flexure

shim

under flexure

osen bolts Add

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Chapter 3: Scale Operations

Power-up Sequence

Scale Operations

Power-up Sequence

Remove all load from the forks and raise the forks off the ground whenever you power

up the scale controller. Start the forklift truck’s motor, and then press the on/off button in

the upper right-hand corner of the controller’s front cover. During the controller’s power-

up sequence, it will display the version number and build number of the scale software.

When the controller is fully powered up, it will display the main weighing screen.

Weighing Screen

All weighing operations can be performed from the scale controller’s main weighing

screen. In addition to displaying current weight data, the screen provides push buttons

used to perform weighing operations and to enter setup mode.

Radio Channel Battery Level Indicator

Time and Date

Radio Communication

Weighing Mode

Maximum Capacity

and Increment Size “~” Indicates when

Scale is in Motion

Weight Reading

Accumulated Weight Tare Weight

Message Bar

Push Buttons

Figure 3-1: Main Weighing Screen

Radio Communication: When the indicator is green, the radios are communicating.

When it is red, there is no communication.

Battery Level Indicator: The blue color indicates the battery level. The indicator will

display a warning message when the battery level is low and when the battery needs to

be changed. The battery discharge cradle has a low-voltage cutoff that shuts off power

to the scale carriage when the battery voltage drops to the “change battery” level

(approximately 10.5 volts).

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METTLER TOLEDO MCFA Forklift Scale Service Manual

Push Buttons The push buttons at the bottom of the main weighing screen are used to perform

weighing functions and to enter setup mode.

Zero

The Zero button is used to zero the scale manually. This feature can be used if the

weight reading on the screen does not return to zero when all load has been removed

from the scale. In order for this button to zero the scale manually, (1) the scale must be

in gross weighing mode and (2) the weight reading on the screen must be within the

range specified in the manual range setup feature. The scale also includes an automatic

zero maintenance (AZM) feature. When AZM is enabled, the scale will be zeroed

automatically if the weight reading is within a specified range.

Tare

The Tare button is used to assign the weight that is currently on the scale as a tare

weight. The tare weight is the weight of an empty pallet or container. It is subtracted

from the gross weight (weight of the loaded pallet or container) to determine the net

weight (weight of the item on the pallet or the material in the container). The tare weight

will be displayed in the Tare field. This button will work only if push button tare is

enabled in scale setup.

Clear

The Clear button is used to remove a tare weight reading or accumulated weight

reading that is displayed on the screen. To remove a tare weight reading, touch the

Clear button and then touch the Tare button. To remove an accumulated weight

reading, touch the Clear button and then touch the Accum button.

Accumulator

The Accum button is used to accumulate a series of weights and sum them to calculate

a total weight. When you touch the Accum button, the gross or net weight that is

displayed on the screen will be added to the weight reading in the Accumulated Weight

field. This button will be available only if basic accumulate is enabled in application

setup.

Gross/Net

The Gross/Net button is used to switch between gross and net weight readings on the

screen. In order to switch to a net weight reading, you must first assign a tare weight.

This button will work only if gross/net switching is enabled in scale setup.

The double arrow button is used to display additional push buttons on the screen.

Setup

The Setup button is used to enter setup mode on the controller. For an explanation of

the setup features and how to use them, refer to the “Scale Setup” section of this

manual.

Keyboard Tare

The Keybd Tare button is used to enter a tare weight manually. The tare weight is the

weight of an empty pallet or container. It is subtracted from the gross weight (weight of

the loaded pallet or container) to determine the net weight (weight of the item on the

pallet or the material in the container). When you touch the Keybd Tare button, a

keypad will appear on the screen. Type the tare weight by touching the numerical keys

on the keypad. Then touch the Enter button. The tare weight will be displayed in the Tare

field. This button will work only if keyboard tare is enabled in scale setup.

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Chapter 3: Scale Operations

Weighing Operations

Audit Log

The Audit Log button is used to view the scale’s log that is required for Weights and

Measures audits. The log lists all calibration and configuration changes.

Filter

The Filter button is used to adjust the vibration filtering for the scale. It lets you adjust

filtering without entering setup mode. You can disable filtering or specify a filtering level

(Light, Lt/Med, Medium, Med/Hvy, or Heavy). Any changes made using this button will

be lost when the scale controller is shut off. At power-up, the scale will revert to the filter

settings that are specified in setup mode.

lb/kg

The lb/kg button is used to switch between weight readings in pounds and kilograms. It

changes the unit of measure for all weights displayed on the screen. This button will

work only if unit switching is enabled in scale setup.

Pro Number

The Pro# Print button is used to enter a shipping number for a SmartWeigh transaction

and create a record of the transaction. This button will be available only if advanced

accumulate is enabled in application setup.

Employee ID

The Employ ID button is used to enter an Employee ID for a SmartWeigh transaction.

This button will be available only if advanced accumulate is enabled in application

setup. When you touch the button, a keypad will appear on screen. Type the Employee

ID by touching the keys on the keypad. Then touch the Enter button.

Weighing Operations

This section describes the scale’s basic weighing operations, which are performed from

the controller’s main weighing screen. You can display a gross weight, use a tare

weight to determine a net weight, and use the accumulator to calculate the sum of a

series of gross or net weights.

Gross Weighing Use the following procedure to find the gross weight of an item:

Lift the item with the forklift.

The gross weight will be displayed in the Weight field.

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METTLER TOLEDO MCFA Forklift Scale Service Manual

Net Weighing with Push

Button Tare Push button tare must be enabled in scale setup. Use the following procedure to find the

net weight of an item:

Lift the empty pallet (or container) with the forklift.

The weight will be displayed as a gross weight in the Weight field.

Touch the Tare button.

The weight of the pallet (or container) will be displayed in the Tare field. The

reading in the Weight field will change to zero.

Lift the loaded pallet (or container) with the forklift. You can remove the pallet (or

container) from the forklift to fill it or fill it while it is on the scale.

The net weight of the item will be displayed in the Weight field. If you wish to view

the gross weight of the loaded pallet (or container), touch the Gross/Net button.

If auto clear is enabled, the gross/net weight and tare weight readings on the screen

will automatically return to zero when the load is removed from the scale.

Otherwise, the tare weight will remain on the screen and can be used to weigh

another loaded pallet (or container). To clear the tare weight, touch the Clear button

and then the Tare button.

Net Weighing with

Keyboard Tare Keyboard tare must be enabled in scale setup. Use the following procedure to find the

net weight of an item:

Lift the loaded pallet (or container) with the forklift.

The weight will be displayed as a gross weight in the Weight field.

Touch the Keybd Tare button.

A keyboard will appear on the screen. Type in the tare weight of the pallet (or

container) by touching the numerical keys on the keyboard. When the correct tare

weight is displayed in the keyboard’s data field, touch the Enter button.

The net weight of the item will be displayed in the Weight field. If you wish to view

the gross weight of the loaded pallet (or container), touch the Gross/Net button.

The tare weight will be displayed in the Tare field.

If auto clear is enabled, the gross/net weight and tare weight readings on the screen

will automatically return to zero when the load is removed from the scale.

Otherwise, the tare weight will remain on the screen and can be used to weigh

another loaded pallet (or container). To clear the tare weight, touch the Clear button

and then the Tare button.

NOTE: You can also use keyboard tare to enter a tare weight before lifting the loaded

pallet (or container) with the forklift.

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Chapter 3: Scale Operations

Weighing Operations

Accumulating Gross

Weights Basic accumulate must be enabled in application setup. Use the following procedure to

accumulate gross weights:

Lift an item with the forklift.

The gross weight will be displayed in the Weight field.

Touch the Accum button.

The gross weight of the item will be displayed in the Accumulated Weight field. The

text above the field will indicate the number of loads that have been accumulated:

“Accumulated weight of 1 item.”

Remove the item from the scale, and then lift the next item.

The gross weight of the item currently on the scale will be displayed in the Weight

field.

Touch the Accum button.

The gross weight of the item will be added to the weight displayed in the

Accumulated Weight field. The text above the field will indicate the number of loads

that have been accumulated: “Accumulated weight of 2 items.”

Repeat Steps 5 to 8 for each additional item to be weighed.

10.

When you have finished accumulating weights, remove the load from the forklift. To

clear the accumulated weight, touch the Clear button and then the Accum button.

Accumulating Net Weights Basic accumulate must be enabled in application setup. Use the following procedure to

accumulate net weights:

Display the net weight to be accumulated:

• If you are using push button tare, lift the empty pallet (or container) and touch

the Tare button. Then lift the loaded pallet (or container).

• If you are using keyboard tare, lift the loaded pallet (or container) and touch

the Keybd Tare button. Then enter the tare weight manually.

Touch the Accum button.

The net weight of the item will be displayed in the Accumulated Weight field. The

text above the field will indicate the number of loads that have been accumulated:

“Accumulated weight of 1 item.”

Remove the item from the scale.

Display the next net weight to be accumulated:

• If you are using pushbutton tare, lift the empty pallet (or container) and touch

the Tare button. Then lift the loaded pallet (or container).

• If you are using keyboard tare, lift the loaded pallet (or container) and touch

the Keybd Tare button. Then enter the tare weight manually.

Touch the Accum button.

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METTLER TOLEDO MCFA Forklift Scale Service Manual

The net weight of the item will be added to the weight displayed in the Accumulated

Weight field. The text above the field will indicate the number of loads that have

been accumulated: “Accumulated weight of 2 items.”

Repeat Steps 4 to 7 for each additional item to be weighed.

When you have finished accumulating weights, remove the load from the forklift. To

clear the accumulated weight, touch the Clear button and then the Accum button.

SmartWeigh Transactions The SmartWeigh option allows you to create records of weighing transactions. To use

the SmartWeigh option, you must enable advanced accumulate in application setup.

Use the following procedure to process a SmartWeigh transaction:

Lift the item with the forklift.

Touch the Employ ID button and then use the keypad to enter an Employee ID.

Touch the Pro# Print button and then use the keypad to enter a Pro number.

The SmartWeigh information screen will be displayed. It lists the weight and other

information about the transaction. Touch the Save button to save a record of the

transaction in a computer file.

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Chapter 4: Scale Setup

Setup Screens

Scale Setup

Setup Screens

The scale controller’s touch screen provides access to the scale’s setup features. These

allow you to calibrate the scale, change how the scale operates, assign passwords, set

communication parameters, and perform diagnostic tests.

To use the scale’s setup features, touch the Setup button on the scale controller’s main

weighing screen. If security-level passwords have been assigned, you will be prompted

to enter a password.

Scale

The scale setup features are used to calibrate the scale and adjust the settings for the

scale’s weighing functions. Touch the Scale button to display buttons for the individual

scale setup features.

Filter Filtering is used to compensate for environmental disturbances such as vibration and

noise. Touch the Filter button to access the filtering features.

Terminal Filter

You can select a filtering level for the scale. Heavy filtering will provide a more stable

weight reading, but it can cause the scale to take longer to stabilize. The default setting

is Medium.

Touch the Terminal Filter button.

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METTLER TOLEDO MCFA Forklift Scale Service Manual

Touch a button to disable filtering or to select a filtering level (Light, Lt/Med,

Medium, Med/Hvy, or Heavy).

Touch the OK button to confirm your selection or the Cancel button to cancel any

changes that you made.

Fsteps

The FSteps feature sets the filter constant used for on-board digital filtering. This is a

simple recursive filter that determines the filtered value by averaging a number (the

FSteps setting) of the most recent samples. The default setting is 20. A higher number

results in heavier filtering; a lower number results in lighter filtering. This constant is set

at the factory and should not need to be adjusted.

Touch the FSteps button to display a keypad on the screen.

Type a number in the data field by touching the numeric keys on the keypad. Valid

Fsteps settings are 1 to 200. Touch the Clear button if you wish to clear the data

field and start over.

Touch the Enter button to confirm your selection or the Cancel button to cancel any

changes that you made.

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Chapter 4: Scale Setup

Scale

FLCLevel

The FLCLevel is another constant used for on-board digital filtering. It represents the

input step change for the load cells that will restart the filter averaging. The default

setting is 0.001. This constant is set at the factory and should not need to be adjusted.

Touch the FLCLevel button to display a keypad on the screen.

Type a number in the data field by touching the numeric keys on the keypad. Valid

FLCLevel settings are 0.01 to 0.0001. Touch the Clear button if you wish to clear

the data field and start over.

Touch the Enter button to confirm your selection or the Cancel button to cancel any

changes that you made.

FINCLevel

The FINCLevel is another constant used for on-board digital filtering. It represents the

input step change for the inclinometers that will restart the filter averaging. The default

setting is 0.01. This constant is set at the factory and should not need to be adjusted.

Touch the FINCLevel button to display a keypad on the screen.

Type a number in the data field by touching the numeric keys on the keypad. Valid

FINCLevel settings are 0.1 to 0.001. Touch the Clear button if you wish to clear the

data field and start over.

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METTLER TOLEDO MCFA Forklift Scale Service Manual

Touch the Enter button to confirm your selection or the Cancel button to cancel any

changes that you made.

Tare The following tare setup features allow you to enable or disable functions for entering

and clearing tare weights. Touch the Tare button to access the features.

Push Button Tare

Push button tare allows you to assign the weight that is currently on the scale as the tare

weight by touching the Tare button on the weighing screen. The default setting is Enabled.

Touch the Push Button button.

Touch the check box to place a check mark in it (enabling the function) or to

remove a check mark (disabling the function).

Touch the OK button to confirm your selection or the Cancel button to cancel any

changes that you made.

Keyboard Tare

Keyboard tare allows you to enter a tare weight manually by touching the Keybd Tare

button on the weighing screen and then typing a weight. The default setting is Disabled.

Touch the Keyboard button.

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Chapter 4: Scale Setup

Scale

Touch the check box to place a check mark in it (enabling the function) or to

remove a check mark (disabling the function).

Touch the OK button to confirm your selection or the Cancel button to cancel any

changes that you made.

Auto Clear

Auto clear automatically clears the tare weight from the terminal when a load is removed

from the scale (the weight reading returns to zero). The default setting is Disabled.

Touch the Auto Clear button.

Touch the check box to place a check mark in it (enabling the function) or to

remove a check mark (disabling the function).

Touch the OK button to confirm your selection or the Cancel button to cancel any

changes that you made.

Zero The zero setup features allow you to specify weight ranges for zeroing the scale. The

zeroing function resets the weight reading for the empty scale to zero. It is used when

temperature changes or material built up on a scale prevents the weight reading from

returning to zero when the scale is emptied. Touch the Zero button to access the

features.

Automatic Zero Maintenance (AZM)

AZM automatically adjusts the scale’s weight reading to zero when the load is removed

from the scale. In order for AZM to zero the scale, the weight reading on the scale must

be within the range specified. The default setting is ±0.5 division (increment).

Touch the AZM button.

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METTLER TOLEDO MCFA Forklift Scale Service Manual

Touch a button to disable AZM or to select an AZM range (±0.5, ±1, or ±3

divisions).

Touch the OK button to confirm your selection or the Cancel button to cancel any

changes that you made.

Power-Up Zero

Power-up zero automatically adjusts the scale’s weight reading to zero when the

controller is powered up. In order to zero the scale automatically at power-up, the

weight reading on the scale must be within the range specified. The default setting is

±10% of scale capacity.

Touch the Power Up button.

Touch a button to disable power-up zero or to select a range (2% or 10% of scale

capacity).

Touch the OK button to confirm your selection or the Cancel button to cancel any

changes that you made.

Manual Zero Range

Manual zero allows you to zero the scale by using the Zero button on the weighing

screen. In order for the manual zero function to zero the scale, the weight reading on the

scale must be within the range specified. The default setting is ±20% of scale capacity.

Touch the Manual Range button.

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Chapter 4: Scale Setup

Scale

Touch a button to disable manual zero or to select a range (2% or 20% of scale

capacity).

Touch the OK button to confirm your selection or the Cancel button to cancel any

changes that you made.

Stability The stability settings allow you to specify the conditions that the scale must meet in

order to be considered stable. Touch the Stability button to access the features.

Motion Range

Motion range allows you to select the range to be used for motion detection. For the

scale to be considered stable, it must produce several consecutive weight readings

within that range. The default setting is ±1 division (increment). When the scale is in

motion, a “~” will be displayed next to the weight reading on the weighing screen. The

zero, tare, and print functions cannot be used when the scale is in motion.

Touch the Motion Range button.

Touch a button to disable motion detection or to select a motion detection range

(0.5, 1, 2, or 3 divisions).

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METTLER TOLEDO MCFA Forklift Scale Service Manual

Touch the OK button to confirm your selection or the Cancel button to cancel any

changes that you made.

Over Capacity

If over capacity is enabled, the display will go blank when the weight on the scale

exceeds the maximum scale capacity. The default setting is Enabled.

Touch the Over Capacity button.

Touch the check box to place a check mark in it (enabling the function) or to

remove a check mark (disabling the function).

Touch the OK button to confirm your selection or the Cancel button to cancel any

changes that you made.

Roll Angle Limit

The roll angle limit is the maximum side-to-side angle for the mast. If the mast roll

exceeds that angle, the weight display will go blank. The default setting is 3 degrees.

Touch the Roll Angle Limit button.

Touch a button to disable roll angle blanking or to select a maximum mast roll

angle (1, 2, or 3 degrees).

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Chapter 4: Scale Setup

Scale

Touch the OK button to confirm your selection or the Cancel button to cancel any

changes that you made.

Pitch Angle Limit

The pitch angle limit is the maximum front-to-back angle for the mast. If the mast pitch

exceeds that angle, the weight display will go blank. The default setting is 5 degrees.

Touch the Pitch Angle Limit button.

Touch a button to disable pitch angle blanking or to select a maximum mast pitch

angle (1, 2, 3, 4, or 5 degrees).

Touch the OK button to confirm your selection or the Cancel button to cancel any

changes that you made.

Battery Levels This screen shows the actual voltage levels that correspond to the battery level indicator

settings on the main weighing screen. The default voltage levels were determined at the

factory and should not need to be changed. Do not use a battery if the voltage level is

below 10.5 volts.

Touch the Battery Levels button to display the current battery voltage settings.

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METTLER TOLEDO MCFA Forklift Scale Service Manual

If you wish to change a voltage setting, touch the button that shows the current

setting. A keypad will be displayed on the screen.

Type a voltage level in the data field by touching the numeric keys on the keypad.

Touch the Clear button if you wish to clear the data field and start over.

Touch the Enter button to confirm your selection or the Cancel button to cancel any

changes that you made.

Touch the Exit button to enter the settings shown on the screen and close the

screen. Touch the Cancel button to cancel any changes that you made.

Units

Select the weight unit to be used for the scale (pounds or kilograms). This calibration

unit will be used when the scale is first powered up. If you change the calibration unit,

you must recalibrate the scale. The default setting is pounds (lb).

Touch the Units button.

Touch a button to select the desired weight unit (lb or kg).

Touch the OK button to confirm your selection or the Cancel button to cancel any

changes that you made.

Capacity

Enter the total capacity of the scale. The capacity must be entered in the calibration unit

specified for the scale. The default setting is 5000 lb (or 2000 kg).

Touch the Capacity button to display a keypad on the screen.

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Chapter 4: Scale Setup

Scale

Type a weight in the data field by touching the numeric keys on the keypad. Touch

the Clear button if you wish to clear the data field and start over.

Touch the Enter button to confirm your selection or the Cancel button to cancel any

changes that you made.

Increment

Select the increment (minimum weight unit to be displayed by the scale). The increment

must correspond to the calibration unit specified for the scale. Larger increments will

result in less weight precision but quicker weighing time. The default setting is 5 lb.

Touch the Increment button.

Touch a button to select an increment size (0.2, 0.5, 1, 2, 5, 10, or 20).

Touch the OK button to confirm your selection or the Cancel button to cancel any

changes that you made.

Gross/Net

Gross/net switching enables the controller to toggle between gross and net weight. Net

weight will be available only after a tare weight has been established. The default setting

is Enabled.

Touch the Gross/Net button.

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METTLER TOLEDO MCFA Forklift Scale Service Manual

Touch the check box to place a check mark in it (enabling the function) or to

remove a check mark (disabling the function).

Touch the OK button to confirm your selection or the Cancel button to cancel any

changes that you made.

Unit Switching

Unit switching enables the controller to toggle between lb and kg. The default setting is

Enabled.

Touch the Unit Switching button.

Touch the check box to place a check mark in it (enabling the function) or to

remove a check mark (disabling the function).

Touch the OK button to confirm your selection or the Cancel button to cancel any

changes that you made.

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Chapter 4: Scale Setup

Scale

Calibration Only qualified service technicians should calibrate the scale. Touch the Calibration

button to access the calibration features.

Where Calibrated

The scale controller can compensate for variations caused by gravitational forces. This

feature shows the gravity factor (geo index) for the location where the scale was

calibrated. The geo index is set to 16 at the factory (16 is the geo index for

Worthington, Ohio, USA). Do not change this geo index unless you perform a full

recalibration of the scale.

If you recalibrate the scale, use the following procedure to set the geo index for the

calibration location.

Touch the Where Calibrated button to display a keypad on the screen.

Type a number in the data field by touching the numeric keys on the keypad (the

range is 0 to 31). Touch the Clear button if you wish to clear the data field and

start over.

Touch the Enter button to confirm your selection or the Cancel button to cancel any

changes that you made.

Where Used

This feature shows the geo index for the location where the scale will be used. You can

change the setting to compensate for local gravitational forces. To determine the geo

index for a location, refer to Chapter 10. You must know the geographical coordinate for

the location and the elevation above sea level.

Touch the Where Used button to display a keypad on the screen.

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METTLER TOLEDO MCFA Forklift Scale Service Manual

Type a number in the data field by touching the numeric keys on the keypad (the

range is 0 to 31). Touch the Clear button if you wish to clear the data field and

start over.

Touch the Enter button to confirm your selection or the Cancel button to cancel any

changes that you made.

Inclinometer

This feature is used to set the pitch and roll reference angles. The serial number, initial

zero values, and initial span values are entered at the factory to match data provided by

the manufacturer of the inclinometer.

Touch the Inclinometer button to display the serial number, zero values, and span

values for the inclinometer. A value can be changed manually by touching the

button for the value and then using the keypad to enter a new value.

Park the forklift on a level surface, remove all load from the forks, raise the forks off

the ground, set the mast to the vertical position, and shut off the forklift’s motor.

Touch the Next button to continue (or touch the Back button to go back a step).

The screen will display the active and indicated pitch and roll reference angles.

Touch the Next button to update the values (or touch the Back button to go back a

step). The system will count down as it updates the values. The new pitch and roll

reference angles will be displayed.

Touch the Finish button to accept the new values.

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Chapter 4: Scale Setup

Scale

Loadcell

This feature is used to set spans for the chain load cells, to calibrate spans for the drag

load cells, and to establish zero constants for all load cells. Touch the Loadcell button.

To view the active load cell span constants, touch the View Constants button. A value

can be changed manually by touching the button for the value and then using the

keypad to enter a new value. The values for the chain load cells (LC3 and LC4) are set

by default to 2500 and should not be changed. To close the view constants screen,

touch the Back button. Changes will be lost if you exit setup without saving them.

Calibrate spans for the drag load cells:

Touch the Calibrate Spans button to calibrate span values for the drag load cells.

Park the forklift truck on a level surface, remove all load from the forks, set the mast

to the vertical position, and raise the forks slightly more than 15 inches off the

ground.

Position a block 15 inches high under the bottom roller on each side of the scale

carriage. Lower the carriage onto the blocks until the chains are slack, and then

raise the carriage off the blocks (repeat this several times to exercise the scale).

With the carriage raised off the blocks, shut off the forklift truck’s motor. Wait about

15 seconds for the scale to stabilize.

Touch the Next button to capture zero. The system will count down as it updates

the values.

Lower the carriage onto the blocks, and wait about 15 seconds for the scale to

stabilize.

Touch the Next button to calibrate the span values. The system will count down as

it updates the values. The new drag load cell span constants will then be

displayed.

Touch the Finish button to accept the new span values.

Raise the carriage and remove the blocks.

Establish zero for the scale:

Touch the Establish Zeros button to display the load cell zero constants.

Touch the Next button to update the constants. The system will count down as it

updates the values.

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METTLER TOLEDO MCFA Forklift Scale Service Manual

The new zero constants will be displayed. A value can be changed manually by

touching the button for the value and then using the keypad to enter a new value.

Touch the Finish button to save the new constants, or touch the Back button to

close the screen without saving the new constants.

Linearity

This feature is used to calibrate the scale’s linearity. We recommend using five test

weights of 1,000 lb each. You can also calibrate linearity using test weights equal to

one half the scale capacity and full scale capacity. Touch the Linearity button.

To view the active linearity constants, touch the View Constants button. A value can be

changed by touching the button for the value and then using the keypad to enter a new

value. To close the view constants screen without making any changes, touch the Back

button.

Check the scale’s linearity to determine if calibration is needed:

• Park the forklift truck on a level surface, raise the forks 12 to 15 inches off the

ground, set the mast to the vertical position, and shut off the forklift truck’s motor.

Place a pallet on the forks, and use the weight of the pallet as the tare weight.

• Record the net weight with no test weight on the scale. Then add the five test

weights one at a time, recording the net weight after each test weight is added. You

should have weight readings for the following test weights: 0, 1000, 2000, 3000,

4000, and 5000 lb. Then remove the test weights from the scale one at a time,

recording the net weight each time you remove a test weight.

If the weight readings are out of tolerance, perform the following calibration procedure:

Park the forklift truck on a level surface, place a pallet on the forks, raise the forks

12 to 15 inches off the ground, set the mast to the vertical position, and shut off the

forklift truck’s motor.

Touch the Calibrate Linearity button to display the linearity test setup. For the

default test setup, all six boxes will be checked and the following weight values will

be listed on the buttons next to the boxes: 0, 1000, 2000, 3000, 4000, and

5000. If you plan to use a different range of weights, reconfigure the test setup to

match those weights. You can select or deselect a step by touching the check box.

You can change a weight value by touching the button to open a keypad that will

allow you to enter a new weight value. When the correct weight values are

displayed, touch the Next button to continue.

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Chapter 4: Scale Setup

Scale

With zero test weight on the scale, touch the Next button. The system will count

down as it updates the values.

Add test weight so that the total weight on the scale equals 1,000 lb, allow the

scale to stabilize, and then touch the Next button. The system will count down as it

updates the values.

Add test weight so that the total weight on the scale equals 2,000 lb, allow the

scale to stabilize, and then touch the Next button. The system will count down as it

updates the values.

Add test weight so that the total weight on the scale equals 3,000 lb, allow the

scale to stabilize, and then touch the Next button. The system will count down as it

updates the values.

Add test weight so that the total weight on the scale equals 4,000 lb, allow the

scale to stabilize, and then touch the Next button. The system will count down as it

updates the values.

Add test weight so that the total weight on the scale equals 5,000 lb, allow the

scale to stabilize, and then touch the Next button. The system will count down as it

updates the values.

Touch the Compute button to calculate the new linearity constants.

10.

The new linearity constants will be displayed. Touch the Finish button to accept the

new constants.

Angle

The following screens will walk you through the procedure for calibrating pitch and roll

angles for the mast. This procedure will compensate for any variation in weight readings

that might occur when the mast is set at different angles. Touch the Angle button.

To view the active angle constants, touch the View Constants button. A value can be

changed manually by touching the button for the value and then using the keypad to

enter a new value. To close the view constants screen without making any changes,

touch the Back button.

Determine if angle calibration is needed by checking the scale’s accuracy with the mast

set at several angles. Use the same test weight for each mast setting. The recommended

test weight is full scale capacity (5,000 lb). To change the test weight amount, touch

the test weight button on the angle calibration screen and then use the keypad to enter a

new weight value.

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METTLER TOLEDO MCFA Forklift Scale Service Manual

• Park the forklift truck on a level surface, set the mast to the vertical position, and

raise the forks 12 to 15 inches off the ground. The forklift truck’s motor should be

shut off when taking weight readings. Place a pallet on the forks, and zero the

scale. Place the test weight on the scale, and record the weight.

• Check the mast pitch: Remove the test weight, set the mast 5 degrees backward,

and zero the scale. Then place the test weight on the scale, and record the weight.

Remove the test weight, set the mast 5 degrees forward, and zero the scale. Then

place the test weight on the scale, and record the weight.

• Check the mast roll: Set the mast to the vertical position. Remove the test weight,

position the forklift truck on a ramp so that the mast is angled approximately 3

degrees to the right, and zero the scale. Then place the test weight on the scale,

and record the weight. Remove the test weight, position the forklift truck on a ramp

so that the mast is angled approximately 3 degrees to the left, and zero the scale.

Then place the test weight on the scale, and record the weight.

If the weight readings are out of tolerance, then calibrate the mast pitch angle or both

the mast pitch and mast roll angles. Use the following procedure to calibrate the mast

pitch angle:

Park the forklift truck on a level surface, place a pallet on the forks, raise the forks

12 to 15 inches off the ground, set the mast to the vertical position, and shut off the

forklift truck’s motor.

Touch the Calibrate Angle button.

Touch the Next button. The system will count down as it updates the zero load

values.

Add the test weight, allow the scale to stabilize, and then touch the Next button.

The system will count down as it updates the loaded values.

Remove the test weight from the scale.

Set the mast so that it is angled approximately 5 degrees backward. Shut off the

forklift truck’s motor.

Touch the Next button. The system will count down as it updates the zero load

values.

Add the test weight, allow the scale to stabilize, and then touch the Next button.

The system will count down as it updates the loaded values.

Remove the test weight from the scale.

10.

Set the mast so that it is angled approximately 5 degrees forward. Shut off the

forklift truck’s motor.

11.

Touch the Next button. The system will count down as it updates the zero load

values.

12.

Add the test weight, allow the scale to stabilize, and then touch the Next button.

The system will count down as it updates the loaded values.

13.

Touch the Compute button to calculate the new pitch angle constants, or touch the

Continue button to continue calibrating both pitch and roll angles.

To calibrate the mast roll angle, continue with the following steps:

14.

Remove the test weight from the scale, and set the mast to the vertical position.

15.

Position the forklift truck on a ramp so that the mast is angled approximately 3

degrees to the right. Shut off the forklift truck’s motor.

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Chapter 4: Scale Setup

Scale

16.

Touch the Next button. The system will count down as it updates the zero load

values.

17.

Add the test weight, allow the scale to stabilize, and then touch the Next button.

The system will count down as it updates the loaded values.

18.

Remove the test weight from the scale.

19.

Position the forklift truck on a ramp so that the mast is angled approximately 3

degrees to the left. Shut off the forklift truck’s motor.

20.

Touch the Next button. The system will count down as it updates the zero load

values.

21.

Add the test weight, allow the scale to stabilize, and then touch the Next button.

The system will count down as it updates the loaded values.

22.

Touch the Compute button to calculate the new pitch and roll angle constants.

23.

Touch the Finish button to accept the new constants.

Download Data

This feature downloads calibration constants from the controller. WARNING: This feature

will overwrite all calibrated data. The only reason to download the constants is if you

have replaced the circuit board in the telemetry enclosure.

Touch the Download Data button. A window will open, explaining that updating the

constants might take 30 seconds and asking if you wish to continue.

Touch the Update button to proceed with the download or the Cancel button to

keep the previous settings.

You will need to restart the scale controller to complete the procedure.

Factory Use The following features are to be used only at the METTLER TOLEDO factory. Touch the

Factory Use button to access the features.

Hardware Tests

Touch the Hardware Tests button to run the hardware tests. The controller will prompt

you to connect it to a manufacturing line PC and then prompt you to scan the 5-part

tag.

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METTLER TOLEDO MCFA Forklift Scale Service Manual

Use a bar code scanner or keyboard to enter the data. Continue through the memory,

display resolution, display color, and calibrate touch tests. The tests are described in the

terminal and maintenance setup sections.

Reset The Reset button is used to reset the scale parameters to the factory default settings.

Touch the Reset button.

Touch the Reset button to restore the default scale parameters or the Cancel button

to keep the current settings.

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Chapter 4: Scale Setup

Application

The application setup features are used to adjust the settings for the system’s

accumulator and SmartWeigh functions. Touch the Application button to display buttons

for the individual application setup features.

Accumulate The scale can accumulate a series of weight readings and sum the readings to

calculate a total weight. In order to use the accumulate function, you must enable it. The

default setting is Disabled.

Touch the Accumulate button.

Touch a button to disable accumulation, enable basic accumulation, or enable

SmartWeigh functions.

Touch the OK button to confirm your selection or the Cancel button to cancel any

changes that you made.

If you select SmartWeigh or disable SmartWeigh by selecting one of the other options,

you will need to restart the controller in order for the change to take effect.

SmartWeigh Touch the SmartWeigh button to access the features.

Save Path

Enter the path to be used when saving SmartWeigh data to a file. The default path is

\DiskC\weighments.csv.

Touch the Save Path button to open the save path screen.

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METTLER TOLEDO MCFA Forklift Scale Service Manual

Type a path in the data field. You will need to connect a keyboard to the controller

to type the path. Use the Clear key if you wish to clear the data field and start over.

Touch the Exit button to confirm your selection.

Company

Enter the ID for the company that is using the scale.

Touch the Company button to display a keypad on the screen.

Type the Company ID in the data field by touching the numeric keys on the keypad.

Touch the Clear button if you wish to clear the data field and start over.

Touch the Enter button to confirm your selection or the Cancel button to cancel any

changes that you made.

Terminal

Enter the ID for the shipping terminal where the scale is being used.

Touch the Terminal button to display a keypad on the screen.

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Chapter 4: Scale Setup

Application

Type the Terminal ID in the data field by touching the numeric keys on the keypad.

Touch the Clear button if you wish to clear the data field and start over.

Touch the Enter button to confirm your selection or the Cancel button to cancel any

changes that you made.

Forklift ID

Enter the ID for the forklift on which the scale is installed.

Touch the Forklift ID button to display a keypad on the screen.

Type the Forklift ID in the data field by touching the numeric keys on the keypad.

Touch the Clear button if you wish to clear the data field and start over.

Touch the Enter button to confirm your selection or the Cancel button to cancel any

changes that you made.

Memory The application log lists communication errors and other notable events. The memory

features allow you to define the maximum size of the log and specify the amount of

detail included in each entry. Touch the Memory button to access the features.

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METTLER TOLEDO MCFA Forklift Scale Service Manual

Application Log Size

This feature allows you to specify the maximum amount of data (in kilobytes) that the

log will store. When the log reaches the maximum, it will begin deleting the earliest

entries as new entries are made. The default setting is 20.

Touch the App Log Size button.

Touch a button to select the amount of data to be stored in the log (10, 20, 50, or

100).

Touch the OK button to confirm your selection or the Cancel button to cancel any

changes that you made.

Application Log Level

This feature allows you to specify the amount of detail included in each entry. You can

select a level from 0 to 9, with 9 being the maximum amount of detail. The default is 2.

The level that is specified affects both the application log and communications log.

Touch the App Log Level button to display a keypad on the screen.

Type a number in the data field by touching the numeric keys on the keypad. Touch

the Clear button to clear the data field and start over.

Touch the Enter button to confirm your selection or the Cancel button to cancel any

changes that you made.

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Chapter 4: Scale Setup

Terminal

Reset The Reset button is used to reset the application parameters to the factory default

settings.

Touch the Reset button.

Touch the Reset button to restore the default application parameters or the Cancel

button to keep the current settings.

Terminal

The terminal setup features are used to set date and time, assign passwords, and set

other terminal functions. Touch the Terminal button to display buttons for the individual

terminal setup features.

Date/Time The date/time feature allows you to change the date and time that are displayed on the

controller and to change the formats in which they are displayed. Touch the Date/Time

button to access the features.

Set

Touch the Set button to change the date or time. To center the calendar on the screen,

place your finger on the calendar’s title bar and drag the calendar to a new position.

• To set the month, touch the arrows on either side of the month that is displayed or

touch the month label to choose from a list of months.

• To set the date, touch a date on the calendar.

• To set the time, enter it in the Current Time field. Touch a part of the current time

(hours, minutes, seconds, or AM/PM) and then use the up and down arrows to

make changes.

• To set the time zone, select it from the combo box.

Touch the Apply button or OK button to accept the changes that you have made. Touch

the X button to close the calendar without making changes.

Format

Touch the Format button to change the formats in which the date and time are

displayed. To center the form on the screen, place your finger on the title bar and drag

the form to a new position. There are five tabs on the form: Regional Settings, Number,

Currency, Time, and Date. Touch the Time or Date tab to make changes.

Set the time format:

• To set the time style, select a format from the combo box: (h:mm:ss tt, hh:mm:ss

tt, H:mm:ss, HH:mm:ss). A sample will be displayed on the tab.

• Combo boxes are also available for setting the format of the time separator (:), AM

symbol, and PM symbol.

Set the date format:

• The short date format includes the date, month, and year. The long date format

includes the day of the week, date, month, and year.

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METTLER TOLEDO MCFA Forklift Scale Service Manual

• To set the short date style, select a format from the combo box: M/d/yy; M/d/yyyy;

MM/dd/yy; MM/dd/yyyy; yy/MM/dd; yyyy/MM/dd.

• A combo box is also available for setting the format of the separator (/).

• To set the long date style, select a format from the combo box: dddd, MMMM

dd,yyyy; MMM dd, yyyy; dddd, dd MMMM, yyyy; dd MMMM, yyyy.

Touch the OK button to accept the changes that you have made. Touch the X button to

close the form without making changes.

Passwords You can assign passwords for three security levels: User, Supervisor, and Service. The

default setting is no passwords. If passwords are assigned, you will need to enter a

password when the controller is powered up (or when you try to enter setup or

calibration). If no passwords are assigned, you will have access to all functions without

entering a password. Touch the Passwords button to display the buttons for user,

supervisor, and service passwords.

User

The user password allows access to the scale’s weighing screen functions. If no other

passwords are assigned, it will also allow access to setup functions.

Touch the User button to assign a password for users. A keypad will be displayed

on the screen.

Type an alphanumeric password in the data field by touching the keys on the

keypad. Passwords must be five characters long. Touch the Clear button if you

wish to clear the data field and start over.

Touch the Enter button to confirm the new password or the Cancel button to cancel

any changes that you made.

Supervisor

The supervisor password allows access to the scale’s weighing screen functions and

setup functions. If a service password is assigned, supervisors will not be allowed

access to the scale and communications setup functions.

Touch the Supervisor button to assign a password for supervisors. A keypad will be

displayed on the screen.

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Chapter 4: Scale Setup

Terminal

Type an alphanumeric password in the data field by touching the keys on the

keypad. Passwords must be five characters long. Touch the Clear button if you

wish to clear the data field and start over.

Touch the Enter button to confirm the new password or the Cancel button to cancel

any changes that you made.

Service

The service password allows access to all scale functions.

Touch the Service button to assign a password for service personnel. A keypad will

be displayed on the screen.

Type an alphanumeric password in the data field by touching the keys on the

keypad. Passwords must be five characters long. Touch the Clear button if you

wish to clear the data field and start over.

Touch the Enter button to confirm the new password or the Cancel button to cancel

any changes that you made.

NOTE: Security restrictions depend on which security levels are being used. If no

password is assigned for a security level, the system will function as though that level

does not exist. For example, if there is a user password but no supervisor or service

passwords, then users will have access to setup and calibration functions. The same is

true of access for assigning passwords. If no service password exists, then a supervisor

will be able to assign one. But once a service password has been assigned, a

supervisor will no longer have access to change the service password.

Calibrate Touch This feature allows you to calibrate the touch screen so that the pointer automatically

appears at any location where your finger touches the screen.

Touch the Calibrate Touch button to start the seven-point calibration procedure.

A circular target will appear on the screen. Touch the center of the target. When you

touch it, the target will move to a new location on the screen.

Continue to touch the center of the target each time it moves until all seven points

have been tested.

When the test is completed, the screen will close automatically.

Operating System Touch the OS button to access the operating system features.

Exit to Operating System

This button is used to close the scale application and display the computer desktop on

the scale controller.

Touch the Exit to OS button.

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METTLER TOLEDO MCFA Forklift Scale Service Manual

Touch the Continue button to close the scale application or the Cancel button to

return to scale setup.

Launch Replog

This button is used to set up communication between the controller and a personal

computer. You will need to use a cable to connect the controller to the computer.

Touch the Launch replog button.

Touch the Continue button to launch the replog or the Cancel button to return to

scale setup without launching the replog.

Save Registry

This button is used to save the Windows CE configuration.

Touch the Save Registry button.

Touch the Continue button to save the registry or the Cancel button to return to

scale setup without saving the registry.

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Chapter 4: Scale Setup

Terminal

Backup Database

This button is used to create a backup file containing the metrological setup data for the

scale.

Touch the Backup Database button.

Touch the Continue button to back up the database or the Cancel button to return

to scale setup without backing up the database.

Restore Database

This button allows you to replace the scale’s metrological setup data with the data

stored in a backup file.

Touch the Restore Database button.

Touch the Continue button to restore the database or the Cancel button to return to

scale setup without restoring the database.

Brand Setup This feature is used to identify the brand of forklift truck on which the scale is installed.

Touch the Brand Setup button.

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METTLER TOLEDO MCFA Forklift Scale Service Manual

Select the brand by touching the Brand 1 or Brand 2 button.

Touch the OK button to confirm your selection or the Cancel button to cancel any

changes that you made.

Reset The Reset button is used to reset the terminal parameters to the factory default settings.

Touch the Reset button.

Touch the Reset button to restore the default terminal parameters or the Cancel

button to keep the current settings.

NOTE: Using the Reset button will delete any passwords that you assigned.

Communications

The communications setup features are used to configure communications between the

scale controller and carriage, as well as communications with other devices. Touch the

Communications button to display buttons for the individual communications setup

features.

Scale Radio You can configure communications between the scale carriage radio and controller

radio. Touch the Scale Radio button to access the scale radio setup features.

Carriage ID

Enter an ID for the carriage radio. The default Carriage ID is 000001.

Touch the Carriage ID button to display a keypad on the screen.

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Chapter 4: Scale Setup

Communications

Type an alphanumeric ID in the data field by touching the keys on the keypad.

Touch the Clear button if you wish to clear the data field and start over.

Touch the Enter button to confirm your selection or the Cancel button to cancel any

changes that you made.

You must restart the scale controller to activate a new selection.

Controller ID

Enter an ID for the controller radio. The default Controller ID is 000001.

Touch the Controller ID button to display a keypad on the screen.

Type an alphanumeric ID in the data field by touching the keys on the keypad.

Touch the Clear button if you wish to clear the data field and start over.

Touch the Enter button to confirm your selection or the Cancel button to cancel any

changes that you made.

You must restart the scale controller to activate a new selection.

Radio Channel

This feature allows you to select the channel used for radio communication between the

controller and carriage. The default channel is 65. If you are using more than one forklift

scale at your facility, select a different channel for each scale.

Touch the Radio Channel button to display a keypad on the screen.

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METTLER TOLEDO MCFA Forklift Scale Service Manual

Type a number in the data field by touching the numeric keys on the keypad. Valid

selections are 1 to 130. Touch the Clear button if you wish to clear the data field

and start over.

Touch the Enter button to confirm your selection or the Cancel button to cancel any

changes that you made.

You must restart the scale controller to activate a new selection.

Controller Power

This feature allows you to select the power level for the controller radio. A high power

level is recommended if the radio transmission experiences interference. The default

setting is 72.

Touch the Controller Power button.

Touch the button for the desired power level (6, 15, 29, 43, 58, or 72). The

numbers are approximate percentages of the maximum power.

Touch the OK button to confirm your selection or the Cancel button to cancel any

changes that you made.

You must restart the scale controller to activate a new selection.

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Chapter 4: Scale Setup

Communications

Carriage Power

This feature allows you to select the power level for the carriage radio. A high power

level is recommended if the radio transmission experiences interference. The default

setting is 86.

Touch the Carriage Power button.

Touch the button for the desired power level (6, 15, 29, 43, 58, 72, 86, or 100).

The numbers are approximate percentages of the maximum power.

Touch the OK button to confirm your selection or the Cancel button to cancel any

changes that you made.

You must restart the scale controller to activate a new selection.

Radio Persist

This feature allows you to select the fall-back time for the controller and carriage radios.

If communication is disrupted, the system will pause (fall back) before continuing to

transmit a signal. The default setting is 40.

Touch the Radio Persist button.

Touch the button for the desired fall-back time (10, 20, 40, 60, 80, 100, 180, or

255).

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METTLER TOLEDO MCFA Forklift Scale Service Manual

Touch the OK button to confirm your selection or the Cancel button to cancel any

changes that you made.

You must restart the scale controller to activate a new selection.

Squelch

The squelch feature is used to suppress background noise generated by the scale

controller. A higher setting provides more noise suppression. The default setting is 39.

Touch the Squelch button to display a keypad on the screen.

Type a squelch level in the data field by touching the numeric keys on the keypad.

Touch the Clear button if you wish to clear the data field and start over.

Touch the Enter button to confirm your selection or the Cancel button to cancel any

changes that you made.

Polling Interval

The polling interval is the time delay (in milliseconds) between a request for data and

the scale’s response. The default setting is 200 for radios operating at 5 Hz.

Touch the Polling Interval button to display a keypad on the screen.

Type a polling interval in the data field by touching the numeric keys on the keypad.

Touch the Clear button if you wish to clear the data field and start over.

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Chapter 4: Scale Setup

Communications

Touch the Enter button to confirm your selection or the Cancel button to cancel any

changes that you made.

Carrier On

This feature sets the controller and carriage radios so that they can broadcast in

constant carrier mode. It is a diagnostics tool that allows you to use a frequency meter

to check the broadcast frequency of the radios. To check the frequency of one radio, you

will need to shut off power to the other radio. In order to return the radios to normal

operating mode, you must restart them.

Touch the Carrier On button.

Touch the Continue button to set the radios to constant carrier mode or the Cancel

button to return to scale setup without changing the radio mode.

COM1 A serial communication port (COM1) is available so that the scale controller can be

connected to printers and other serial devices. Touch the COM1 button to view or

change the serial communication settings.

Baud Rate

Specify the baud rate for serial communications. The default setting is 38400.

Touch the Baud Rate button.

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METTLER TOLEDO MCFA Forklift Scale Service Manual

Touch the button for the desired baud rate setting (9600, 19200, 38400, 57600,

or 115200).

Touch the OK button to confirm your selection or the Cancel button to cancel any

changes that you made.

Parity

Specify the parity for serial communications. The default setting is Even.

Touch the Parity button.

Touch the button for the desired parity setting (None, Odd, or Even).

Touch the OK button to confirm your selection or the Cancel button to cancel any

changes that you made.

Data Bits

Specify the number of data bits for serial communications. The default setting is 8.

Touch the Data Bits button.

Touch the button for the desired data bit setting (7 or 8).

Touch the OK button to confirm your selection or the Cancel button to cancel any

changes that you made.

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Chapter 4: Scale Setup

Maintenance

Stop Bits

Specify the number of stop bits for serial communications. The default setting is 1.

Touch the Stop Bits button.

Touch the button for the desired stop bit setting (1, 1.5, or 2).

Touch the OK button to confirm your selection or the Cancel button to cancel any

changes that you made.

Reset The Reset button is used to reset the communications parameters to the factory default

settings.

Touch the Reset button.

Touch the Reset button to restore the default communications parameters or the

Cancel button to keep the current settings.

Maintenance

The maintenance setup features are used to monitor and test the scale’s operations.

Touch the Maintenance button to display buttons for the individual maintenance setup

features.

Log The application log keeps a list of communication errors and other notable events. You

can view the log or delete entries from the log. Touch the Log button to access the

features.

View Application Log

This button opens the application log so that you can view the log entries.

Touch the View App Log button.

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METTLER TOLEDO MCFA Forklift Scale Service Manual

Touch the Exit button to close the log.

Clear App Log

Touch the Clear App Log button.

Touch the Continue button to delete all existing log entries or the Cancel button to

keep the current entries.

Diagnostics The diagnostics features are used to check system operations. Touch the Diagnostics

button to access the features.

Memory

Touch the Memory button to test the compact flash memory. Touch the Start button to

perform the test.

Display Resolution

Touch the Display Resolution button to test the screen’s resolution at four settings.

When all four resolutions have been displayed, touch the OK button to complete the test.

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Chapter 4: Scale Setup

Maintenance

Display Color

Touch the Display Color button to test the screen’s colors: black, red, green, blue, and

white. When all five colors have been displayed, touch the OK button to complete the

test.

Streaming Data

The streaming data log keeps track of the data transmitted between the controller and

carriage radios. The amount of data recorded depends on the application log level (see

application setup).

Touch the Streaming Data button to open the log.

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METTLER TOLEDO MCFA Forklift Scale Service Manual

Touch the Pause button to stop the system from displaying new entries so that you

can read the log.

After viewing the log, touch the Clear button to delete all log entries or the Exit

button to close the log.

Data Screen

The data screen displays data that is used to check the condition of the load cells. It

also displays the pitch and roll angles for the mast.

Touch the Data Screen button.

Touch the Zero button to establish the existing zero setting as a reference point.

Touch the Clear button if you wish to clear the zero reference.

Touch the Exit button to return to the setup menu.

Communications Timing

This screen displays the system’s communications timing data (in milliseconds). The

system averages data from a series of communications. You can reset the data so that

the system starts averaging from the current transmission.

Touch the Comms Timing button.

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Chapter 4: Scale Setup

Maintenance

Touch the Reset button to start averaging a new series of data.

Touch the Exit button to close the screen.

Battery Voltage

This screen displays the current battery voltage level and the setting for the alarm used

to signal that the battery needs to be changed.

Touch the Battery Voltage button to view the battery settings.

Touch the Exit button to return to the setup menu.

Radio Power

This screen displays the current receive and transmit power for the controller and

carriage radios. The radio power level is set in communications setup.

Touch the Radio Power button.

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METTLER TOLEDO MCFA Forklift Scale Service Manual

Touch the Exit button to return to the setup menu.

Ambient Noise

This screen is used to check the ambient noise level for the radio channels. Lower

ambient noise levels provide better communication. For a forklift scale, you should

select a radio channel with a noise level of 20 or lower.

Touch the Ambient Noise button. The noise level will be shown for the radio

channel that is currently being used.

To view the noise level for another channel, touch the Channel # button. A keypad

will be displayed on the screen.

Type in a number by touching the numeric keys on the keypad. Touch the Clear

button if you wish to clear the data field and start over

Touch the Enter button to confirm your selection.

You can now view the ambient noise level for the new channel. Touch the Exit

button to close the screen.

This feature is used to check the ambient noise levels on radio channels. To change the

channel used for radio communication, go to the Radio Channel button in

communications setup.

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Chapter 4: Scale Setup

Exit Setup

Radio Version

This screen displays the radio firmware version for the controller and carriage radios.

Touch the Radio Version button to view the version numbers.

Touch the Exit button to close the screen.

Reset The Reset button is used to reset all setup parameters to the factory default settings.

Touch the Reset button.

Touch the Reset button to restore the default parameters or the Cancel button to

keep the current settings.

Exit Setup

The Exit Setup button is used to exit setup mode and return to the scale’s main

weighing screen. You will be prompted to confirm any setup changes before exiting.

Touch the Exit Setup button.

Touch the Save button to save any configuration changes, or touch the Cancel

button to cancel the changes and return to the previous settings.

The controller will return to the main weighing screen.

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Chapter 5: Routine Care and Maintenance

General

Routine Care and Maintenance

General

Once you have installed your scale, you should have an authorized METTLER TOLEDO

representative periodically inspect and calibrate it. If the scale is used for legal-for-trade

purposes, consult the local weights and measures authorities for minimum inspection

requirements. Contact your local authorized METTLER TOLEDO service representative for

information about periodic inspection and calibration services.

IMPORTANT: As part of the regular maintenance schedule, check the bolts that secure

the two chain load cell mounts to the carriage. Check the torque of the bolts after the first

100 hours that the forklift scale has been in use, and check it every 1,000 hours

thereafter. The bolts on the simplex version should be torqued to 50 ft-lb (see Figure 5-

1). The bolts on the triplex version should be torqued to 180 ft-lb (see Figure 5-2).

Torque Bolts to 50 ft-lb Chain Load Cell

Master Link

Chain Mount

Figure 5-1: Chain Mount Assembly (Simplex Version)

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METTLER TOLEDO MCFA Forklift Scale Service Manual

Chain Load Cell

Master Link

Chain Mount

Torque Bolts to 180 ft-lb

Figure 5-2: Chain Mount Assembly (Triplex Version)

Cleaning

Clean the scale controller’s cover with a soft, clean cloth that has been dampened with

a mild window-type cleaner or detergent. DO NOT USE ANY TYPE OF INDUSTRIAL

SOLVENT OR CHEMICALS. DO NOT SPRAY CLEANER DIRECTLY ONTO THE UNIT. DO

NOT HOSE DOWN.

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Chapter 6: Troubleshooting

General

Troubleshooting

General

If a scale is not working properly, find out as much about the problem as possible. Try

to determine whether the problem is constant or intermittent. Mechanical and electrical

influences can cause malfunctions, so be patient and use sound logic when

troubleshooting.

WARNING

PERMIT ONLY QUALIFIED PERSONNEL TO SERVICE THIS

EQUIPMENT. EXERCISE CARE WHEN MAKING CHECKS,

TESTS, AND ADJUSTMENTS THAT MUST BE MADE WITH

POWER ON. FAILING TO OBSERVE THESE PRECAUTIONS

CAN RESULT IN BODILY HARM.

DANGER

IF USED IN A HAZARDOUS AREA, THE HAZARDOUS AREA

MUST BE MADE SAFE PRIOR TO INSTALLATION,

REPLACEMENT, OR TROUBLESHOOTING. FAILURE TO

COMPLY COULD RESULT IN PERSONAL INJURY, DEATH,

AND/OR PROPERTY DAMAGE.

WARNING

BEFORE CONNECTING/DISCONNECTING ANY INTERNAL ELECTRONIC COMPONENTS

OR INTERCONNECTING WIRING BETWEEN ELECTRONIC EQUIPMENT, ALWAYS

REMOVE POWER AND WAIT AT LEAST 30 SECONDS. FAILURE TO OBSERVE THESE

PRECAUTIONS COULD RESULT IN BODILY HARM OR DAMAGE TO OR DESTRUCTION

OF THE EQUIPMENT.

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METTLER TOLEDO MCFA Forklift Scale Service Manual

Error Messages

The following messages are displayed in the message bar on the controller’s main

weighing screen.

Message Remedy

ERR: Load is not stable – cannot take tare! Wait for scale to stabilize and then capture tare weight.

ERR: Cannot take a negative tare! Remove load from scale and zero scale.

ERR: Invalid mode – must be in Gross mode! Switch scale to gross weighing mode.

ERR: Load is not stable – cannot take zero! Wait for scale to stabilize and then capture zero.

ERR: Invalid mode – clear Tare to rezero! Clear the tare weight and then capture zero.

ERR: Current weight %6.0f, > manual zero range! Remove load from scale.

INFO: Configuration changes saved! Message appears when you exit setup and save changes.

INFO: Configuration changes abandoned! Message appears when you exit setup without saving changes.

ERR: Access to Setup not authenticated! Check the password and enter it again.

ERR: No Tare, ‘Net’ Invalid Mode Capture a tare weight before switching to net weighing mode.

ERR: Load is not stable – cannot accumulate! Wait for scale to stabilize and then accumulate.

ERR: AZM weight %6.0f, > manual zero range! Remove load from scale.

SEND Radio Comm PID ERROR System will resend data automatically.

READ Radio Comm PID ERROR System will reread data automatically.

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Chapter 6: Troubleshooting

Error Messages

The following messages are displayed in pop-up windows on the scale controller.

Message Remedy

Radio controller not communicating. Check carriage battery. Make sure radio channel selected in

setup matches channel indicated by blinking light in telemetry

box.

WARN: Controller Radio ID does not match database. Do you

want to update the database Controller ID?

Update Controller ID.

WARN: Controller Radio Power does not match database. Do

you want to update controller power?

Update controller power.

WARN: Controller Radio Persist does not match database. Do

you want to update controller persist?

Update controller persist.

WARN: Carriage Radio Power does not match database. Do you

want to update carriage power?

Update carriage power.

WARN: Carriage Radio Persist does not match database. Do

you want to update carriage persist?

Update carriage persist.

Carriage Calibration Constants do not match database.

Updating the database will take about 30 seconds. Do you

want to update the database?

Update database.

Failed to load Calibration Constants from Carriage Radio Recycle power to scale controller.

No Scale Available Check carriage battery. Make sure radio channel selected in

setup matches channel indicated by blinking light in telemetry

box.

WARN: Radio controller parameters do not match database.

Controller Channel = %i. Database Channel = %i. Do you want

to update the Controller Channel and Carriage Channel with the

database values?

Update controller channel and carriage channel.

WARN: Radio controller parameters do not match database.

Controller Channel = %i. Database Channel = %i. Do you want

to update the Controller Channel with the database values?

Update controller channel.

Carriage Scale is not communicating. Check carriage battery. Make sure radio channel selected in

setup matches channel indicated by blinking light in telemetry

box.

WARN: Carriage Radio ID does not match database. Carriage

Radio ID = %i. Database ID = %i. Do you want to update the

database?

Update database.

Force Calibration Constants to Carriage Radio: Updating

Constants to the Carriage may take 30 seconds. Reset Scale

when Complete.

Update constants. Then recycle power to scale controller.

Initialize Carriage parameters failed. Try to initialize carriage parameters again.

Data is unstable. Wait for scale to stabilize before each calibration step.

Battery Voltage Low. Replace Battery. Replace battery in scale carriage.

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METTLER TOLEDO MCFA Forklift Scale Service Manual

Scale Controller

Make sure that the scale controller is receiving power and is communicating with the

scale carriage.

• The controller is powered by the forklift truck’s battery. When the forklift truck’s

motor is shut off, the controller will continue to operate until an internal time delay

cuts off power. With the forklift truck’s motor running, power up the controller by

pressing the on/off button on the front cover. If the controller does not start, check

the wiring that connects the controller to the battery to make sure that it is not

damaged or loose.

• The controller communicates with the scale carriage by radio transmission. If there

is a communication problem, the message “No Scale Communication” will be

displayed on the controller’s main weighing screen. Check the scale carriage

battery to make sure that it is charged and that it is inserted into the battery

compartment correctly. The battery compartment is wired to the printed circuit board

(PCB) inside the telemetry enclosure. Make sure that the battery wire is not loose or

damaged.

• If the scale carriage is sending a signal, the channel indicator on the telemetry box

will be flashing. The flashing red light indicates which radio channel is being used.

The sequence starts with five quick flashes, followed by a pause. Then there is a

series of slower flashes for each numeral, with a pause between numerals. For

example, five quick flashes, a pause, six slower flashes, a pause, and then 5

slower flashes indicates channel 65 (the default channel). Zero is indicated by ten

flashes. Since you can use radio channels 1 to 130, a channel can consist of as

few as one numeral or as many as three numerals.

Check Mechanical

Components

Check the scale to make sure the mechanical components are not damaged, worn, or

binding.

• Check the scale’s flexures to make sure they are not bent or warped.

• Make sure that no scale components are loose. All bolts should be tightened

securely.

• Make sure that the scale carriage moves freely when it is raised and lowered.

• Make sure that that scale is not binding. The only scale components that should be

touching the mast are the rollers.

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Chapter 6: Troubleshooting

Check Overload Gaps

The overload bumpers are designed to protect the load cells and flexures from being

damaged if an excessive load is placed on the scale. Use a feeler gauge to check the

overload bumper gaps. All gaps should be set to 0.020 inch ±0.005 inch (see Figure

6-1).

0.020 inch

Figure 6-1: Overload Bumper Gaps

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METTLER TOLEDO MCFA Forklift Scale Service Manual

Check Wiring 1.

Remove power from the system.

Remove the cover from the telemetry enclosure and check the interior for moisture

or foreign material.

Make sure that all wiring connections are tight and that no insulation material is

touching the terminal contacts.

Check all load cell connections to make sure they are wired correctly. The wiring

color codes are shown in Figure 6-2.

Check the cable connections and cord grips. If the cord grips are loose, tighten the

nuts on the cord-grip clamp bar. Use a nut driver to tighten the nuts. Be careful to

tighten the nuts only to the point at which the cables will not slide through the cord

grips. Do not overtighten the nuts.

(Black) -

(Red) +

To Battery

(Green) +EXE

(Black) –EXE

(Yellow) Shield

(White) +IN

(

Red

)

-IN

To Left Chain

Load Cell

(Green) +EXE

(Black) –EXE

(Yellow) Shield

(White) +IN

(

Red

)

-IN

To Left Drag

Load Cell

(Green) +EXE

(Black) –EXE

(Yellow) Shield

(White) +IN

(

Red

)

-IN

To Right

Chain Load

To Right Drag

Load Cell

(Green) +EXE

(Black) –EXE

(Yellow) Shield

(White) +IN

(

Red

)

-IN

To Inclinometer

Radio Channel

Indicato

Figure 6-2: Load Cell Wiring Codes

Check Force Data

The force data being communicated to the scale controller provides a good indication of

how the load cells are performing.

Power up the scale controller.

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Chapter 6: Troubleshooting

Check Load Cells

Touch the Setup button to enter setup mode.

Open the data screen by touching the Maintenance button, the Diagnostics button,

and the Data Screen button.

Compare the force readings for the left drag load cell and the right drag load cell.

Compare the force readings for the left chain load cell and the right chain load cell.

If the force data is out of tolerance, check the load cells to make sure they are working

properly. The “Weight” reading for each drag load cell should be approximately -60 lb

(±40 lb). The “Weight” readings for the chain load cells should be approximately equal

(±100 lb). The “Total” readings for the drag load cells and chain load cells should be

opposite and approximately equal. For example, if the drag load cell total is -300, the

chain load cell total should be approximately +300. The calibrated weight is the sum of

those two numbers and should be approximately zero.

Check Load Cells 1.

Remove power from the system. Fully disconnect each load cell and check for

proper input/output resistances (see Table 6-1).

Measuring Points Resistance

+Exc (Green) to -Exc (Black) Greater than 1,000 ohms (typically 1,160 ohms)

+Sig (White) to -Sig (Red) 1,000 ±5 ohms

Table 6-1: Load Cell Measuring Points

If resistance is within specification, perform a shorted-signal symmetry test.

•

Short the signal leads together and place one multimeter lead on the shorted

signals and one lead on the +Excitation wire. Note the resistance value.

•

Remove the lead from the +Excitation wire and place it on the –Excitation wire.

The two resistance values should be approximately equal.

If the load cells pass the shorted-signal test, reconnect them and reapply power to

the scale. Confirm that the proper excitation voltage is reaching the load cells by

placing multimeter leads on the excitation positions of each load cell terminal.

If proper excitation voltage is reaching the load cells, check the output signal from

each cell by disconnecting the signal leads and measuring voltage output. If one

cell has a particularly high or low dead-load output, it is suspect. The maximum

output possible from any cell is 30 mV at 15 VDC excitation and loaded to gross

capacity.

If any load cell has an unusual signal, remove all load from that cell.

•

With the power on, measure the output from the suspect load cell. The no-load

zero output should be ±1.5% of the full scale output. For example, if the

excitation voltage is 15 VDC, then the full scale output would be 30 mV and

the no-load zero output should be within ±0.45 mV.

If a load cell fails any of the above tests, replace it.

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METTLER TOLEDO MCFA Forklift Scale Service Manual

Load Cell Replacement

If tests indicate that a load cell is not working properly, remove the load cell and replace

it with a new one.

Removing a Chain Load

Cell (Simplex)

Raise the carriage to a height that will make it easy to reach the load cells and

other scale components.

Shut off the forklift truck’s motor.

Remove the battery by pressing the tab toward the center of the battery and pulling

the battery from the battery compartment.

Remove the cover to the scale’s telemetry enclosure. The cover is held in place by

seven flat head cap screws. Leave the socket head screw in place. It attaches the

enclosure to the carriage.

The load cell cables are wired to the four terminal strips on the printed circuit board

(PCB) inside the telemetry enclosure. Locate the cable for the load cell that you are

replacing. You should be able to identify it by the tag attached to the cable.

Disconnect the cable’s wires from the terminal strip by inserting the tip of a flat-

blade screwdriver into the slot next to each wire and removing the wire from the

terminal.

Remove the five Phillips head screws that attach the PCB to the enclosure. Move

the PCB out of the way so that you have access to the cord-grip clamp bar (see

Figure 6-3). In order to remove the PCB, you might need to disconnect the battery

wires and unplug the inclinometer.

Terminal Strips

Cord-Grip Clamp Bar PCB

Telemetry Enclosure

Figure 6-3: Telemetry Enclosure

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Chapter 6: Troubleshooting

Load Cell Replacement

Loosen the six nuts on the cord-grip clamp bar. This will loosen the cord grips so

that you can remove the cable.

Remove the socket head screw that secures the telemetry enclosure to the carriage.

Pull the load cell cable through the cord grip to remove it from the telemetry

enclosure.

10.

The load cell cables are routed through the scale carriage under the cover plates

located at the top and bottom of the carriage. Remove the cover plate that conceals

the cable for the load cell you are replacing.

11.

Disconnect the chain anchor from the mast by removing the lower nut from the

threaded anchor (see Figure 6-4).

Jam Nut

Mast

Jam Nuts

Chain Anchor

Figure 6-4: Chain Anchor Assembly

12.

Pull the chain up and over the pulley.

13.

Remove the three bolts that secure the chain mount to the carriage. Then remove

the entire assembly (chain mount, load cell, and chain) from the carriage (see

Figure 6-5).

Bolts Chain Load Cell

Master Link

Chain Mount

Figure 6-5: Chain Mount Assembly

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METTLER TOLEDO MCFA Forklift Scale Service Manual

14.

Remove the cotter pin from the master link that secures the load cell to the chain

mount (See Figure 6-6). Take apart the master link, using a C-clamp or similar

device to press the master link through the link plates. Do not use a hammer or

other tool to strike the master link. It could damage the link.

Master Link

Link Plate (Large Holes)

Cotter Pin

Link Plate (Small Holes)

Figure 6-6: Master Link Assembly

15.

Remove the cotter pin and master link that secure the load cell to the chain.

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Chapter 6: Troubleshooting

Load Cell Replacement

Installing a New Chain

Load Cell (Simplex)

Use a master link to connect the new load cell to the chain. The chain should be

connected to the top of the load cell (the end opposite the load cell cable).

Assemble the master link as shown in Figure 6-6. Using a C-clamp or similar

device, press the master link assembly together just enough so that you can insert

the cotter pin in the holes. If the link is too tight, it can bind against the load cell

and chain.

Use a master link to connect the other end of the load cell to the chain mount.

Make sure that the load cell cable is facing away from the three bolt holes in the

chain mount. Assemble the master link as shown in Figure 6-6. Using a C-clamp

or similar device, press the master link assembly together just enough so that you

can insert the cotter pin in the holes. If the link is too tight, it can bind against the

load cell and chain mount.

Bolt the chain mount to the carriage, using the three bolts that were removed earlier

(see Figure 6-5). Torque all three bolts to 60 ft-lb (or 120% of the prescribed

torque value). Loosen all three bolts so that all torque is relieved. Retighten all bolts

to the prescribed torque of 50 ft-lb. The application of a medium-grade thread

locker is acceptable.

Route the chain up and over the pulley.

Remove the lower nut from the threaded chain anchor. Insert the threaded chain

anchor into the mounting hole in the mast. Place the lower nut on the threaded

anchor and tighten it until both it and the upper nut are tight against the mast (see

Figure 6-4).

If the load cell is on the opposite side of the carriage from the telemetry enclosure,

route the load cell cable through the scale carriage under the cover plate that you

removed.

Insert the load cell cable through the cord grip into the telemetry enclosure.

Wire the load cell cable to the terminal strip on the printed circuit board (PCB) inside

the telemetry enclosure. Connect the wires according to the wiring codes in Figure 6-

2. To connect a wire, insert the tip of a flat-blade screwdriver into the appropriate

slot in the terminal and insert the wire into the opening across from the slot.

Tighten the six nuts on the cord-grip clamp bar (see Figure 6-3). Use a nut driver

to tighten the nuts. Be careful to tighten the nuts only to the point at which the

cables will not slide through the cord grips. Do not overtighten the nuts.

10.

Use the socket head screw to secure the telemetry enclosure to the carriage.

11.

Replace the PCB in the enclosure and secure it with the five Phillips head screws. If

you disconnected the battery wire and inclinometer from the PCB, reconnect them.

12.

Coil any excess cable and store it in the open area of the carriage where the cover plate

was removed. Replace the cover plate and secure it with six Phillips head screws.

13.

Replace the cover on the telemetry enclosure and secure it with seven flat head

screws.

14.

Insert the battery in the battery compartment.

15.

Power up the scale controller and enter its setup mode. Open the data screen and

check the output for the two chain load cells. The output should be approximately

equal (±100 lb). Adjust the tension on the chain connected to the new load cell

until the outputs are within tolerance (refer to the “Adjust Load Cell Force” procedure

in this chapter).

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METTLER TOLEDO MCFA Forklift Scale Service Manual

Removing a Drag Load Cell

(Simplex)

Remove the forks from the lift truck.

Raise the inner mast high enough to allow room to slide the carriage down and out

of the mast.

Shut off the forklift truck’s motor.

Obtain a crane (or other lifting device) with a capacity of at least 500 lb. Wrap a

sling securely around the upper part of the carriage. Use the crane to raise the sling

high enough that it supports the weight of the carriage.

Remove the battery by pressing the tab toward the center of the battery and pulling

the battery from the battery compartment.

Disconnect the two chain anchors from the mast by removing the lower nut from

each threaded anchor (see Figure 6-4).

Pull the chains up and over the pulleys.

Use the crane to lower the carriage and remove it from the bottom of the mast.

Place the carriage on a stable working surface, with the front side of the carriage

facing downward.

10.

Remove the cover to the scale’s telemetry enclosure. The cover is held in place by

seven flat head cap screws. Leave the socket head screw in place. It attaches the

enclosure to the carriage.

11.

The load cell cables are wired to the four terminal strips on the printed circuit board

(PCB) inside the telemetry enclosure. Locate the cable for the load cell that you are

replacing. You should be able to identify it by the tag attached to the cable.

Disconnect the cable’s wires from the terminal strip by inserting the tip of a flat-

blade screwdriver into the slot next to each wire and removing the wire from the

terminal.

12.

Remove the five Phillips head screws that attach the PCB to the enclosure. Move

the PCB out of the way so that you have access to the cord-grip clamp bar (see

Figure 6-3). In order to remove the PCB, you might need to disconnect the battery

wires and unplug the inclinometer.

13.

Loosen the six nuts on the cord-grip clamp bar. This will loosen the cord grips so

that you can remove the cable.

14.

Remove the socket head screw that secures the telemetry enclosure to the carriage.

15.

Pull the load cell cable through the cord grip to remove it from the telemetry

enclosure.

16.

The load cell cables are routed through the scale carriage under the cover plates

located at the top and bottom of the carriage. Remove the cover plate that conceals

the cable for the load cell you are replacing.

17.

Remove the top flexure on the side of the scale where you will be replacing the load

cell. Note the position of any shims that are under the flexure so that you can

replace them later.

18.

Loosen the three nuts on the threaded rod that anchors the load cell to the upper

carriage mount (see Figure 6-7). Be careful not to turn the load cell while

loosening the nuts. Hold the load cell in position, and turn the nuts with a wrench.

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Chapter 6: Troubleshooting

Load Cell Replacement

Loosen Nuts

and Remove

Threaded Rod

Drag Load Cell

Mounting

Block

Remove Two Bolts

Figure 6-7: Drag Load Cell Assembly

19.

Unscrew the threaded rod to remove it from the load cell.

20.

Remove the two bolts that secure the lower mounting block to the carriage.

21.

Remove the load cell and lower mounting block through the opening in the back

side of the carriage.

22.

Loosen the jam nut at the bottom of the load cell and unscrew the load cell from

the threaded rod connected to the mounting block.

Installing a New Drag Load

Cell (Simplex)

Screw the threaded rod that is connected to the lower mounting block into the hole

at the bottom of the new load cell (see Figure 6-7). Make sure that the end of the

threaded rod does not extend into the gap in the load cell.

Position the load cell below the upper carriage mount in the scale carriage. Make

sure that the load cell cable faces the back of the carriage.

Insert the threaded rod through the hole in the upper carriage mount. Place a nut

on the threaded rod above the carriage mount and two nuts below the carriage

mount.

Screw the lower end of the threaded rod into the hole in the top of the new load cell.

Again, make sure that the end of the threaded rod does not extend into the gap in

the load cell.

Tighten the three jam nuts that secure the load cell to the upper carriage mount.

Make sure that there is clearance between the sides of the load cell and the

carriage.

Replace the top flexure, making sure to insert any shims in their original locations.

If the load cell is on the opposite side of the carriage from the telemetry enclosure,

route the load cell cable through the scale carriage under the cover plate that you

removed.

Insert the load cell cable through the cord grip into the telemetry enclosure.

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METTLER TOLEDO MCFA Forklift Scale Service Manual

Wire the load cell cable to the terminal strip on the printed circuit board (PCB)

inside the telemetry enclosure. Connect the wires according to the wiring codes in

Figure 6-2. To connect a wire, insert the tip of a flat-blade screwdriver into the

appropriate slot in the terminal and insert the wire into the opening across from the

slot.

10.

Tighten the six nuts on the cord-grip clamp bar (see Figure 6-3). Use a nut driver

to tighten the nuts. Be careful to tighten the nuts only to the point at which the

cables will not slide through the cord grips. Do not overtighten the nuts.

11.

Use the socket head screw to secure the telemetry enclosure to the carriage.

12.

Replace the PCB in the enclosure and secure it with the five Phillips head screws. If

you disconnected the battery wire and inclinometer from the PCB, reconnect them.

13.

Coil any excess cable and store it in the open area of the carriage where the cover

plate was removed. Replace the cover plate and secure it with six Phillips head

screws.

14.

Use the crane to lift the carriage and slide it up into the mast from the bottom of the

mast. Block the carriage to hold it in position.

15.

Route the chains up and over the pulleys.

16.

Insert each chain anchor into its mounting hole in the mast, and screw a nut onto

the bottom end of each threaded anchor (see Figure 6-4). Tighten the jam nuts

against the mast to secure the chains.

17.

Bolt the lower mounting block to the carriage and tighten the jam nuts (see Figure

6-7).

18.

After the scale carriage is secured to the mast, carefully remove the sling and any

additional blocking. Replace the forks on the carriage.

19.

Insert the battery in the battery compartment.

20.

Power up the scale controller and enter its setup mode. Open the data screen and

check the output for the two drag load cells. The output should be approximately

equal (the target is -60 lb ±40 lb). Adjust the load cells so that they are within

tolerance (refer to the “Adjust Load Cell Force” procedure in this chapter).

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6-14

Chapter 6: Troubleshooting

Load Cell Replacement

Removing a Chain Load

Cell (Triplex)

Raise the carriage to a height that will make it easy to reach the load cells and other

scale components.

Shut off the forklift truck’s motor.

Remove the battery by pressing the tab toward the center of the battery and pulling

the battery from the battery compartment.

Remove the cover to the scale’s telemetry enclosure. The cover is held in place by six

flat head cap screws.

The load cell cables are wired to the four terminal strips on the printed circuit board

(PCB) inside the telemetry enclosure (see Figure 6-8). Locate the cable for the load

cell that you are replacing. You should be able to identify it by the tag attached to the

cable. Disconnect the cable’s wires from the terminal strip by inserting the tip of a flat-

blade screwdriver into the slot next to each wire and removing the wire from the

terminal.

Figure 6-8: Telemetry Enclosure

Cord-Grip Clamp Bar

Telemetry Enclosure

PCB

Terminal Strips

Loosen the six nuts on the cord-grip clamp bar. This will loosen the cord grips so that

you can remove the cable.

Pull the load cell cable through the cord grip to remove it from the telemetry

enclosure.

The load cell cables are routed through the scale carriage under the cover plate

located at the bottom of the carriage. Remove the cover plate.

Disconnect the chain anchor from the mast by removing the lower nut from the

threaded anchor (see Figure 6-9).

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METTLER TOLEDO MCFA Forklift Scale Service Manual

Figure 6-9: Chain Anchor Assembly

10.

Pull the chain up and over the pulley.

11.

Remove the two bolts that secure the chain mount to the carriage. Then remove the

entire assembly (chain mount, load cell, and chain) from the carriage (see Figure 6-

10).

Figure 6-10: Chain Mount Assembly

Bolts

Jam Nut

Mast

Jam Nuts

Chain Anchor

Chain Load Cell

Master Link

Chain Mount

12.

Remove the cotter pin from the master link that secures the load cell to the chain

mount (See Figure 6-11). Take apart the master link, using a C-clamp or similar

device to press the master link through the link plates. Do not use a hammer or other

tool to strike the master link. It could damage the link.

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6-16

Chapter 6: Troubleshooting

Load Cell Replacement

Figure 6-11: Master Link Assembly

Master Link

Link Plate (Large Holes)

Cotter Pin

Link Plate (Small Holes)

13.

Remove the cotter pin and master link that secure the load cell to the chain.

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METTLER TOLEDO MCFA Forklift Scale Service Manual

Installing a New Chain

Load Cell (Triplex)

Use a master link to connect the new load cell to the chain. The chain should be

connected to the top of the load cell (the end opposite the load cell cable). Assemble

the master link as shown in Figure 6-11. Using a C-clamp or similar device, press

the master link assembly together just enough so that you can insert the cotter pin in

the holes. If the link is too tight, it can bind against the load cell and chain.

Use a master link to connect the other end of the load cell to the chain mount. Make

sure that the load cell cable is facing away from the bolt holes in the chain mount.

Assemble the master link as shown in Figure 6-11. Using a C-clamp or similar

device, press the master link assembly together just enough so that you can insert the

cotter pin in the holes. If the link is too tight, it can bind against the load cell and

chain mount.

Bolt the chain mount to the carriage, using the two bolts that were removed earlier

(see Figure 6-10). Torque all three bolts to 216 ft-lb (or 120% of the prescribed

torque value). Loosen all three bolts so that all torque is relieved. Retighten all bolts

to the prescribed torque of 180 ft-lb. The application of a medium-grade thread locker

is acceptable.

Route the chain up and over the pulley.

Remove the lower nut from the threaded chain anchor. Insert the threaded chain

anchor into the mounting hole in the mast. Place the lower nut on the threaded

anchor and tighten it until both it and the upper nut are tight against the mast (see

Figure 6-9).

Insert the load cell cable through the cord grip into the telemetry enclosure.

Wire the load cell cable to the terminal strip on the printed circuit board (PCB) inside

the telemetry enclosure. Connect the wires according to the wiring codes in Figure 6-2.

To connect a wire, insert the tip of a flat-blade screwdriver into the appropriate slot in

the terminal and insert the wire into the opening across from the slot.

Tighten the six nuts on the cord-grip clamp bar (see Figure 6-8). Use a nut driver to

tighten the nuts. Be careful to tighten the nuts only to the point at which the cables

will not slide through the cord grips. Do not overtighten the nuts.

Coil any excess cable and store it in the open area of the carriage where the cover plate

was removed. Replace the cover plate and secure it with four Phillips head screws.

10.

Replace the cover on the telemetry enclosure and secure it with six flat head screws.

11.

Insert the battery in the battery compartment.

12.

Power up the scale controller and enter its setup mode. Open the data screen and

check the output for the two chain load cells. The output should be approximately

equal (±100 lb). Adjust the tension on the chain connected to the new load cell until

the outputs are within tolerance (refer to the “Adjust Load Cell Force” procedure in this

chapter).

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6-18

Chapter 6: Troubleshooting

Load Cell Replacement

Removing a Drag Load Cell

(Triplex)

Remove the forks from the lift truck.

Raise the inner mast high enough to allow room to slide the carriage down and out of

the mast.

Shut off the forklift truck’s motor.

Obtain a crane (or other lifting device) with a capacity of at least 500 lb. Wrap a

sling securely around the upper part of the carriage. Use the crane to raise the sling

high enough that it supports the weight of the carriage.

Remove the battery by pressing the tab toward the center of the battery and pulling

the battery from the battery compartment.

Disconnect the two chain anchors from the mast by removing the lower nut from

each threaded anchor (see Figure 6-9).

Pull the chains up and over the pulleys.

Use the crane to lower the carriage and remove it from the bottom of the mast.

Place the carriage on a stable working surface, with the front side of the carriage

facing downward.

10.

Remove the cover to the scale’s telemetry enclosure. The cover is held in place by six

flat head cap screws. If you are replacing the left drag load cell, you will need to

remove the entire telemetry enclosure to be able to reach the load cell. To remove the

enclosure, you will need to let out some of the excess battery cable that is coiled

inside the enclosure.

11.

The load cell cables are wired to the four terminal strips on the printed circuit board

(PCB) inside the telemetry enclosure (see Figure 6-8). Locate the cable for the load

cell that you are replacing. You should be able to identify it by the tag attached to the

cable. Disconnect the cable’s wires from the terminal strip by inserting the tip of a flat-

blade screwdriver into the slot next to each wire and removing the wire from the

terminal.

12.

Loosen the six nuts on the cord-grip clamp bar. This will loosen the cord grips so that

you can remove the cable.

13.

Pull the load cell cable through the cord grip to remove it from the telemetry

enclosure.

14.

The load cell cables are routed through the scale carriage under the cover plate

located at the top of the carriage. Remove the cover plate.

15.

Remove the top flexure on the side of the scale where you will be replacing the load

cell. Note the position of any shims that are under the flexure so that you can replace

them later.

16.

Loosen the nuts on the threaded rods that anchor the load cell to the upper and lower

carriage mounts (see Figure 6-12). That will allow you to rotate the load cell enough

to grip the top part of the load cell with a 1.25-inch open-end wrench (or clamp).

While gripping the load cell with the wrench, loosen the jam nut that is tightened

against the top of the load cell.

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METTLER TOLEDO MCFA Forklift Scale Service Manual

Loosen Nuts Remove

Threaded Rod

Loosen Nut

Grip with

Wrench

Remove

Two

Bolts

Mounting

Block

Figure 6-12: Drag Load Cell Assembly

17.

After loosening the three nuts on the threaded rod connected to the top of the load

cell, unscrew the threaded rod to remove it from the load cell.

18.

Remove the two bolts that secure the lower mounting block to the carriage.

19.

Remove the load cell and lower mounting block through the opening in the back side

of the carriage.

20.

Loosen the jam nut at the bottom of the load cell and unscrew the load cell from the

threaded rod connected to the mounting block. Grip the bottom part of the load cell

with a wrench when loosening the jam nut.

Installing a New Drag Load

Cell (Triplex)

Screw the threaded rod that is connected to the lower mounting block into the hole at

the bottom of the new load cell (see Figure 6-12). Make sure that the end of the

threaded rod does not extend into the gap in the load cell.

Position the load cell below the upper carriage mount in the scale carriage. Make

sure that the load cell cable faces the front of the carriage.

Bolt the lower mounting block to the carriage and tighten the jam nuts (see Figure 6-

12). Grip the bottom part of the load cell with a wrench when tightening the jam nut

against it. Be careful not to damage the load cell by twisting it.

Insert the other threaded rod through the hole in the upper carriage mount. Place a

nut on the threaded rod above the carriage mount and two nuts below the carriage

mount.

Screw the lower end of the threaded rod into the hole in the top of the new load cell.

Again, make sure that the end of the threaded rod does not extend into the gap in the

load cell.

Tighten the three jam nuts that secure the load cell to the upper carriage mount. Grip

the top part of the load cell with a wrench when tightening the jam nut against it. Be

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6-20

Chapter 6: Troubleshooting

Load Cell Replacement

careful not to damage the load cell by twisting it. When all nuts are tightened, the

load cell should be positioned squarely.

Replace the top flexure, making sure to insert any shims in their original locations.

Insert the load cell cable through the cord grip into the telemetry enclosure.

Wire the load cell cable to the terminal strip on the printed circuit board (PCB) inside

the telemetry enclosure. Connect the wires according to the wiring codes in Figure 6-

2. To connect a wire, insert the tip of a flat-blade screwdriver into the appropriate slot

in the terminal and insert the wire into the opening across from the slot.

10.

Tighten the six nuts on the cord-grip clamp bar (see Figure 6-8). Use a nut driver to

tighten the nuts. Be careful to tighten the nuts only to the point at which the cables

will not slide through the cord grips. Do not overtighten the nuts. If the telemetry

enclosure was removed, mount it to the scale carriage in its original position.

11.

Coil any excess cable and store it in the open area of the carriage where the top cover

plate was removed. Replace the cover plate and secure it with four Phillips head

screws.

12.

Use the crane to lift the carriage and slide it up into the mast from the bottom of the

mast. Block the carriage to hold it in position.

13.

Route the chains up and over the pulleys.

14.

Insert each chain anchor into its mounting hole in the mast, and screw a nut onto the

bottom end of each threaded anchor (see Figure 6-9). Tighten the jam nuts against

the mast to secure the chains.

15.

After the scale carriage is secured to the mast, carefully remove the sling and any

additional blocking. Replace the forks on the carriage.

16.

Insert the battery in the battery compartment.

17.

Power up the scale controller and enter its setup mode. Open the data screen and

check the output for the two drag load cells. The output should be approximately

equal (the target is -60 lb ±40 lb). Adjust the load cells so that they are within

tolerance (refer to the “Adjust Load Cell Force” procedure in this chapter).

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METTLER TOLEDO MCFA Forklift Scale Service Manual

Adjust Load Cell Force

After replacing a load cell, check the scale’s force data to see if adjustments are needed.

Touch the Setup button on the scale controller to enter setup mode.

Open the data screen by touching the Maintenance button, the Diagnostics button,

and the Data Screen button.

Park the forklift truck on a level surface, remove all load from the forks, raise the

forks 12 to 15 inches off the ground, set the mast to the vertical position, and shut

off the forklift truck’s motor.

Touch the Zero button to reset the scale to zero.

Compare the weight readings for the left drag load cell and the right drag load cell.

The reading for each load cell should be approximately -60 lb (±40 lb). If either

load cell is outside this range, adjust the load cell until the reading is within the

range.

•

Each drag load cell is connected to a lower mounting block by a length of

threaded rod. Loosen the jam nut on the top side of the mounting block.

•

Then adjust the jam nut on the bottom side of the mounting block, tightening

the nut to increase the force or loosening the nut to decrease the force. Do not

turn the load cell.

•

After making the adjustment, tighten the upper jam nut against the mounting

block.

Compare the weight readings for the left chain load cell and the right chain load

cell. Each reading should be approximately equal (±100 lb). If necessary, adjust

the chain anchors until both readings are within this range.

•

Loosen the jam nut on the top side of the carriage mounting block.

•

Then adjust the jam nut on the bottom side of the mounting block, tightening

the nut to increase the force or loosening the nut to decrease the force. As the

force on one load cell goes up, the force on the other load cell will go down.

•

After making the adjustment, tighten the upper jam nut against the mounting

block.

Touch the Exit button to close the data screen.

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6-22

Chapter 7: Calibration

General

Calibration

General

A forklift scale is calibrated at the factory and should not need to be recalibrated when it

is installed. As part of the normal maintenance schedule, have a qualified service

technician check the scale’s calibration periodically. Calibration should also be checked

whenever a load cell is replaced. If the scale is within accepted tolerances, there is no

need to recalibrate it.

Calibrate Load Cells

Check the span values for the drag load cells. With the scale controller in setup mode,

open the data screen. Park the forklift truck on a level surface, remove all load from the

forks, set the mast to the vertical position, and then raise and lower the carriage several

times to exercise the scale. Position a block 15 inches high under the bottom roller on

each side of the scale carriage. Touch the Zero button, and then lower the carriage onto

the blocks. The “Calibrated Weight” reading is the sum of the totals for the drag load

cells and the chain load cells. It should be zero (±2 lb). If the reading is out of

tolerance, perform the following calibration procedure:

Touch the Setup button to enter setup mode.

Open the load cell calibration screen by touching the Scale button, the Calibration

button, and the Loadcell button.

Touch the Calibrate Spans button.

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METTLER TOLEDO MCFA Forklift Scale Service Manual

Park the forklift truck on a level surface, remove all load from the forks, set the mast

to the vertical position, and raise the forks slightly more than 15 inches off the

ground.

Position a block 15 inches high under the bottom roller on each side of the scale

carriage. Lower the carriage onto the blocks until the chains are slack, and then

raise the carriage off the blocks (repeat this several times to exercise the scale).

With the carriage raised off the blocks, shut off the forklift truck’s motor. Wait about

15 seconds for the scale to stabilize.

Touch the Next button. The system will count down as it updates the values.

Lower the carriage onto the blocks, and wait about 15 seconds for the scale to

stabilize.

Touch the Next button. The system will count down as it updates the values. The

new drag load cell span constants will then be displayed.

10.

Touch the Finish button to accept the new span values.

11.

Raise the carriage and remove the blocks.

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7-2

Chapter 7: Calibration

Span Adjustment

A correctly adjusted scale will give you the same weight reading no matter where on the

forks you place a test weight. If the weight readings at the shift test locations are out of

tolerance, shift adjust the scale to correct the problem.

Park the forklift truck on a level surface, place a pallet on the forks, raise the forks 12 to

15 inches off the ground, set the mast to the vertical position, and shut off the forklift

truck’s motor. Then check the scale’s repeatability by placing a test weight on the same

location on the pallet several times to make sure that you get the same weight reading

each time.

After verifying the scale’s repeatability, check to see if the scale needs to be shift

adjusted. For shift adjustments, we recommend using test weights equal to one half the

scale’s maximum weighing capacity. The test weights must meet the specified National

Institute of Standards and Technology Handbook 44 accuracy requirements.

NOTE: When performing a shift adjustment, use the weight readings on the data screen

instead of those on the main weighing screen. The weight readings on the data screen

are displayed to two decimal places, although the number in the second decimal place

might not be stable.

Shift Test Locations

Place a pallet or other flat surface (approximately 4 feet by 4 feet) on the forks and

make sure that it is level. Figure 7-1 shows test weight locations (1, 2, 3, and 4) at the

center of each quadrant of the pallet. Place the test weight at location 1 and record the

weight reading. Then move the test weight to location 2 and record the weight reading.

Continue until you have taken a weight reading at each of the four locations.

Flexure

Heel Heel

A D

Flexure

Toe Toe

Figure 7-1: Shift Adjustment Locations (Simplex Version Shown)

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METTLER TOLEDO MCFA Forklift Scale Service Manual

Ideally, the scale will give you the same weight reading at all four locations. The weight

readings at the heel and toe of either or both forks should be within Handbook 44

tolerance requirements (±2.5 lb for weights up to 2,500 lb). If the weight readings are

out of tolerance, you will need to shift adjust the scale. This is done by adding shims to

the flexures at the locations shown in Figure 7-1. To determine where to add shims,

refer to Table 7-1.

If weight reading 1 is greater than 2 → Shim at location A

If weight reading 2 is greater than 1 → Shim at location B

If weight reading 3 is greater than 4 → Shim at location C

If weight reading 4 is greater than 3 → Shim at location D

Table 7-1: Shim Locations

The shims adjust the differences between the weight readings at the heel and toe of an

individual fork. Adjust the weight readings so that they are as near to equal as possible.

If one weight reading is slightly higher, it should be the reading at the toe of the fork.

Shimming at the front of a flexure (location A) will increase the weight reading at the toe

of the fork (location 2). Because the shim affects the entire fork, it will also slightly

increase the weight reading at the heel (location 1).

Shimming at the back of a flexure (location B) will decrease the weight reading at the

toe of the fork (location 2). Because the shim affects the entire fork, it will also slightly

decrease the weight reading at the heel (location 1).

A pallet places load on both forks. So when a pallet is used, shimming under a flexure

will affect the readings at all four test weight locations. For example, shimming at

location A or B will change the readings at locations 1 and 2, but it will also change the

readings at locations 3 and 4 to a lesser extent.

Keep in mind that, in addition to balancing the weight readings at the heel and toe of

each fork, you are also trying to balance the weight readings of the two forks.

Shimming Procedure

Do not remove the bolts from more than one flexure at a time. The flexures connect the

two sections of the scale carriage. If you unbolt the two top or bottom flexures, the

sections of the carriage could separate and cause injury or damage the flexures.

DANGER

DO NOT REMOVE THE BOLTS FROM MORE THAN ONE

FLEXURE AT A TIME WHILE THE CARRIAGE IS INSTALLED

ON THE FORKLIFT. UNBOLTING MORE THAN ONE FLEXURE

COULD RESULT IN BODILY HARM OR PROPERTY DAMAGE.

Remove the bolts from the side of the flexure where shims will be added.

Loosen the bolts on the opposite side of the flexure.

Place a shim under the flexure, aligning the bolt holes in the shim with those in the

flexure. We recommend starting with the thinnest shim and gradually increasing

the shim thickness as needed to balance the weight readings.

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7-4

Chapter 7: Calibration

Calibrate Linearity

Replace the bolts that were removed, and tighten all bolts. Torque the bolts to 90 ft-

lb.

Repeat steps 1-4 for the second flexure if needed.

Take new weight readings at all four test weight locations. If the weight readings

are still not equal, repeat the procedure to add additional shimming.

When you have finished shift adjusting the scale, you should get approximately the

same weight reading at all four test weight locations.

Add shim

under flexure

Loosen bolts

on opposite

side of flexure

Remove bolts

to add shim

Figure 7-2: Shimming Procedure (Simplex Version Shown)

Calibrate Linearity

Check the scale for linearity errors. We recommend using five 1,000-lb test weights.

Use the weight readings on the data screen instead of those shown on the main

weighing screen. The weight readings on the data screen are accurate to two decimal

places.