Weighlog 100Onboard Weighing System

User GuideInstallation Manual

Issue Date 1/2007

Loup Electronics

Service and Technical SupportPLEASE CONTACT YOUR NEAREST DISTRIBUTOR

If unknown Contact Loup Electronics2960 North 38th Street

Lincoln, NE. 68504Phone: 402-464-7131

Fax: 402-464-7104Toll Free: 877-489-5687

© Copyright Loup Electronics Inc. 2006

Contents

1. Overview 3

2. Load Sensor Installation 62.1 Load Sensor 6 2.2 Installing Load Sensor 7 2.3 Mounting Load Sensor 9

3. Ref/Dir Sensor 103.1 Sensor Orentation 103.2 Sensor Mounting 113.3 Sensor Wiring 12

4. Remote Enter Switch 134.1 Switch Mounting 134.2 Switch Wiring 13

5. Head Unit 145.1 Head Unit Mounting 145.2 Head Unit Mounting Locations 15

6. Junction Box 166.1 Junction Box Head Unit Connection 166.2 Junction Box Mounting 17

7. Power Supply 18

8. Wiring 19

Page 2

OVERVIEW

Page 3

Weighlog Kits and Contents

Head UnitMounting Kit

Weighlog 100Head Unit

Weighlog 100Junction Box

Reference/DirectionSensor Kit Pressure Sensor Kit

Power Supply KitRemote Enter

Switch KitTee Adaptor

Fitting Kit

OVERVIEW

Page 4

Load Sensor: This is either a 250 bar rated pressure sensor installed in the lift cylinderhydraulic circuit, or in some instances a strain sensor mounted on the top side of the lift arm(example: on certain telescopic handlers).

Reference/Direction Position Sensor: The pressure/strain must be measured with the Lift arm in the same position each time. The reference/direction sensor is mounted nearthe lift arm pivot point. It senses when the lift arm is in the correct weighing position, and if theload is being lifted or lowered. The sensors are triggered by a magnet mounted on the sideof the lift arm.

Remote Enter button: This is mounted next to the lift lever and is used to recordthe bucket weight, clear the channels and used in the zero bucket routine.

Head Unit and wiring: The head unit is supplied with a universal mounting bracketassembly allowing it to be mounted in almost any configuration. A single multi-conductor leadconnected to a small Junction Box. Sensor and power connections are also made at the junction box. The junction box has mounting holes if required.

The Weighlog 100 is intended for use on industrial and agricultural loaders; Such as Skid steers,Small wheel loaders and some Telescopic Handlers.

It measures, displays and records the net weight lifted, based on the lift system hydraulicpressure. Pressure sensing is problematic on certain types of equipment due to the design of the

hydraulic system. In these instances strain sensing technology may be used instead.

Overview

System Components

Important Safety Precautions !In addition to observing site safety requirements, before working on the machine always:-

Make sure that the bucket is down on the ground and all pressure is released from thehydraulic system, before loosening any hydraulic coupling or fitting.

To Prevent the machine from being accidentally started while working on it, Alwaysremove the ignition key.

Keep other persons in the vicinity of the machine fully aware of your intentions duringinstallation and initial calibration.

OVERVIEW

Page 5

The Weighlog system consists of a numberof standard kits, which are designed to fit awide range of loaders.Mounting positions will vary according to thetype of machine, however this manual gives general guidelines that apply to all machines.The installation may require some modificationof the brackets provided for mounting the reference/direction sensors. Normal installation requires only basic handtools.

Typical Mounting Positions Shown

1. Pressure Sensor2. Strain Sensor (Optional)3. Reference/Direction Sensor4. Magnet5. Head Unit6. Remote Enter Button

LOAD SENSOR

Page 6

Load Sensor

The load sensor (fig. 2a) is connected bya flexible hose into the pressure side ofthe hydraulic circuit, using a tee fitting.Depending on the machine, you may be using a threaded tee piece, SAE flangecoupling, or if there is no suitable coupling you may have to drill and tapinto a suitable point.The machine is normally specified whenordering a Weighlog kit so the correctadaptor should be in the kit.

Where to tee in

Identify the lift hose on one of the main lift cylinders. Trace the lines back towardthe valve block , (at some point the lines from the other cylinder will join into a single line). Identify a suitable coupling which allows enough room to be split andthe tee adaptor to be inserted, or in the absence of a suitable coupling, a pointwhich can be drilled and tapped. The tee in points could be anywhere betweenthe lift cylinder and the valve block but ideally should be as close as possibleto the lift cylinder.

1.

Make sure that the bucket is down on the ground and all pressure is releasedfrom the hydraulic system, before loosening any hydraulic fitting! Alwaysloosen or open the cap on the hydraulic tank to help release any pressure.

2. Thoroughly clean around the tee in point before splitting, to prevent the ingressof dirt into the system.

3. Make sure that the tee in point will allow the hose to reach the load sensor mounting location. The load sensor needs to be mounted up under the machinewhere it is protected.

LOAD SENSOR

Page 7

Installing the Load Sensor

The load sensor contains a snubber to protect if from shock loading. This consistsof a diagonally drilled hole 0.3 mm in diameter. It is possible to block this hole withdebris causing the sensor to malfunction.

If a load sensor is installed on a machine where there may be particles of debrisin the oil, or the installer is unable to ensure the components being installed arekept clean, it is advisable to pre fill the flexible hose with clean oil.

When a load sensor is installed the first supply of oil also contains all the debris and contamination in the lines feeding it. Once this line has filled there is no flow of oil and consequently no risk of contamination arriving at the sensor. In order to avoidthis problem we recommend that if you suspect there is the possibility of contaminationin the oil then please ensure the hose feeding the sensor is pre filled with clean oil.

Please note that the pressure sensor must be mounted with the hose connection at thetop, so that all the air can bleed out of the sensor. If you do not mount the sensor as illustrated below premature failure may occur due to air being trapped inside.

LOAD SENSOR

Page 8

SAE Flange Coupling1. Install the 1/8" x 1/4" BSP adaptor and Dowty

seal to one of the two 1/8" BSP ports on the flange. Install the plug with Dowty seal to theremaining BSP port (Fig1).

2. Loosen and remove the four flange bolts andsplit the coupling. Insert the flange plateensuring the "O" rings are properly seatedand that the 1/4" BSP port is in a convenientlocation.

3. Replace the hose using the longer bolts suppliedin the kit. Use caution to ensure the "O" rings stayin place. Check the orentation of the fittings thatthey allow room for tighening and hose connection(Fig2).Torque the bolt to manufactures recommendation.If this is not know use the following torques:

3/4" Flange 21-29 ft-lb1" Flange 27-35 ft-lb11/4" Flange 35-45 ft-lb

Fig 1

Fig 2

Threaded Tees

1. Install the 1/4" BSP adaptor tee in the location selected. BSP, JIC, Metric and ORFS fittings areavailable.

2. Loosen and remove the hose and install the fitting into the line as shown in (Fig3).

Fig. 3

Tapped PortIn cases where there is no suitable coupling, you must drilland tap a 1/8" BSP port into a convenient block or fitting.If possible remove the component to be drilled.Center punch and drill a 3mm pilot hole. Then open out to8.8mm and tap with 1/8"BSP tap.Ensure all cuttings are flushed out of the line, then install the1/8" x 1/4" BSP adaptor with dowty seal as shown in (Fig4).

Fig. 4

LOAD SENSOR

Page 9

Mounting the Load Sensor1. Connect the hydraulic hose to the tee

fitting and route the hose towards thesensor mounting location. Connect tothe load sensor and mount the sensorin a well protected area, one that canalso be accessed for servicing.

NOTE:Mount the pressure sensor in a wellprotected area, in an upside downposition as shown. This helps preventair bubbles from hitting the loadsensor diaphragm.

Bleeding the Load SensorThis can be done whenever convenient during the installation procedure.Lift the boom so that it is a few inches off the floor. Have an assistant loosenthe hydraulic fitting to allow any air to escape. You may have to bleed the sensor more than once. It is recommended that the machine is worked for5 to 10 minutes and then the bleeding procedure be repeated.

Load Sensor Connection2. Connect the extension cable to the weatherpack connector on the sensor lead and

route back to the Junction box. Cable tie wires securely to existinghydraulic lines or hoses.Avoid coiling excess cable. Leave a small amount of slack at the sensor for movement.If the sensor cable is long enough to reach the J-Box then make a short pig tail with the extension cable rather than cutting the sensor cable.

3. Connect the wires according to the labelon the Junction box lid.Color Function Terminal #Red +V 10Blue oV 9Green Signal 8

NOTE: There is no provision for strain relief on these connections. Its recommended thatsensor cables are cable tied back very near the junction box.

121110 9 8 7 6 5 4 3 2 1

Reference/Direction Sensor

Page 10

Reference/Direction SensorFirst establish the most convenient weighingposition. If possible sensor position should beat the middle of the lift height. In some casesthis is not possible. Position the sensors sothe weight reading will be obtained as highas possible .The sensor and magnet must bearranged so the magnet is opposite the sensorface at the weighing position. The sensors are identified by the tags "R"for Reference and"D" for Direction Sensor.

NOTE: If you take the sensor clamp apart whenthe sensors are reassembled the directionsensor must be on the bottom (first sensorthe magnet will pass).

1. Lift the bucket to the height you want theweight reading to be taken.

2. General purpose mounting brackets areprovided which can be modified ifnecessary. The sensor can be mountedparallel or at right angles to the lift arm.

Its recommended that the sensor bepositioned at least 10 inches from the liftarm pivot point.The magnet should pass the end of thesensor, 1/4" to 1/2" away from the sensorsas shown.

Use caution positioning the bracketsto ensure they will not interfere withthe lift arms when fully raised!

1/4" to 1/2" inch

10 inches

Reference/Direction Sensor

Page 11

Reference/Direction Sensor Mounting

3. Assemble the Reference/Direction clamp assembly as shown. The bracket is designed so that the sensor may be installed on either side of the machine, by rotating the angle bracket 90 degrees.Remove the original M8 bolt from the green nylon clamp, and replace it with longer M8 x M60 mm. Then tighten with the sensors in the correct position.The clamp with sensors should then be inserted into the clamp holder, and tightened into position using the M8 self-locking nut supplied.The whole assembly can then be bolted to the angle bracket at the suitable angle for the specific installation, using the two M6 x 16mm bolts and nuts provided. Mounting locations vary by machine type shown below are mounting options.

Skid Steer top rear of cab Skid Steer front of cage

Small Wheel Loader lift arm pivot point Small Wheel Loader lift arm pivot point

Reference/Direction Sensor

Page 12

Reference/Direction Sensor MountingMagnet mounting

Mark the hole positions drill and tap 2 holes M6 in the lift arm for the magnetbracket. In some cases the magnet can be mounted directly onto the lift armbut you must install the fiber washer between the magnet an the lift arm.Install the bracket and attach the magnet using the stainless steel screw andthe fiber washer between the magnet and bracket.

Do not drill the lift arm above the centerline of the lift arm!

Ref/Dir Sensor ConnectionConnect the extension cable to theWeatherpack connector on the sensorlead, route the cable back to the junction box. Secure the cable withwire ties to avoid damage to the cable.

Connect the wire according to the labelon the Junction Box lid.

Color Function Terminal #Blue Common 6GreenRed Ref. Sig. 7Yellow Dir. Sig. 4

121110 9 8 7 6 5 4 3 2 1

Remote Enter Switch

Page 13

Remote Enter SwitchMount the Remote Enter Switch either onthe lift lever using a hose clamp or wireties, or mount with screws provided within easy access of the operator.

Connect the wires according to the labelon the Junction box lid.Color Function Terminal #Blue 0v 3Brown Signal 1

Remote Enter

121110 9 8 7 6 5 4 3 2 1

External AlarmAn External alarm is optional. Mount thealarm buzzer where it will stay dry.

Connect the wires according to the labelon the Junction box lid.Color Function Terminal #Blue 0v 9Brown Signal 11

Head Unit

Page 14

Head UnitConfirm with the machine operator on where to mount the head unit in the cab.The head unit has a 3 foot gray cable with a 18 pin IDC connector, ready forconnection into the Junction Box.

Mounting the Head UnitThe head unit is supplied with a seperatemounting kit including the following parts.1 Long Bracket1 Short Bracket3 Clamping Knobs1 Cover Plate1 Mounting Plate2 Self Tapping Screws

1. Snap the cover plate into the recess of thelong bracket.

2. The bracket kit is designed to offer maximumflexibility in positioning the head unit, from theright or left side of the cab, the dashboard orfrom an overhead position.Assemble the two brackets, and mountingplate with clamping knobs, and attach to the head unit.As you will notice, you can index eachpivot point on the mounting bracket toangle the head unit in relation to the mounting plate.

3. After establishing the orientation of the bracket, attach the mounting plate to the cab with the self tapping screws provided.

If you are installing the mounting plate to plastic like the dashboard or other cabmoulding, its recommended you use machine screws with washers or plate the back for added strength.

Never Drill into a ROPS frame. Do not attempt to adjust themounting bracket withoutfirst loosening the clampknobs. You will only succeedin damaging the bracket.

Head Unit

Page 15

Remote Enter

Head Unit Mounting

Optional Mounting Locations

Junction Box

Page 16

Remote Enter

Junction Box

The Junction Box provides connections forthe 18 conductor head unit cable, all thesensors and the power supply.

The Junction Box is not sealed. It should belocated where is will be protected forexcessive moisture and dirt.

1. The Junction Box can be mounted using thescrews provided, or left in-line with the cables.

2. Connect the head unit cable onto the PCBheader as shown.

NOTE:The red wire on the 10 way plug goes onpin 1 of the connector.

The Blue/Red wire on the 8 way plug goeson pin 11 of the connector.

3. Locate the cable grommet into the groovein the juction box, cable tie the head unitlead onto the moulded flange to providestrain relief.

4. Connect the Sensors. The Wiring Connectionsare printed on the lid of the Junction Box.The connections are also shown in theappropriate sections in the manual.

Red Wire Pin 1

Red/Blue Pin 11

Note: No means of strain reliefis provided for the sensorcables. Its recommendedthat you cable tie themsecurely to prevent strainon the screw terminalconnections.

Junction Box

Page 17

Remote Enter

Junction Box Mounting

Optional Mounting Locations

Power Supply

Page 18

Remote Enter

Power Supply

Blue Wire - Ground 0vBrown Wire - Power +v

A toggle switch is providedin the kit and must be usedif the power supply is notkeyed. The Weighlog unithas no power button andwill remain on if the toggleswitch is not used. Thesupply can be 12 or 24 voltthe system will operate oneither one.

Weighlog Power Connection Options

Battery Connection

Key Switch Connection

Fuse ConnectionSupplied with kit

Fuse ConnectionSupplied with kit

Toggle SwitchSupplied with kit

Toggle SwitchSupplied with kit

Note:With this option toggle switch must be used as the Head Unit has no power button.

Weighlog 100/200 Junction Box

Weighlog 100/200 Junction Box

Wiring Connections

Brown WirePower +VBlue WireGround oV

The Brown and Blue wiresconnect to the male spadeterminals in the center ofthe Junction Box ONLY.