Weighlog 200Onboard 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. 2007

Contents

1. Overview 3

2. Load Sensor Installation 6 2.1 Load Sensor 6 2.2 Installing Load Sensor 7 2.3 Mounting Load Sensor 9

3. Ref/Dir Sensor 10 3.1 Sensor Orentation 10 3.2 Sensor Mounting 11 3.3 Sensor Wiring 12

4. Remote Enter Switch 13 4.1 Switch Mounting 13 4.2 Switch Wiring 135. Head Unit 14 5.1 Head Unit Mounting 14 5.2 Head Unit Mounting Locations 15

6. Junction Box 16 6.1 Junction Box Head Unit Connection 16 6.2 Junction Box Mounting 17

7. Power Supply 18 14

8. Wiring 19

Page 2

OVERVIEW

Page 3

Weighlog Kits and Contents

Head UnitMounting Kit

Weighlog 200Head Unit

Weighlog 200Junction 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 200 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 the remaining BSP port (Fig1).2. Loosen and remove the four flange bolts and split the coupling. Insert the flange plate ensuring the "O" rings are properly seated and that the 1/4" BSP port is in a convenient location.3. Replace the hose using the longer bolts supplied in the kit. Use caution to ensure the "O" rings stay in place. Check the orentation of the fittings that they 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-lb 1" Flange 27-35 ft-lb 11/4" 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 are available.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 the sensor mounting location. Connect to the load sensor and mount the sensor in a well protected area, one that can also be accessed for servicing.

NOTE:Mount the pressure sensor in a well protected area, in an upside down position as shown. This helps prevent air bubbles from hitting the load sensor diaphragm.Bleeding the Load Sensor

This 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 loosen the 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 for 5 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 existing hydraulic 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 label on the Junction box lid. Color Function Terminal # Red +V 10 Blue oV 9 Green Signal 7

NOTE: There is no provision for strain relief on these connections. Its recommended that sensor 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 when the sensors are reassembled the direction sensor must be on the bottom (first sensor the magnet will pass).

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

2. General purpose mounting brackets are provided which can be modified if necessary. The sensor can be mounted parallel or at right angles to the lift arm.

Its recommended that the sensor be positioned at least 10 inches from the lift arm pivot point. The magnet should pass the end of the sensor, 1/4" to 1/2" away from the sensors as shown. Use caution positioning the brackets

to 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 magnet bracket. In some cases the magnet can be mounted directly onto the lift arm but 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 and the fiber washer between the magnet and bracket.

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

Ref/Dir Sensor Connection Connect the extension cable to the Weatherpack connector on the sensor lead, route the cable back to the junction box. Secure the cable with wire ties to avoid damage to the cable.

Connect the wire according to the label on the Junction Box lid.Color Function Terminal #Blue Common 6Green Red Ref. Sig. 5Yellow Dir. Sig. 2

121110 9 8 7 6 5 4 3 2 1

Remote Enter Switch

Page 13

Remote Enter Switch Mount the Remote Enter Switch either on the lift lever using a hose clamp or wire ties, or mount with screws provided within easy access of the operator.

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

Remote Enter

121110 9 8 7 6 5 4 3 2 1

External Alarm An External alarm is optional. Mount the alarm buzzer where it will stay dry.

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

Head Unit Confirm 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 for connection into the Junction Box.

Mounting the Head Unit The head unit is supplied with a seperate mounting kit including the following parts. 1 Long Bracket 1 Short Bracket 3 Clamping Knobs 1 Cover Plate 1 Mounting Plate 2 Self Tapping Screws

1. Snap the cover plate into the recess of the long bracket.2. The bracket kit is designed to offer maximum flexibility in positioning the head unit, from the right or left side of the cab, the dashboard or from an overhead position. Assemble the two brackets, and mounting plate with clamping knobs, and attach to the head unit. As you will notice, you can index each pivot point on the mounting bracket to angle 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 cab moulding, 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 the mounting bracket without first loosening the clamp knobs. You will only succeed in damaging the bracket.

Head Unit

Page 14

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 for the 18 conductor head unit cable, all the sensors and the power supply.

The Junction Box is not sealed. It should be located where is will be protected for excessive moisture and dirt.

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

2. Connect the head unit cable onto the PCB header as shown.

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

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

3. Locate the cable grommet into the groove in the juction box, cable tie the head unit lead onto the moulded flange to provide strain relief.

4. If an ICP 200 printer is being installed then connect the 4 way PCB connector as shown. Also cable tie this lead to provide stain relief.

5. Connect the sensors. The wiring connections are printed on the lid of the Junction Box. The connections are also shown in the appropriate sections in the manual.

Red Wire Pin 1

Red/Blue Pin 11

Note:No means of strain relief is provided for the sensor cables. Its recommended that you cable tie them securely to prevent strain on the screw terminal connections.

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.

Printer Comm Line Connection

The Printer cable supplied has three connections1. Power 12 or 24 volt supply (same as scale). Blue Wire - Ground 0v Brown Wire - Power +v2. Printer Connection (DB 9 Pin connector)3. Printer Comm Line (rail connector Blue & Green wires)

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.