Avery Weigh-Tronix WI-125 Service Manual
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Avery Weigh-Tronix WI-125 Service Manual

Avery Weigh-Tronix WI-125 Service Manual

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WI-125 (QTLTSC)
Indicator and System
Service Manual

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Summary of Contents for Avery Weigh-Tronix WI-125

  • Page 1 WI-125 (QTLTSC) Indicator and System Service Manual...

  • Page 2: Table Of Contents

    Reset Menu and Master Clear ..................29 Master Clear Menu ....................30 Reset Menu ......................30 Indicator Diagnostics ....................... 31 WI-125 QTLTSC Troubleshooting Tips ................33 Resistance Test of QTLTSC Weigh Bars ................ 36 Technical Illustrations and Assemblies ................37...
  • Page 3 WI-125 Specifications Dimensions: 9.37" W x 6.75" H x 3.75" D (23.8 cm x 17.1 cm x 9.5 cm) Power: 10 to 90 VDC, 300 mA minimum Display: 8 digits, 7-segment LCD, 0.6 inch high with annunciators and backlighting. Display Rate:...

  • Page 4: Introduction

    Opera- tions mode is fully explained in the WI-125 (QTLTSC) Indicator User's Manual (PN 29608-0013) . Use this mode to perform tests on the WI-125. The test mode is covered in Test Mode the Indicator Diagnostics section of this manual.

  • Page 5: Keyboard

    ZERO UNITS SELECT CLEAR Figure 1 WI-125 Keyboard Enters a pushbutton tare in gross/net operation. This key's TARE factory default is OFF and it must be enabled for use. Accesses the gross weighing mode from any other function G / N and activates the net weighing mode if a tare is active.

  • Page 6: Configuration Mode

    This section of the manual explains how to view and set up parameters in the configuration mode. Follow the configuration menu and instructions in Figure 2 to set up the WI-125 indicator to suit your specific needs. Below are explanations for each section of the menu. The non-bold heading for each section is the pathway you follow on the configuration menu to get to the parameter or parameter options shown in bold text.
  • Page 7 Setup, Scale, Units, Capacity, Division, Zero- -Percent, Percent With this option you can set the plus and minus percent of capacity that the indicator can zero. For example, if the capacity of the scale is 10,000 lb and the zero range is ±2%, key in 2 for both the positive and negative ranges.
  • Page 8 Figure 2...
  • Page 10 Setup, Scale, Options, Angles, Tare, ID - Hour With this option you can choose to have the clock disabled (OFF) or the mode of clock you want. You can choose the 12 hour clock display or the 24 hour clock display. If the clock is disabled, HOUR will not appear in the SECURITY section of this menu and DAY will not appear in the OPTIONS or SECURITY section of this menu.
  • Page 11 Setup, Scale, Options, Security, Serial, Print, Button, Enquire, Auto - Broad. Broad. stands for broadcast. If you enable ON (broadcast), weight data is transmitted at the display rate. Choosing OFF disables the broadcast. If broadcast is enabled, the Button, Enquire, and Auto selections are overridden and will not function.

  • Page 12: Customizing The Layout Menu

    (See Figure 4.) As in the other WI-125 menus, the SELECT key opens up the next level of the menu. There is one more level of information under the print commands in the layout menu.

  • Page 13: Ascii Strings

    ASCII strings are stored under the ASCII print commands, such as numbers ASCII Strings 1, 3, 5, 7, etc. An ASCII string is a sequence of ASCII code numbers. Each code number is preceded on the indicator display by a sequence number. ASCII is an acronym for See Figure 5.
  • Page 14 #31- Sets WP-233 printer to 40 column print mode #73- I #15- Makes double wide characters until a carriage return #88- X #14- Makes double high characters until a carriage return #32- Space #87- W #87- W #69- E #73- I #73- I #45- - #71- G...

  • Page 15: Examples And Step By Step Instructions

    Example A: To change the second print command from 2 GROSS to 2 Examples and Step by HOUR : Step Instructions 1. Scroll to the HOUR print command in the submenu under 2 GROSS . 2. Press SELECT. The print command 2 GROSS is now changed to 2 HOUR .

  • Page 16: Deleting An Ascii Print Command After The Ascii Codes Are Cleared

    1. With 1 ASCII displayed, press Deleting an ASCII Print CLEAR. Command After the ASCII The item is removed from the menu Codes Are Cleared and all the following items move up one number value on the menu. What was item 2 becomes item 1, etc.
  • Page 17 Table 2 ASCII Control Codes NOTE: To repeat a control code a number of times, enter the control code #, a decimal, and the number of times you want it repeated. Spaces, letters, or carriage returns can easily be repeated this way.

  • Page 18: Calibration

    Calibration Entering the Configura- Calibration of the QTLTSC system consists of two processes; cornering and calibration of the system. Cornering makes the Weigh Bars work together. tion Mode to Calibrate Calibration of the system makes the indicator work with the scale. If the the System indicator provides linear but incorrect readings, you need only perform a span adjustment.

  • Page 19: J-Box Information

    J-Box Information You make trim and balance adjustments in the J-box. The J-box is shown at right. Trim and balance adjustments make up the cornering procedure. Cornering makes the Weigh Bars work to- gether and is usually not required unless you replace a Weigh Bar or junction box.

  • Page 20: Trim Potentiometer Adjustment

    The right fork and left forks are those that are on the right and 1. Set the WI-125 indicator to read in one pound divisions by following the left when you are sitting in steps shown in Figure 7. Remember to reset divisions to five pound the lift truck seat.

  • Page 21: Balance Potentiometer Adjustment

    The following directions will enable you to adjust the scale so that it is Balance Potentiometer insensitive to changes in fork position. Adjustment 1. Place the cornering weight (recommend 50% of capacity) on the center of the right fork and record the weight. Move the right fork in six inches.

  • Page 22: Spanning Adjustment For An Existing Calibration

    This spanning procedure applies only to those systems that already Spanning Adjustment have the 16 data points in memory. for an Existing Respanning may save time if your system is simply out of tolerance and the Calibration 16 step data acquisition is not necessary. Use this spanning procedure if weight value remains the same when the system is tipped but the weight is inaccurate.
  • Page 23 3. Unload the scale, zero the indicator by pressing the ZERO key and weigh the known weight again. If the weight reading is still incorrect, respan the indicator by following steps “a” through “o” above. 4. Check the scale for load shift sensitivity (cornering error). a.

  • Page 24: Step-By-Step Instructions For Acquiring Data Points

    1a. Level the forklift. With only a pallet on the scale and ACQUIRE displayed on the WI-125, press SELECT. Once the number on the scale is steady, press SELECT again. 01 is displayed.
  • Page 25 4a. Bring the lift truck back to a level position, then tilt the forks forward between five and ten degrees. Press SELECT. Once the number on the scale is steady, press SELECT again. 04 is displayed. 4b. Press SELECT. bUSy is displayed briefly and then ACQUIRE is redisplayed.
  • Page 26 10a. Leave the weight on the scale and tilt forks backward, beyond level, to between five and ten degrees. Press SELECT. Once the number on the scale is 10 is displayed. steady, press SELECT again. 10b. Press SELECT. bUSy is displayed briefly and then ACQUIRE is redisplayed.
  • Page 27 15a. Leave the weight on the scale and tilt forks back, beyond level, to between five and ten degrees. Press SELECT. Once the number on the scale is steady, press SELECT again. 15 is displayed. 15b. Press SELECT. bUSy is displayed briefly and then ACQUIRE is redisplayed.

  • Page 28: Calculating New Lift Capacity

    Calculating New Lift Capacity The QTLTSC lift truck scale comes in ITA Class II (16" high, 5,000 lb) and ITA Class III (20" high, 5,000 and 10,000 lb) models. Each class comes in several widths for cleat type carriages. Measure the height and width of the lift truck carriage.

  • Page 29: Making A Ramp

    Lift truck with no scale Lift truck with scale Figure 9 Recalculating Lift Truck Capacity 1. With plywood, build two ramps, following the diagram below. Making a Ramp 2. Nail them together. Board H (in inches) W (in inches) L (in inches) 24"...

  • Page 30: Replacing A Transducer On The Qtltsc Carriage

    Replacing a Transducer on the QTLTSC Carriage 1. Remove forks. Disassembly 2. Raise lift truck carriage and remove mounting hooks from bottom of Tools needed for QuickTach carriage. Class II and III 5000 lb 3. Remove junction box shield. carriages: 4.

  • Page 31: Loosening Procedure

    Set screws should be loosened with care. Loosening can be accomplished Loosening Procedure quickly, but do not rush to completely loosen individual set screws. Remem- ber that the intent is to slowly release the preload force. All set screws should be loosened uniformly and usually there is no need to remove any set screw from the tensioner body during loosening.

  • Page 32: Reset Menu And Master Clear

    Reset Menu and Master Clear If the indicator's memory, calibration or other data becomes corrupted, a reset menu will become active. RESET will be displayed telling you there has been a problem. You may also choose to perform a Master Clear to reset the setup, or adjust data values to default values.

  • Page 33: Master Clear Menu

    Master Clear Menu Within the RESET menu at right, you may need to toggle switch S1-1 to correct power- up problems after exchanging EEPROMs. If SETUP, ADJUST, or DATA are set to defaults, they will not appear in the menu. If SETUP, ADJUST, or DATA appear, you have the option to reset one, two, or all three of them to default values.

  • Page 34: Indicator Diagnostics

    Indicator Diagnostics The test mode is used to test various functions of the WI-125. The test menu is shown in Figure 12. Instructions for using the test menu are found below. Figure 12 Test Menu 1. Enter the test mode from gross/net operation by pressing and holding the MENU key until tESt is displayed.
  • Page 35 Below are the specific directions and explanations for the items you see in the test menu. VERSION — Under version are the Weigh-Tronix part number and revision number for the software found in your machine. Weigh-Tronix part numbers are divided into two parts: the prefix and the dash number.

  • Page 36: Wi-125 Qtltsc Troubleshooting Tips

    WI-125 QTLTSC Troubleshooting Tips 1. Powered Indicator a. If there is a readout check the other tips b. If there is no readout check for voltage on the Quick Disconnect power supply connector, must have at least 10.5 volts DC and 150mA.
  • Page 37 2. If you get weight readout, remove the 12-pin test cable and con- nect in the interface cable. a. If you get center dashes, than replace the interface cable. b. If you get weight readout on a system that uses a Connector style J-box: Replace the J-box.
  • Page 38 10. All 0000s or 9999s after fitting data in calibration. This means the points in the calibration were too far out of tolerance for the WI-125 to mathematically configure the calibration. It would be wise to do a Master Clear and then recalibrate.

  • Page 39: Resistance Test Of Qtltsc Weigh Bars

    Resistance Test of QTLTSC Weigh Bars Perform these resistance checks to test the legal for trade lift truck scale Weigh Bars. With the meter set on the appropriate ohms scale, check the following values between the color coded wires on the section of the cord connected to the Weigh Bar or the corresponding pin out for the connector.

  • Page 40: Technical Illustrations And Assemblies

    “Locktite” #242, (W-T p/n 15566- 0061) to all threaded fastners. Do not apply to cable connectors ITEM DESCRIPTION W-T P/N WI-125 LIFT TRUCK (QTLTSC ) INDICATOR ASSY 47955-0014 12-72VDC PWR CABLE (12’ long) 19266-0041 J-BOX SHIELD 48190-0017 WEIGH BAR ASSY 48304-0010 RETRACTABLE INTFC.
  • Page 41 “Locktite” #242, (W-T p/n 15566-0061) to all threaded fastners. Do not apply to cable connectors ITEM DESCRIPTION W-T P/N WI-125 Lift Truck (QTLTSC ) Indicator Assy 47955-0014 DC Pwr Cable (12’ long) 19266-0041 J-BOX Shield 50811-0012 Weigh BAR Assy, 48304-0010 Retractable Interface Cable Assy (18’-20’...
  • Page 42 WI-125 LIFT TRUCK (QTLTSC) 10,000 lb-CLASS III- SCALE CARRIAGE MAJOR COMPONENTS ASSEMBLY ITEM DESCRIPTION W-T P/N WI-125 Lift Truck (QTLTSC ) Indicator Assy 47955-0014 DC Pwr Cable (12’ long) 19266-0041 J-BOX Channel Shield 52529-0011 Weigh Bar Assy 48304-0010 Retractable Interface Cable Assy (18’-20’ stretched)
  • Page 43 WI-125 (QTLTSC) INDICATOR PARTS ASSEMBLY ITEM DESCRIPTION W-T P/N SILICONE KEYPAD GASKET 1055-10389 KEYPAD ASSY 45957-0016 BACKER PLATE 29422-0017 MAIN PC BOARD ASSY 29400-0146 ENCLOSURE SEALING BRACKET 1067-09677 FRONT ENCLOSURE 45902-0012 REAR ENCLOSURE 46477-0015 LEVEL SENS BD TO MAIN BD CABLE ASSY...
  • Page 44 WI-125 LIFT TRUCK (QTLTSC) SYSTEM BLOCK DIAGRAM...
  • Page 45 WI-125 (QTLTSC) INDICATOR EXTERNAL INTERFACE CONNECTIONS...
  • Page 46 WI-125 (QTLTSC) INDICATOR PC BOARD IDENTIFICATION W/ PIN-OUTS...
  • Page 47 WI-125 (QTLTSC) INDICATOR PC BOARD IDENTIFICATION W/ PIN-OUTS...
  • Page 48 WI-125 (QTLTSC) INDICATOR WI-125 (QTLTSC) J-BOX/LEVEL SENSOR KEYPAD ASSY AND SCHEMATIC PARTS AND ASSY ITEM DESCRIPTION W-T P/N J-Box Assy 48369-0012 J-Box Cover 48371-0018 Cover Gasket 48373-0016 Screw, #10 x 1/2” L 14505-0050 Flat Washer, #10 14475-0056 Connector Assy 12-pin (male)
  • Page 49 WI-125 (QTLTSC) INDICATOR J-BOX ASSY w / INSIDE TERMINATION (with pigtail), J-BOX ASSY w / CONNECTORS (with pigtail) ITEM Lift Truck Weigh-Bar Cable Pin-Out DESCRIPTION W-T P/N J-Box Assembly P/N 52040-0011 PC Board Assy 50768-0015 J-Box Enclosure 50782-0017 J-Box Cover...
  • Page 50 LIFT TRUCK QTLTSC SCALE CARRIAGE INSTALLATION INSTRUCTIONS • Installing the Quick-Tach Carriage Remove the customer's forks before you mount the Quik-Tach carriage Check the forks for wear or damage and make any necessary repairs. • Clean and inspect the customer's lift truck carriage. Both the upper and lower sections of the carriage should be flat and not twisted or bent out of shape.
  • Page 51 Measure across J1B to J4B. Adjust the LB to equal the Left Balance Readout. Measure across J1B to J5B. Adjust the RB to equal the Right Balance Readout. Follow the corner and balance procedure in the WI-125 QTLTSC Service Manual to fine-tune the J-Box readings. Equipment required for the weighbar connector modification •...
  • Page 52 LIFT TRUCK QTLTSC SCALE CARRIAGE J-BOX DURABILITY ENHANCER KIT (P/N 52231-0010) INSTRUCTIONS ENHANCING YOUR J-BOX’S DURABILITY The second step is the reinforcing of the components inside the J-box. Figure 2 shows a diagram of RTV placement on a J-box PC board. Open the J-box and find the following components: To enhance the durability of your lift truck J-Box, Weigh-Tronix has produced this kit for fighting the effects of extreme vibration.
  • Page 53 Daily Inspection Checklest For Lift Truck Scale Users Check scale carriage for loose, worn, bent, or broken components. Inspect forks for damage. Check locking pins on forks for proper function. Inspect cables from the junction box to Weigh Bars for wear. Inspect retractable cable for pinched, rubbed, stretched, or damaged areas.
  • Page 54 Weigh-Tronix 1000 Armstrong Dr. Fairmont, MN 56031 USA Telephone: 507-238-4461 Facsimile: 507-238-4195 e-mail: industrial@weigh-tronix.com www.weigh-tronix.com Weigh-Tronix Canada, ULC 217 Brunswick Blvd. Pointe Claire, QC H9R 4R7 Canada Telephone: 514-695-0380 Facsimile: 514-695-6820 Weighing Products & Systems Weigh Bar ® is a registered trademark of Weigh-Tronix Inc. 10/11/00 125LTSER.P65 PN 29602-0019e3 Printed in USA...

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